Mitsubishi V5A51, V5A51-7-ACA, V5A51-7-SDA, V5A51-7-CCA1, V5A51-7-CCA2 USER MANUAL

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Page 1

AUTOMATIC

TRANSMISSION

V5A51

CONTENTS

GENERAL INFORMATION 23E-0-3................................................

1. SPECIFICATIONS 23E-1-1...................................................

TRANSMISSION MODEL TABLE 23E-1-1....................................

GENERAL SPECIFICATIONS 23E-1-2.......................................

SERVICE SPECIFICATIONS 23E-1-3........................................

VALVE BODY SPRING IDENTIFICATION 23E-1-4.............................

TORQUE SPECIFICATIONS 23E-1-5.........................................

SNAP RING, THRUST RACE, SPACER AND PRESSURE PLATE

FOR ADJUSTMENT 23E-1-7................................................

SEALANTS 23E-1-12.......................................................

LUBRICANTS 23E-1-13.....................................................

2. SPECIAL TOOLS 23E-2-1....................................................

3. TRANSMISSION AND TRANSFER 23E-3-1.....................................

4. TRANSFER CASE ADAPTER 23E-4-1.........................................

5. TRANSMISSION 23E-5-1.....................................................

6. REVERSE AND OVERDRIVE CLUTCH 23E-6-1.................................

7. SECOND BRAKE 23E-7-1....................................................

8. LOW/REVERSE ANNULUS GEAR 23E-8-1.....................................

9. CENTER SUPPORT 23E-9-1..................................................

10. UNDERDRIVE CLUTCH 23E-10-1..............................................

11. VALVE BODY 23E-11-1.......................................................

12. DIRECT ANNULUS GEAR 23E-12-1............................................

13. DIRECT CLUTCH 23E-13-1....................................................

14. OUTPUT SHAFT SUPPORT 23E-14-1..........................................

15. TRANSFER 23E-15-1.........................................................

16. TRANSFER CASE PLATE 23E-16-1............................................

17. INPUT GEAR 23E-17-1........................................................

18. COUNTER GEAR 23E-18-1....................................................

19. REAR OUTPUT SHAFT 23E-19-1..............................................

20. FRONT OUTPUT SHAFT 23E-20-1.............................................

21. TRANSFER DRIVE SHAFT 23E-21-1...........................................

22. SHIFT RAIL DRIVE GEAR 23E-22-1............................................

23. 2-4WD SHIFT RAIL AND H-L SHIFT RAIL 23E-23-1..............................

23E-0-1

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23E-0-2

NOTES

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V5A51 -

General Information

23E-0-3

GENERAL INFORMATION

This transmission is the newly developed 5-speed automatic transmission that merges advanced electronic technology and mechanical technology. (1) A hydraulic balance mechanism is incorporated for the transmission clutch, allowing speed changes

at ultra-high speeds to be handled.

(2) The weight has been reduced by using precision sheet metal pressing of the clutch retainer, etc.,

and using aluminum die cast for the oil pump housing, etc.

