Mitsubishi Outlander manuals

Mitsubishi Outlander: Transaxle

DISASSEMBLY AND ASSEMBLY

CAUTION

<F6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. RR roll stopper bracket
  2. FR roll stopper bracket
  3. Corrugate clamp bracket
  4. O-ring
  5. Oil filler tube
  6. Oil level gauge
  7. Harness bracket
  8. Spring washer
  9. Manual control lever
  10. Corrugate clamp bracket
  11. Control cable bracket
  12. Corrugate clamp bracket
  13. Breather hose

<W6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Transfer assembly
  2. RR roll stopper bracket
  3. FR roll stopper bracket
  4. Corrugate clamp bracket
  5. O-ring
  6. Oil filler tube
  7. Oil level gauge
  8. Harness bracket
  9. Spring washer
  10. Manual control lever
  11. Corrugate clamp bracket
  12. Control cable bracket
  13. Corrugate clamp bracket
  14. Breather hose

<F6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Park/neutral position switch
  2. Turbine sensor
  3. O-ring
  4. Baffle plate
  5. O-ring
  6. Transaxle assembly
  7. Torque converter
  8. O-ring
  9. ATF adjusting bolt
  10. Detent spring
  11. Control valve assembly
  12. Control valve cover gasket
  13. Control valve cover
  14. Snap ring
  15. Terminal assembly
  16. Lip seal
  17. Lip seal
  18. Pressure test port bolt
  19. O-ring

<W6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Park/neutral position switch
  2. Turbine sensor
  3. O-ring
  4. Baffle plate
  5. O-ring
  6. Transaxle assembly
  7. Torque converter
  8. O-ring
  9. ATF adjusting bolt
  10. Detent spring
  11. Control valve assembly
  12. Control valve cover gasket
  13. Control valve cover
  14. Snap ring
  15. Terminal assembly
  16. Lip seal
  17. Lip seal
  18. Pressure test port bolt
  19. O-ring

<F6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Parking pawl
  2. Parking pawl shaft
  3. Return spring
  4. Pawl shaft plate
  5. Outer race
  6. Reduction gear assembly
  7. Reduction gear lubrication tube
  8. Outer race
  9. Reduction gear taper bearing shim
  10. Outer race
  11. Differential assembly
  12. Outer race
  13. Differential taper bearing shim
  14. Needle bearing
  15. Bearing race
  16. RR sun gear (front side)
  17. Bearing race
  18. Needle bearing
  19. Output gear set
  20. Thrust washer
  21. Low clutch assembly
  22. FR carrier
  23. Needle bearing
  24. FR internal gear
  25. Needle bearing
  26. FR sun gear
  27. Needle bearing
  28. 3-5 Reverse clutch assembly
  29. Needle bearing
  30. Bearing race
  31. Oil pump assembly
  32. Input shaft
  33. O-ring
  34. Converter housing
  35. Side oil seal
  36. Magnet
  37. Oil strainer
  38. O-ring
  39. O-ring
  40. Transaxle case
  41. O-ring

<W6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Parking pawl
  2. Parking pawl shaft
  3. Return spring
  4. Pawl shaft plate
  5. Outer race
  6. Reduction gear assembly
  7. Reduction gear lubrication tube
  8. Outer race
  9. Reduction gear taper bearing shim
  10. Outer race
  11. Differential assembly
  12. Outer race
  13. Differential taper bearing shim
  14. Needle bearing
  15. Bearing race
  16. RR sun gear (front side)
  17. Bearing race
  18. Needle bearing
  19. Output gear set
  20. Thrust washer
  21. Low clutch assembly
  22. FR carrier
  23. Needle bearing
  24. FR internal gear
  25. Needle bearing
  26. FR sun gear
  27. Needle bearing
  28. 3-5 Reverse clutch assembly
  29. Needle bearing
  30. Bearing race
  31. Oil pump assembly
  32. Input shaft
  33. O-ring
  34. Converter housing
  35. Magnet
  36. Oil strainer
  37. O-ring
  38. O-ring
  39. Transaxle case
  40. O-ring

