Steps 1-44

REASSEMBLY

CAUTION:
^ Never reuse the gasket, O-rings, oil seals, etc. Always replace with new ones when assembling.
^ Never use grease other than blue petroleum jelly and white Vaseline.
^ Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
^ Never apply sealant or adhesive to gaskets.
^ When replacing a bushing, replace the assembly which it belongs to.
^ During the work, always use bare hands or vinyl gloves. Do not use cotton gloves. Use nylon cloth or paper towels when necessary. Do not use shop towels.

CAUTION: Never reuse a gasket.





1. Install a new gasket and output shaft support.
2. Tighten the eight output shaft support mounting bolts to the specified torque.
Specified torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)





CAUTION: Make sure the thrust bearing is mounted in the correct direction.





3. Install the bearing retainer and thrust bearing number 13 onto the output shaft.








IDENTIFICATION OF THRUST BEARING AND THRUST RACE





4. Install new seal rings (two large pieces and two small pieces) onto the output shaft.
5. Install the output shaft into the output shaft support.





CAUTION: Make sure thrust bearing number 12 is mounted in the correct direction.





6. Apply Vaseline or petroleum jelly on the thrust bearing number 12, and then install on the front end of the output shaft.





7. Install the underdrive clutch.





8. Apply Vaseline or petroleum jelly on the thrust bearing number 11, and then install on the front end of the underdrive clutch retainer.





CAUTION: Make sure thrust bearing number 11 is mounted in the correct direction.





9. Install the underdrive clutch hub.





10. Apply Vaseline or petroleum jelly on the thrust bearing number 10, and then install it on the underdrive clutch hub.





CAUTION: Make sure thrust bearing number 10 is mounted in the correct direction.





11. Install the output flange.





12. Apply Vaseline or petroleum jelly on the thrust bearing number 9, and then install on the output flange.





CAUTION: Make sure thrust bearing number 9 is mounted in the correct direction.





CAUTION: Measure and record the thickness of the thrust race number 8 to be assembled.

13. Apply Vaseline or blue petroleum jelly on the thrust race number 8 being used, and then install it on the rear side of the center support.

CAUTION:
^ Install the center support so that the oil holes shown in the illustration face the lower side of the transmission case.
^ Make sure that the thrust race number 8 attached to the rear side of the center support does not fall off.





14. Install the center support.





15. Remove the two output shaft support mounting bolts.
16. Using the two removed bolts, install special tool MB991603 to the specified torque.
17. Select the thrust race number 8 with the following procedure:
1. Fix a dial gauge to special tool MB991603.





2. Push the output shaft, and the output flange in alternately, and then measure the end play of output shaft.

NOTE:
^ When pushing the output shaft in, take care that the center support does not move.
^ When pushing the output flange in, use the special tool MB998304.





3. Reinstall by selecting the thrust race number 8 installed by the procedure (B) so that the end play of output shaft becomes the standard value.

NOTE: Refer to the thickness recorded in step 13.

Standard value: 0.25 - 0.55 mm (0.0098 - 0.0217 inch)
4. Measure the end play again, and confirm that it is within the standard value.

NOTE: Carry this step out with special tool MB991603 and dial gauge installed.

18. Using the following steps, select the snap ring for fixing the center support.





1. Install the snap ring used for fixing the center support used.





2. After pushing the output shaft, and the center support in alternately, and then measure the end play of center support.

NOTE: When pushing the output shaft in, be sure to push them in to the point where the center support touches the snap ring.





3. Select the snap ring for fixing the center support installed in step 18 (1) so that the end play of the center support is at the standard value. Then, reassemble.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)
4. Measure the end play again, and confirm that it is within the standard value.





19. Using the following steps, select the snap ring for adjusting the brake reaction plate end play and second brake end play, and the pressure plate for adjusting the low/reverse brake end play.





1. Install the wave spring onto the low/reverse brake piston.





2. Install special tool MB991632 onto the position shown in the illustration instead of the pressure plate for the low/ reverse brake. Install the brake disc, brake plate and snap ring.

CAUTION: Pay close attention to the assembly direction of the reaction plate.





