Automatic Trans: Overhaul: Transaxle: Disassembly

CAUTION:

Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
Work on a rubber mat and keep it clean at all times.
Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
If the transaxle body has been damaged, disassemble and clean the cooler system.

Remove the transfer and O-ring < W4A4B >.
Remove the torque converter.
Use a dial gauge to measure the input shaft end play.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt, gaskets and the oil cooler feed tube.

Fig 1: Measuring Input Shaft End Play Using Dial Gauge
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the air breather by jabbing a screw driver into the air breather and prying it up.

Fig 2: Removing Air Breather
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 3: Identifying Input Shaft And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.
Loosen the manual control lever tightening nut, and then remove the manual control lever and the park/neutral position switch.

Fig 4: Identifying Manual Control Lever And Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the Sealing cap and o-ring.

Fig 5: Identifying Sealing Cap And O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 6: Locating Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control shaft detent.

Fig 7: Identifying Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disconnect the solenoid valve harness from the valve body by disconnecting the fluid temperature sensor and all the connectors.

Fig 8: Identifying Fluid Temperature Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Make sure that the manual control lever and the park/neutral position switch are removed. See step 9.
- Do not remove the bolts (four pieces) shown in the illustration.
Remove the valve body mounting bolts (twenty seven pieces).

Fig 9: Identifying Bolts Which Are Not Removing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket, and the steel balls (two pieces).

Fig 10: Removing Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.

Fig 11: Removing Snap Ring From Connector
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 12: Identifying Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring.

Fig 13: Accumulator Piston And Spring Description Chart
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 14: Identifying Accumulator Piston And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 15: Identifying Control Lever Shaft And Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (eighteen pieces), and then remove the torque converter housing.

Fig 16: Locating Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential bearing outer race and spacer from the torque converter housing.
Remove the O-rings (two pieces).

Fig 17: Locating Differential Bearing Outer Race And Spacer In Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential < F4A4B > or center differential < W4A4B >.

Fig 18: Locating Differential (F4A4B) Or Center Differential (W4A4B)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 19: Removing Oil Filter
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Remove the oil pump mounting bolts (six pieces).

Fig 20: Locating Oil Pump Mounting Bolts
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Use special tools MD998333 in position shown in the drawing.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 21: Removing Oil Pump Using Special Tools MD998333
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 22: Removing Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 23: Removing Underdrive Clutch And Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 24: Removing Thrust Bearing Number 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 25: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 26: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking roller support shafts (two pieces), and then remove the parking pawl and parking roller support.

Fig 27: Removing Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the rear cover and input shaft rear bearing.
Remove thrust race number 8.
Remove the seal rings (four pieces).

Fig 28: Locating Seal Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 29: Locating O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 30: Removing Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 31: Removing Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 32: Removing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 33: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 34: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 35: Removing Second Brake Piston And Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (two pieces), brake discs (three pieces) and pressure plate.

Fig 36: Removing Brake Discs
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 37: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 38: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reaction plate and the brake disc.

Fig 39: Removing Reaction Plate And Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 40: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.
NOTE: *Includes the brake discs removed in step 49.

Fig 41: Removing brake plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 42: Removing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998903 and MD998924, compress the one-way clutch inner race.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
  
  Fig 43: Compressing One-Way Clutch Inner Race Using Special Tools MD998903 And MD998924
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 44: Identifying Transfer Drive Gear Bearing Mounting Bolts
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear bearing mounting bolts (three or four pieces).
Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

Fig 45: Removing Transfer Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 46: Removing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cap by jabbing a screw driver into the center of the cap and prying it up.

Fig 47: Straightening Staked Portions From Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a chisel, straighten the staked portions from the output shaft jam nut.
CAUTION: The jam nut is reverse threaded.

Fig 48: Removing Output Shaft Jam Nut Using Special Tools MB991625 And MB990607
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 49: Locating Bearing Retainer Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolts.

Fig 50: Removing Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 51: Removing Differential Bearing Outer Race From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.
Remove the snap ring.
Remove the differential bearing outer race from the transaxle case.