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Stud bolt
  2. Stud bolt
  3. O-ring
  4. Cooler tube (IN)
  5. Washer
  6. Cooler tube (OUT)
  7. Washer
  8. Side cover
  9. O-ring
  10. Side oil seal
  11. O-ring
  12. Water-cooled transmission fluid cooler
  13. O-ring
  14. Speed sensor

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Snap ring
  2. Diaphragm spring retainer
  3. Diaphragm spring
  4. D-ring
  5. Low-reverse brake piston
  6. D-ring
  7. Needle bearing
  8. RR carrier assembly
  9. Snap ring
  10. Retaining plate
  11. Drive plate
  12. Driven plate
  13. Drive plate
  14. Retaining plate
  15. Needle bearing
  16. RR sun gear (rear side)
  17. Snap ring
  18. One-way clutch
  19. Driven plate
  20. Retaining plate
  21. Side cover
  22. Spacer
  23. Needle bearing
  24. High clutch assembly
  25. Reduction sun gear
  26. Reduction carrier
  27. Needle bearing
  28. Reduction internal gear
  29. Needle bearing
  30. High clutch hub

INSTALLATION LOCATION OF ADJUST SHIM, NEEDLE BEARING AND THRUST WASHER

Mitsubishi Outlander. Automatic Transaxle Overhaul

Required special tools:

DISASSEMBLY

CAUTION Do not disassemble parts other than those described in this volume.

1. Remove the transfer from the transaxle. <W6AJ>

2. Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.

3. Remove the harness bracket from the transaxle.

4. Remove the oil filler tube and oil level gage from the transaxle.

5. Remove the control cable bracket and breather hose from the transaxle.

6. Remove the torque converter from the transaxle.

Mitsubishi Outlander. Automatic Transaxle Overhaul

7. Remove the vehicle speed sensor from the transaxle case.

8. Remove the O-ring from the vehicle speed sensor.

Mitsubishi Outlander. Automatic Transaxle Overhaul

9. Remove the turbine sensor from the transaxle case.

10.Remove the O-ring from the turbine sensor.

Mitsubishi Outlander. Automatic Transaxle Overhaul

11.Remove the park/neutral position switch.

Mitsubishi Outlander. Automatic Transaxle Overhaul

12.Remove the water-cooled transmission fluid cooler from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

13.Remove the O-ring from the water-cooled transmission fluid cooler.

Mitsubishi Outlander. Automatic Transaxle Overhaul

14.Remove the pressure test port bolt from the transaxle case.

15.Remove the O-ring from the pressure test port bolt.

Mitsubishi Outlander. Automatic Transaxle Overhaul

16.Remove the baffle plate from the converter housing.

17.Remove the O-ring from the baffle plate.

Mitsubishi Outlander. Automatic Transaxle Overhaul

18.Remove stud bolts from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

19.Remove the cooler tube (IN) from the side cover.

Mitsubishi Outlander. Automatic Transaxle Overhaul

20.Remove the cooler tube (OUT) from the side cover.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Be careful not to break the terminal body.

21.Remove the snap ring from the terminal body and push the terminal body into the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

22.Remove the control valve cover from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

23.Remove the control valve cover gasket from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

24.Remove control valve assembly mounting bolts A and B.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Remove the control valve assembly by pulling it straight.

25.Remove the control valve assembly from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Be careful not to drop the manual valve.

26.Remove the manual valve from the control valve.

Mitsubishi Outlander. Automatic Transaxle Overhaul

27.Remove the oil temperature sensor and bracket from the control valve.

28.Remove the bracket from the oil temperature sensor.

Mitsubishi Outlander. Automatic Transaxle Overhaul

29.Remove the terminal assembly from the control valve.

Mitsubishi Outlander. Automatic Transaxle Overhaul

30.Remove the detent spring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

31.Remove lip seals from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Do not damage the manual shaft oil seal mounting surface of the transaxle case when removing the manual shaft oil seal.

32.Using a flat-head screwdriver or equivalent, remove the manual shaft oil seal from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

33.Remove the transmission fluid adjusting bolt from the transaxle case.