3. Install the reaction plate and snap ring that was used.
4. Install a dial gauge onto special tool (MD998913) so that the end contacts the brake reaction plate. Measure the end play by moving special tool MB991632.
5. Select the snap ring installed in step 19 (3) so that the end play is within the standard value. Then, reassemble.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)
6. Measure the end play again, and confirm that it is within the standard value.

CAUTION: Pay close attention to the shape and assembly direction of the brake plate A installation.





7. Next, install special tool MB991632 instead of the pressure plate for the second brake. Install the four brake discs and three brake plates.
8. Install the return spring, second brake and snap ring.








9. Install a dial gauge onto special tool MD998913 so the end contacts the special tool. Move special tool MB991632 and measure the moving amount. Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
Standard value: 1.49 - 1.95 mm (0.0587 - 0.0768 inch)
10. Remove the snap ring, second brake, return spring and special tool MB991632 installed in step (8).
11. Install the pressure plate selected in step (9), and install the return spring, second brake and snap ring again.








12. Install a dial gauge onto special tool MD998913 so the end contacts the special tool. Move special tool MB991632 and measure the moving amount. Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
End play standard value (reference): 1.35 - 1.81 mm (0.0531 - 0.0713 inch)
1.65 - 2.11 mm (0.0650 - 0.0831 inch)
13. Remove the parts installed in steps 19 (1) to (12).

CAUTION: Make sure thrust bearing number 7 is mounted In the correct direction.

20. Apply Vaseline or petroleum jelly on the thrust bearing number 7, and then install on the rear side of the low/reverse annulus gear.

CAUTION: Make sure that thrust bearing number 7 attached to the rear side of the low/reverse annulus gear does not fall off.

21. Install the low/reverse annulus gear.

22. Install the reverse sun gear.

23. Install the wave spring to the low/reverse brake piston.

24. Install the pressure plate, brake disc and brake plate selected in step 19 (12).

25. Install the snap ring.

CAUTION: Make sure the reaction plate in the proper direction.

26. Install the reaction plate.

27. Install the snap ring selected in step 19 (5).

CAUTION: Make sure the brake plate (reaction plate side) is installed in the proper direction.

28. Install the brake disc, brake plate and pressure plate selected in step 19 (9).

CAUTION: Install the return spring end coil side so that it faces the back of the transmission.(Only for one side end coil type)

29. Install the return spring and second brake.

30. Install the snap ring.

CAUTION: Make sure thrust bearing number 4 is installed in the proper direction.

31. Apply Vaseline or petroleum jelly on the thrust bearing number 4, and then install on the reverse sun gear.

CAUTION: Make sure thrust bearing number 3 is mounted in the correct direction.

32. Apply Vaseline or petroleum jelly on the thrust bearing number 3, and then install on the overdrive clutch hub.
33. Install the overdrive clutch hub.

CAUTION: Make sure thrust bearing number 2 is mounted in the correct direction.

34. Install the reverse and overdrive clutch.
35. Apply Vaseline or petroleum jelly on the thrust bearing number 2, and then install on the reverse and overdrive clutch.

36. Apply Vaseline or petroleum jelly on the thrust race number 1 being used, and then install on the oil pump.

CAUTION: Never reuse a gasket.

37. Install special tools MD998412 at the position shown in the illustration, and using this as a guide, install the oil pump and gasket.
38. Tighten the ten oil pump mounting bolts to the specified torque.
Specified torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)

39. Using special tool MD998316, set a dial gauge as shown in the illustration. Measure the end play of the input shaft, and select the thrust race installed in step 36 so that the end play is at the standard value. Then, reassemble.
Standard value: 0.25 - 0.81 mm (0.0098 - 0.0319 inch)
40. Measure the end play again, and confirm that it is within the standard value.

CAUTION: Evenly squeeze out the sealant so that it is not insufficient or excessive.

41. Apply the sealant MITSUBISHI genuine sealant part number MR166584 or equivalent on the converter housing.

42. Install the converter housing.
43. Tighten the eight converter housing mounting bolts to the specified torque.
Specified torque: 48 ± 6 Nm (35 ± 4 ft. lbs.)

44. Install the parking roller rod to the detent lever.