SECTIONAL VIEW <TRANSMISSION>

12345678910111213

1. Torque converter clutch

2. Torque converter

3. Oil pump

4. Overdrive clutch

5. Reverse clutch

6. Overdrive planetary carrier

7. Second brake

8. Output planetary carrier

9. Low/reverse brake

10. One-way clutch

Mar. 2000Mitsubishi Motors Corporation

11. Center support

12. Underdrive clutch

13. Output shaft support

14. Parking gear

15. Output shaft

16. One-way clutch

17. Direct clutch

18. Valve body

19. Input shaft

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23E-0-4

V5A51 -

SECTIONAL VIEW <TRANSFER>

1 2 3 4 5 6 7 8 9 10

General Information

1. Transfer input gear

2. H-L clutch

3. Low speed gear

4. 2-4WD clutch sleeve

5. Drive sprocket

6. Chain

7. Viscous coupling

8. Center differential planetary carrier

9. Transfer drive shaft

10. Rear output shaft

11. Front output shaft

12. Counter shaft gear

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V5A51 -

HYDRAULIC CONTROL SYSTEM

General Information

23E-0-5

12 3 4 5

17 18

1. Reverse clutch

2. Low/reverse brake

3. Second brake

4. Underdrive clutch

5. Overdrive clutch

6. Torque converter clutch

7. Fail-safe valve A

8. Fail-safe valve B

9. Torque converter clutch control valve

10. Switching valve

11. Cooler

12. Low-reverse brake pressure control valve

13. Second brake pressure control valve

14. Underdrive clutch pressure control valve

15. Overdrive clutch pressure control valve

16. Torque converter clutch control solenoid valve

17. Low-reverse brake solenoid valve

18. Second brake solenoid valve

19. Underdrive clutch solenoid valve

20. Overdrive clutch solenoid valve

21. Torque converter pressure control valve

22. Regulator valve

23. Manual valve

24. Oil filter

25. Oil pan

26. Oil pump

27. Oil strainer

28. Reduction brake

29. Direct clutch

30. Fail-safe valve C

31. Reduction brake pressure control valve

32. Reduction brake solenoid valve

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V5A51 -

Specifications

1. SPECIFICATIONS

TRANSMISSION MODEL TABLE - MODEL 2001

Transmission models Vehicle model Engine model

EUR V5A51-7-ACA V65W, V75W 6G74

V5A51-7-SDA V68W, V78W 4M41

EXP V5A51-7-CCA1 V75W 6G74

V5A51-7-CCA2 V65W, V75W 6G74

V5A51-7-SDA1 V78W 4M41

23E-1-1

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23E-1-2

V5A51 -

Specifications

GENERAL SPECIFICATIONS

Item V5A51

Torque converter Type 3-element, with torque converter clutch

Transmission Type 5-speed, fully automatic

Gear ratio 1st 3.789

2nd 2.057

3rd 1.421

4th 1.000

5th 0.731

Reverse 3.865

Transfer Type 2-speed constant mesh

Gear ratio High 1.000

Low

1.900

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V5A51 -

Specifications

SERVICE SPECIFICATIONS

TRANSMISSION

Item Standard value

Direct planetary carrier mm 0.25 - 0.55

Underdrive clutch end play mm 1.6 - 1.8

Input shaft end play mm 0.25 - 0.81

Direct clutch end play mm 1.0 - 1.2

Overdrive clutch end play mm 2.0 - 2.2

Overdrive clutch return spring retainer end play mm 0 - 0.09

Second brake end play mm 1.49 - 1.95

Center support end play mm 0 - 0.16

Brake reaction plate end play mm 0 - 0.16

Reverse clutch end play mm 1.5 - 1.7

23E-1-3

Low/reverse brake end play mm 1.65 - 2.11

TRANSFER

Item Standard value Limit

Input gear bearing end play mm 0 - 0.06 -

Countershaft gear end play mm 0 - 0.15 -

Countershaft gear bearing end play mm 0 - 0.08 -

2-4WD clutch hub end play mm 0 - 0.08 -

H-L clutch hub end play mm 0 - 0.08 -

Rear output shaft preload mm 0.12 - 0.24 -

Rear output shaft end play mm 0 - 0.12 -

Rear output shaft bearing end play mm 0 - 0.08 -

Rear output shaft annulus gear end play mm 0 - 0.08 -

Differential lock hub end play mm 0 - 0.08 -

Clearance between outer synchronizer ring and drive sprocket mm - 0.3

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23E-1-4

V5A51 -

VALVE BODY SPRING IDENTIFICATION

Specifications

Item Wire

diameter mm

Orifice check ball spring 0.5 4.5 15.4 15