34.Remove the O-ring from the ATF adjusting bolt.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Mounting bolts are Torx E20 bolts.

35.Remove converter housing mounting bolts.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

36.Lightly tap the converter housing with a plastic hammer or equivalent to remove.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Do not damage the converter housing when removing the side oil seal.

37.Remove the side oil seal from the converter housing using a pin punch or equivalent. <F6AJ>

Mitsubishi Outlander. Automatic Transaxle Overhaul

38.Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the converter housing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

39.Remove the reduction gear taper bearing shim from the converter housing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

40.Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the converter housing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

41.Remove the differential taper bearing shim from the converter housing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

42.Remove the O-ring from the input shaft.

Mitsubishi Outlander. Automatic Transaxle Overhaul

43.Remove the oil pump assembly and oil strainer as one unit.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

44.Remove the oil strainer from the oil pump assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

45.Remove the magnet from the oil strainer.

Mitsubishi Outlander. Automatic Transaxle Overhaul

46.Remove the O-ring from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

47.Remove the input shaft.

Mitsubishi Outlander. Automatic Transaxle Overhaul

48.Remove the bearing race and needle bearing from the 3-5 reverse clutch drum.

Mitsubishi Outlander. Automatic Transaxle Overhaul

49.Remove the 3-5 reverse clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

50.Remove the needle bearing from the FR sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

51.Remove the FR sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

52.Remove the needle bearing from the FR sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

53.Remove the FR internal gear and FR carrier as one unit.

Mitsubishi Outlander. Automatic Transaxle Overhaul

54.Remove the FR internal gear and needle bearing from the FR carrier.

Mitsubishi Outlander. Automatic Transaxle Overhaul

55.Remove the low clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

56.Remove the thrust washer from the drum support.

Mitsubishi Outlander. Automatic Transaxle Overhaul

57.Remove the differential assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

58.Remove the pawl shaft plate.

Mitsubishi Outlander. Automatic Transaxle Overhaul

59.Remove the return spring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

60.Remove the parking pawl shaft.

Mitsubishi Outlander. Automatic Transaxle Overhaul

61.Remove the parking pawl.

Mitsubishi Outlander. Automatic Transaxle Overhaul

62.Remove the reduction gear lubrication tube.

Mitsubishi Outlander. Automatic Transaxle Overhaul

63.Remove the reduction gear assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Mounting bolts are Torx E16 bolts.

64.Remove the side cover.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

65.Remove the spacer and needle bearing from the side cover.

Mitsubishi Outlander. Automatic Transaxle Overhaul

66.Remove the O-ring from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

67.Remove the high clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

68.Remove the reduction sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

69.Remove the reduction carrier.

Mitsubishi Outlander. Automatic Transaxle Overhaul

70.Remove the needle bearing from the reduction internal gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

71.Remove the reduction internal gear from the high clutch hub.

Mitsubishi Outlander. Automatic Transaxle Overhaul

72.Remove the needle bearing from the reduction internal gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

73.Remove the high clutch hub.

Mitsubishi Outlander. Automatic Transaxle Overhaul

74.Remove the needle bearing from the RR sun gear on the rear side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

75.Remove the RR sun gear on the rear side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

76.Remove the needle bearing from the RR carrier assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.

77.Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

78.Using a flat-head screwdriver or equivalent, remove the snap ring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

79.Remove the one-way clutch and RR carrier assembly as one unit.

Mitsubishi Outlander. Automatic Transaxle Overhaul

80.Separate the one-way clutch and RR carrier assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

81.Remove the needle bearing from the RR carrier assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

82.Using a flat-head screwdriver or equivalent, remove the snap ring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.

83.Remove the low-reverse brake retaining plate, drive plate and driven plate.

Mitsubishi Outlander. Automatic Transaxle Overhaul

84.Remove the RR sun gear on the front side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

85.Remove the bearing race from the RR sun gear on the front side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

86.Remove the needle bearing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

87.Using the special tool MB992195, remove the snap ring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

88.Remove the diaphragm spring retainer.

Mitsubishi Outlander. Automatic Transaxle Overhaul

89.Remove the diaphragm spring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.

90.Feed air through the oil hole as indicated in the illustration to remove the low-reverse brake piston from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

91.Remove D-rings from the low-reverse brake piston.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Mounting bolts are Torx E18 bolts.

92.Remove the Output gear set.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

93.Remove the O-ring from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Do not damage the transaxle case when removing the side oil seal.

94.Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

95.Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the transaxle case equivalent.

Mitsubishi Outlander. Automatic Transaxle Overhaul

96.Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

ASSEMBLY

CAUTION Never reuse the outer race.

1. Using the special tool MB991550, Install the outer race of the differential side bearing on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Never reuse the outer race.

2. Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

3. Measure an interference (A) of the reduction gear assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the reduction gear assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the reduction gear assembly on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Set the outer race on the reduction gear bearing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L1 from the outer race to the end face of the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Place a block on the end face of the converter housing and measure distance L2 to the reduction gear taper bearing shim mounting surface.
  2. Calculate distance L3 from the end face of the converter housing to the outer race of the reduction gear assembly from the following formula.

    L3 = L2 - Height of block

  3. Calculate the thickness of the reduction gear taper bearing shim from the following formula.

    Thickness of reduction gear taper bearing shim = L3 - L1 + Interference
    Standard value: 0.16 − 0.22 mm (0.006 − 0.009 in) (For reduction gear preload)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Never reuse the reduction gear taper bearing shim.

4. Install a selected reduction gear taper bearing shim on the converter housing. Refer to "SERVICE DATA" for selecting the reduction gear taper bearing shim.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Never reuse the outer race.

5. Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the converter housing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

6. Measure an interference (A) of the differential assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the differential assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the differential assembly on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Set the outer race on the differential side bearing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L1 from the outer race to the end face of the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L2 from the end face of the converter housing to the differential taper bearing shim mounting surface of the converter housing.
  2. Calculate the thickness of the differential taper bearing shim from the following formula.

    Thickness of differential taper bearing shim = L2 - L1 + Interference
    Standard value: 0.19 − 0.25 mm (0.008 − 0.010 in) (For differential preload)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Never reuse the differential taper bearing shim.

7. Install a selected differential taper bearing shim on the converter housing. Refer to "SERVICE DATA" for selecting the differential taper bearing shim.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Never reuse the outer race.

8. Using the special tool MB991550 <F1CJA> or MB991445 <W1CJA>, Install the outer race of the differential side bearing on the converter housing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

9. Install an O-ring on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Mounting bolts are Torx E18 bolts.

10.Install the output gear set. Refer to the following or the exploded view for the tightening torque.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Tightening torque: 41 +- 1 N*m (30 +- 1 ft-lb)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

11.Install D-rings on the low-reverse brake piston.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Apply transmission fluid to the low-reverse brake piston before installation.

12.Install the low-reverse brake piston on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

13.Install the diaphragm spring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

14.Install the diaphragm spring retainer.

Mitsubishi Outlander. Automatic Transaxle Overhaul

15.Using the special tool MB992195, install the snap ring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Measure the end play at more than two locations and obtain the average of the measurements.

16.Measure the clearance (A) of the low-reverse brake using the following procedure. Refer to "SERVICE DATA" for the specified low-reverse brake clearance.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. While compressing the drive plates, driven plates and retaining plate, measure the thickness L1 of the pack.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

NOTE: If there is no appropriate plate, use the special tool, MD998917

  1. Measure thickness L2 of the one-way clutch.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L3 from the end face of the transaxle case to the low-reverse brake piston.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Temporarily assemble the snap ring, one-way clutch and snap ring to the transaxle case.
  2. Measure distance L4 from the end face of the transaxle case to the one-way clutch, while pulling up the one-way clutch.
  3. Remove the temporarily assembled snap ring, one-way clutch and snap ring from the transaxle case.
  4. Calculate the clearance using the following formula. Clearance = L3 - (L1 + L2 + L4)
  5. Select an appropriate retaining plate so that the specified clearance is obtained. Refer to "SERVICE DATA" for selecting the retaining plate.