Torque converter clutch control valve spring 0.7 5.9 28.1 19

Damping valve spring 1.0 7.7 35.8 17

Torque converter pressure control valve spring 1.6 11.2 29.4 9.5

Fail-safe valve A spring 0.7 8.9 21.9 9.5

Pressure control valve spring 0.7 7.6 37.7 25

Line relief valve spring 1.0 7.0 17.3 10

Regulator valve spring 1.3 13.3 44.6 10.5

Outside diameter mm

Free height mm

Number of loops

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V5A51 -

Specifications

TORQUE SPECIFICATIONS

TRANSMISSION

Item Torque Nm

Output shaft support mounting bolt 23 ± 3

Upper valve body mounting bolt 11 ± 1

Park/neutral position switch mounting bolt 11 ± 1

Anchor plug 98 ± 15

Oil pan mounting bolt 11 ± 1

Oil filter mounting bolt 6 ± 1

Oil pump mounting bolt 23 ± 3

Cable end bracket mounting bolt 48 ± 6

Converter housing to transmission case tightening bolt 48 ± 6

Output shaft speed sensor mounting bolt 11 ± 1

23E-1-5

Reduction brake piston nut 19 ± 3

Separating plate mounting bolt 6 ± 1

Solenoid support mounting bolt 6 ± 1

Transfer to transfer case adapter tightening bolt 35 ± 6

Transmission case to transfer case adapter tightening bolt 48 ± 6

Input shaft speed sensor mounting bolt 11 ± 1

V alve body mounting bolt 11 ± 1

Detent spring mounting bolt 6 ± 1

Manual control lever mounting nut 22 ± 3

Lower valve body mounting bolt 11 ± 1

Lower valve body cover mounting bolt 11 ± 1

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23E-1-6

V5A51 -

Specifications

TRANSFER

Item Torque Nm

Dynamic damper 35 ± 6

Transfer case cover tightening bolt 19 ± 2

Input gear bearing retainer mounting bolt 20 ± 2

Transfer case to chain cover tightening bolt 35 ± 6

Rear bearing retainer mounting bolt 20 ± 2

Transfer case plate to transfer case tightening bolt and nut 35 ± 6

Rear cover to chain cover tightening bolt 35 ± 6

Shift actuator mounting bolt 11 ± 1

4LLC switch 35 ± 6

2WD switch 35 ± 6

Center differential lock switch 35 ± 6

4H switch 35 ± 6

2WD-4WD switch 35 ± 6

Vehicle speed sensor mounting bolt 11 ± 1

Front outoput sensor mounting bolt 11 ± 1

Rear output sensor mounting bolt 11 ± 1

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V5A51 -

Specifications

23E-1-7

SNAP RING, THRUST RACE, SPACER AND PRESSURE PLATE FOR ADJUSTMENT

TRANSMISSION Thrust race (for adjustment of direct planetary carrier end play)

Thickness mm Identification symbol Part number

1.6

1.8

2.0

2.2

2.3

None None None None None

MR276705 MR276706 MR276707 MR276708 MR276709

Snap ring (for adjustment of underdrive clutch and overdrive clutch end play)

Thickness mm Identification symbol Part number

1.6

1.7

1.8

1.9

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

3.0

Brown None Blue Brown None Blue Brown None Blue Brown None Blue Brown None Blue

MD759960 MD759961 MD759962 MD758892 MD750841 MD750842 MD750843 MD750844 MD750845 MD750846 MD750847 MD750848 MD750849 MD750850 MD750851

Thrust race (for adjustment of input shaft end play)

Thickness mm Identification symbol Part number

1.4

1.6

1.8

2.0

2.2

2.4

2.6

None None None None None None None

MD723063 MD707267 MD723064 MD707268 MD723065 MD724358 MD754798

Snap ring (for adjustment of overdrive clutch return spring retainer end play)

Thickness mm Identification symbol Part number

1.48

1.53

1.58

1.63

Brown Black None Brown

MR336158 MR336159 MR336160 MR336161

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23E-1-8

V5A51 -

Specifications

Pressure plate (for adjustment of second brake end play)

Thickness mm Identification symbol Part number

1.6

1.8

2.0

2.2

2.4

2.6

2.8

3.0

F E D C B A 0 1

MR336390 MR336391 MR336392 MR336393 MR336394 MR336395 MR336396 MR336397

Snap ring (for adjustment of center support and brake reaction plate end play)

Thickness mm Identification symbol Part number

2.2

2.3

2.4

2.5

None Blue Brown None

MD756784 MD756785 MD758552 MD758553

Snap ring (for adjustment of reverse clutch end play)