    Standard value: 1.9 − 2.2 mm (0.07 − 0.09 in) (For low-reverse brake clearance)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

17.Install the needle bearing.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Apply vaseline to the bearing race before installation.

18.Install the bearing race on the RR sun gear on the front side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

19.Install the RR sun gear on the front side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

20.Install the needle bearing on the RR carrier assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

21.Install the RR carrier assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Ensure that the various plates are installed in the correct order.

22.Install the low-reverse brake drive plate, driven plate and selected retaining plate on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

23.Using a flat-head screwdriver or equivalent, install the snap ring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

24.Install the one-way clutch.

Mitsubishi Outlander. Automatic Transaxle Overhaul

25.Using a flat-head screwdriver or equivalent, install the snap ring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Measure the end play at more than two locations and obtain the average of the measurements.

26.Measure the clearance (A) of the 2-6 brake using the following procedure. Refer to "SERVICE DATA" for the specified 2-6 brake clearance.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. While compressing the drive plates, driven plates and retaining plate, measure thickness L1 of the pack.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

NOTE: If there is no appropriate plate, use the special tool, MD998917

  1. Measure distance L2 from the end face of the transaxle case to the snap ring.

CAUTION When measuring L3, use the same straight bar as used when L2 is measured.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L3 from the end face of the side cover to the 2-6 brake piston.
  2. Calculate the clearance using the following formula.

    Clearance = L2 - (L1 + L3)

  3. Select an appropriate retaining plate so that the specified clearance is obtained. Refer to "SERVICE DATA" for selecting the retaining plate.

    Standard value: 1.9 − 2.2 mm (0.07 − 0.09 in) (For 2-6 brake clearance)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

27.Install the needle bearing on the RR carrier assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

28.Install the RR sun gear on the rear side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

29.Install the needle bearing on the RR sun gear on the rear side.

Mitsubishi Outlander. Automatic Transaxle Overhaul

30.Install the high clutch hub.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

31.Install the needle bearing on the reduction internal gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

32.Install the reduction internal gear on the high clutch hub.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

33.Install the needle bearing on the reduction internal gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

34.Install the reduction carrier.

Mitsubishi Outlander. Automatic Transaxle Overhaul

35.Install the reduction sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Measure the end play at more than two locations and obtain the average of the measurements.

36.Measure the reduction sun gear end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified reduction sun gear end play (A).

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L2 from the reduction carrier to the reduction sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L3 from the end face of the side cover to the end face of the high clutch support area.
  2. Calculate the end play using the following formula.

    End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer

  3. Select an appropriate spacer so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the spacer.

    Standard value: 0.4 − 0.7 mm (0.02 − 0.03 in) (For reduction sun gear end play)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Measure the end play at more than two locations and obtain the average of the measurements.

37.Measure the side cover end play (A) in the following procedure. Refer to "SERVICE DATA" for the specified side cover end play (A).

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L2 from the end face of the side cover to the needle bearing mounting surface.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L3 from the contact surface with the needle bearing of the high clutch drum to the snap ring of the cancel cover in the following procedure.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L4 from the high clutch drum edge to the snap ring of the cancel cover.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure height L5 of the high clutch drum.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L6 from the underside of the high clutch drum to the contact surface with the needle bearing.
  2. Calculate L3 using the following formula.

L3 = L5 - (L4 + L6) + Thickness of straight bar

  1. Calculate the end play using the following formula.

    End play = L2 - (L1 + L3) - Thickness of needle bearing

  2. Select an appropriate needle bearing so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the needle bearing.

    Standard value: 0.70 − 1.05 mm (0.028 − 0.041 in) (For side cover end play)

Mitsubishi Outlander. Automatic Transaxle Overhaul

38.Install the high clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Ensure that the various plates are installed in the correct order.

39.Install the 2-6 brake drive plate, driven plate and selected retaining plate on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

40.Install an O-ring on the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

41.Install an appropriate spacer and the needle bearing on the side cover.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

42.Apply the sealant to the transaxle case mounting surface of the side cover (almost the center line of the surface).

Specified sealant: Three Bond 1216B

Mitsubishi Outlander. Automatic Transaxle Overhaul

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Mounting bolts are Torx E16 bolts.

43.Install the side cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.

Mitsubishi Outlander. Automatic Transaxle Overhaul

Tightening torque: 27 +- 2 N*m (20 +- 1 ft-lb)

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION Measure the end play at more than two locations and obtain the average of the measurements.

44.Measure the drum support end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified drum support end play (A).

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L1 between the end face of the RR internal gear splines and the oil pump mounting surface of the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L2 between the thrust washer mounting surface of the drum support and the oil pump mounting surface of the transaxle case.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L3 using the following procedure.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the FR carrier on the low clutch assembly.

CAUTION

  1. Install the needle bearing on the FR carrier.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the FR internal gear on the FR carrier.

CAUTION

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the needle bearing on the FR sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the FR sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

  1. Install the needle bearing on the FR sun gear.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Install the 3-5 reverse clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

  1. Measure distance L3 between A and B.
  1. Calculate the end play using the following formula.

    End play = L3 - (L1 - L2) - Thrust washer thickness

  2. Select an appropriate thrust washer so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the thrust washer.

    Standard value: 0 − 0.35 mm (0 − 0.014 in) (For drum support end play)

Mitsubishi Outlander. Automatic Transaxle Overhaul

45.Install the reduction gear assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

46.Install the reduction gear lubrication tube.

Mitsubishi Outlander. Automatic Transaxle Overhaul

47.Install the parking pawl.

Mitsubishi Outlander. Automatic Transaxle Overhaul

48.Install the parking pawl shaft.

Mitsubishi Outlander. Automatic Transaxle Overhaul

49.Install the return spring.

Mitsubishi Outlander. Automatic Transaxle Overhaul

50.Install the pawl shaft plate. Refer to the following or the exploded view for the tightening torque.

Tightening torque: 7.9 N*m (70 in-lb)

Mitsubishi Outlander. Automatic Transaxle Overhaul

51.Install the differential gear assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

52.Install an appropriate thrust washer on the drum support.

Mitsubishi Outlander. Automatic Transaxle Overhaul

53.Install the low clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

54.Install the FR carrier on the low clutch assembly.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

55.Install the needle bearing on the FR carrier.

Mitsubishi Outlander. Automatic Transaxle Overhaul

56.Install the FR internal gear on the FR carrier.

Mitsubishi Outlander. Automatic Transaxle Overhaul

CAUTION

57.Install the needle bearing on the FR sun gear.

Mitsubishi O<ul></ul></table></ul><div style=

READ NEXT:

 Side Cover

DISASSEMBLY AND ASSEMBLY Side cover D-ring 2-6 brake piston D-ring Spring retainer Snap ring Seal ring Required special tools: MB992196: Spring compressor DISASSEMBLY 1. Remove the seal r

 Differential

DISASSEMBLY AND ASSEMBLY Disassembly Steps Final gear Differential side bearing (transmission case side) Differential side bearing (converter housing side) Differential sub-assembly Required

 Transfer

DISASSEMBLY AND ASSEMBLY <Vehicles with S-AWC> Disassembly steps Dust seal guard Oil seal O-ring Dust seal Oil seal Cover Transfer <Vehicles without S-AWC> Disassembly steps

SEE MORE:

 Wheel Speed Sensor

REMOVAL AND INSTALLATION CAUTION The vehicle speed detection encoder collects any metallic particle easily, because it is magnetized. Make sure that the encoder should not collect any metallic particle. Check that there is not any trouble prior to reassembling it. Pre-removal and post-installation

 Keyless entry system

Press the remote control switch, and all doors and the tailgate will be locked or unlocked as desired. It is also possible to operate the door mirrors, electric window. 1- LOCK switch. 2- UNLOCK switch. 3- Indicator lamp. To lock Press the LOCK switch (1), and all doors and the tailgate w

© 2010-2021 Copyright www.mioutlander.com