Thickness mm Identification symbol Part number

1.6

1.7

1.8

1.9

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

None Blue Brown None Blue Brown None Blue Brown None Blue Brown None

MD761088 MD761089 MD761090 MD758947 MD756690 MD756691 MD756692 MD756693 MD756694 MD756695 MD756696 MD756697 MD756698

Snap ring (for adjustment of direct clutch end play)

Thickness mm Identification symbol Part number

1.9

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

3.0

Mar. 2000Mitsubishi Motors Corporation

Brown None Blue Brown None Blue Brown None Blue Brown None Blue

MD758946 MD753397 MD753398 MD753399 MD753400 MD753401 MD753402 MD753403 MD753404 MD753405 MD753406 MD753497

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V5A51 -

Specifications

Snap ring (for adjustment of low/reverse brake end play)

Thickness mm Identification symbol Part number

23E-1-9

1.8

2.0

2.2

2.4

2.6

2.8

3.0

E D C B A 0 1

MD759425 MD759426 MD759427 MD759428 MD759429 MD759430 MD759431

TRANSFER Spacer (for adjustment of input gear bearing end play)

Thickness mm Identification symbol Part number

2.30

2.35

2.40

2.45

2.50

None Red White Blue Green

MD704199 MD704200 MD704201 MD704202 MD704203

Spacer (for adjustment of countershaft gear end play)

Thickness mm Identification symbol Part number

1.77

1.91

2.05

2.19

2.33

None Blue Brown White Red

MB896728 MB896729 MB896730 MB896731 MB896732

Snap ring (for adjustment of countershaft gear bearing end play)

Thickness mm Identification symbol Part number

1.48

1.62

Blue None

MB919176 MB919177

Snap ring (for adjustment of H-L clutch hub end play)

Thickness mm Identification symbol Part number

2.18

2.25

2.32

2.39

None None None None

MR410928 MR410929 MR410930 MR410931

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23E-1-10

V5A51 -

Specifications

Snap ring (for adjustment of differential lock hub end play)

Thickness mm Identification symbol Part number

2.56

2.63

2.70

2.77

2.84

2.91

2.98

None Red White Blue Yellow Green Brown

MD738386 MD738387 MD738388 MD738389 MD738390 MD738391 MD738392

Snap ring (for adjustment of 2-4WD clutch hub end play)

Thickness mm Identification symbol Part number

2.56

2.63

2.70

2.77

2.84

None Red White Blue Yellow

MD738393 MD738394 MD738395 MD738396 MD738397

Snap ring (for adjustment of rear output shaft bearing end play)

Thickness mm Identification symbol Part number

2.26

2.33

2.40

2.47

None Red White Blue

MD73431 1 MD734312 MD734313 MD734314

Snap ring (for adjustment of rear output shaft annulus gear end play)

Thickness mm Identification symbol Part number

1.90

1.94

1.98

2.02

2.06

2.10

None None None None None None

MR305024 MR305025 MR305026 MR305027 MR305028 MR305029

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V5A51 -

Specifications

Snap ring (for adjustment of rear output shaft preload)

Thickness mm Identification symbol Part number

23E-1-11

1.57

1.63

1.69

1.75

1.81

1.87

1.93

1.99

2.05

2.11

2.17

2.23

2.29

2.35

2.41

2.47

2.53

2.59

2.65

2.71

None None None None None None None None None None None None None None None None None None None None

Spacer (for adjustment of rear output shaft end play)

MR486340 MR486341 MR486342 MR486343 MR486344 MR486345 MR486346 MR486347 MR477935 MR477936 MR477937 MR477938 MR477939 MR477940 MR477941 MR477942 MR477943 MR477944 MR477945 MR477946

Thickness mm Identification symbol Part number

2.57

2.63

2.69

2.75

2.81

2.87

2.93

2.99

3.05

3.11

3.17

3.23

3.29

3.35

3.41

3.47

3.53

3.59

3.65

3.71

3.77

3.83

3.89

3.95

None None None None None None None None None None None None None None None None None None None None None None None None

MR477950 MR477951 MR477952 MR477953 MR477954 MR477955 MR477956 MR477957 MR477958 MR477959 MR477960 MR477961 MR477962 MR477963 MR477964 MR477965 MR477966 MR477967 MR477968 MR486348 MR486349 MR486350 MR486351 MR486352

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23E-1-12

V5A51 -

Specifications

SEALANTS

TRANSMISSION

Item Specified sealant

Oil pan MITSUBISHI genuine sealant part No. MR166584 or

equivalent

Transfer case adapter (transmission side) MITSUBISHI genuine sealant part No. MR166584 or

equivalent

TRANSFER

Item Specified sealant

Bearing retainer mounting bolt MITSUBISHI genuine sealant part No. MD997740 or

equivalent

Chain cover MITSUBISHI genuine sealant part No. MD997740 or

equivalent

Transfer case cover MITSUBISHI genuine sealant part No. MD997740 or

equivalent

Rear cover MITSUBISHI genuine sealant part No. MD997740 or

equivalent

Sealing cap 3MTMAAD part No. 8672 or equivalent

Transfer case plate MITSUBISHI genuine sealant part No. MD997740 or

equivalent

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V5A51 -

Specifications

23E-1-13

FORM-IN-PLACE GASKET (FIPG)

The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size. Since the FIPG used in the transmission hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas.

Disassembly

The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.

Surface preparation

Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old FIPG remaining in the bolt holes.

Form-in-place gasket application

When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG.

LUBRICANTS

TRANSFER

Item Specified lubricant

Lip of transfer case oil seal MITSUBISHI genuine grease part No. 0101011 or

equivalent

Lip of transfer case plate oil seal

Lip of rear cover oil seal

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V5A51 -

Special Tools

2. SPECIAL TOOLS

TRANSMISSION

Tool Number Name Use

MB990929 Installer adapter Installation of transfer case adapter oil seal

MB990938 Handle Use with installer adapter

MD998727 Oil pan remover Removal of oil pan

23E-2-1

MD998333 Oil pump remover Removal of oil pump

MB991693 Reduction brake

stopper

MB991633 Reduction brake

wrench set

MB991603 Bearing installer

stopper

Adjustment reduction brake piston

Measurement of direct planetary carrier and center support end plays

MD998304 Oil seal installer Measurement of direct planetary carrier end

play

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23E-2-2

Tool UseNameNumber

V5A51 -

Special Tools

MB991632 Clearance dummy

plate

MD998913 Dial gauge exten-

sion

MD998412 Guide Installation of oil pump

MD998316 Dial gauge support Measurement of input shaft end play

Measurement of brake reaction plate, second brake and low/reverse brake end plays

MD999590 Spring compressor Removal and installation of reverse and

overdrive clutch spring retainer snap ring

MD998924 Spring compressor

retainer

MB991629 Spring compressor Measurement of overdrive clutch and under-

MB991789 Spring compressor Adjustment reverse clutch end play

Use with spring compressor

drive clutch end plays

MB991630 Spring compressor Removal and installation of center support

snap ring and direct clutch snap ring

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Tool UseNameNumber

MD998907 Spring compressor Removal and installation of underdrive clutch

V5A51 -

Special Tools

spring retainer snap ring

23E-2-3

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23E-2-4

V5A51 -

Special Tools

TRANSFER

Tool Number Name Use

MB990932 Installer adapter Installation of oil seal

MB990938 Handle Use with installer adapter

MB990936 Installer adapter Installation of oil seal

MD998801 Bearing remover Removal and installation of bearing

MD998812 Installer cap Use with installer and installer adapter

MD998826 Installer adapter

(52)

MD998818 Installer adapter

(38)

Installation of transfer input gear bearing

Installation of countershaft gear bearing, front output shaft bearing

MD998917 Bearing remover Removal and installation of bearing

MD998814 Installer-200 Use with installer cap and installer adapter

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Tool UseNameNumber

V5A51 -

Special Tools

23E-2-5

MD998824 Installer adapter

(50)

MD998813 Installer-100 Use with installer cap and installer adapter

MD998830 Installer adapter

(66)

MD998192 Bearing puller Installation of transfer drive shaft bearing

Installation of rear output shaft bearing

Installation of transfer drive shaft bearing

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V5A51 -

Transmission and Transfer

3. TRANSMISSION AND TRANSFER

DISASSEMBLY AND ASSEMBLY

35±6Nm

23E-3-1

Disassembly steps

1. Transfer

2. Cable end bracket

3. Harness bracket

4. Harness bracket

"AA 5. Transfer case adapter

6. Transmission

48±6Nm

35±6Nm

ASSEMBLY SERVICE POINT

"AA

After squeezing out and applying sealant on the transfer case

3mm diameter

adapter at the section indicated in the illustration, install onto the transmission case.

Specified sealant:

Caution

Mar. 2000Mitsubishi Motors Corporation

TRANSFER CASE ADAPTER INSTALLATION

MITSUBISHI genuine sealant part No. MR166584 or equivalent

Evenly squeeze out and apply the sealant so that it is not excessive and does not ooze out.

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V5A51 -

Transfer Case Adapter

4. TRANSFER CASE ADAPTER

DISASSEMBLY AND ASSEMBLY

23E-4-1

Disassembly steps

1. Parking sprag shaft

"CA 2. Parking sprag spring

3. Parking sprag

"BA 4. Sealing cap

5. Parking roller support shaft

6. Parking roller support

"AA 7. Oil seal

8. Transfer case adapter

MB990938

MB990929

ASSEMBLY SERVICE POINTS

"AA

Use the special tools to install the oil seal.

OIL SEAL INSTALLATION

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23E-4-2

V5A51 -

Transfer Case Adapter

Sealing cap

1.5 mm

"BA

SEALING CAP INSTALLATION

1. Press the sealing caps into the dimensions shown in the illustration so that they are not slanted.

2. Apply sealant as shown in the illustration.

Specified sealant:

"CA

PARKING SPRAG SPRING INSTALLATION

AAD part No. 8672 or equivalent

Attach the end of the spring to the position shown in the illustration.

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V5A51 -

5. TRANSMISSION

DISASSEMBLY AND ASSEMBLY

Transmission

23E-5-1

11±1Nm

22±3Nm

11±1Nm

6±1Nm

11±1Nm

1. Input shaft speed sensor

2. Output shaft speed sensor

3. Manual control lever

4. Park/neutral position switch

5. Snap ring

6. Parking gear

7. Oil pan

8. Oil filter

11±1Nm

6±1Nm

Apply automatic transmission fluid to all moving parts before installation.

9. O-ring

10. Detent spring

11. Oil temperature sensor

12. Valve body

13. O-ring

14. Snap ring

15. Solenoid valve harness

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23E-5-2

V5A51 -

Transmission

23 25

Apply automatic transmission fluid to all moving parts before installation.

16. Oil seal

17. Oil seal

18. Oil strainer

19. Seal ring

20. Accumulator piston (for overdrive clutch)

21. Accumulator spring

22. Accumulator piston (for second brake)

23. Inner spring

24. Outer spring

25. Accumulator piston (for low/reverse brake)

26. Inner spring

27. Outer spring

28. Accumulator piston (for underdrive clutch)

29. Inner spring

30. Outer spring

31. Snap ring

32. Accumulator cover

33. O-ring

34. Accumulator spring

35. Accumulator piston (for reduction brake)

36. Accumulator piston (for direct clutch)

37. Seal ring

38. Spring pin

39. Pin

40. Manual control shaft

41. O-ring

42. O-ring

43. Detent lever

44. Parking roller rod

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48±6Nm

23±3Nm

V5A51 -

Transmission

23E-5-3

45. Converter housing

46. Oil pump

47. Oil pump gasket

48. Thrust race No.1

49. Thrust bearing No.2

50. Reverse and overdrive clutch

51. Thrust bearing No.3

Apply automatic transmission fluid to all moving parts before installation.

52. Overdrive clutch hub

53. Thrust bearing No.4

54. Reverse sun gear

55. Snap ring

56. Second brake

57. Return spring

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23E-5-4

V5A51 -

Transmission

Apply automatic transmission fluid to all moving parts before installation.

58. Pressure plate

59. Brake plate

60. Brake disc

61. Low/reverse annulus gear

62. Thrust bearing No.7

63. Snap ring

Mar. 2000Mitsubishi Motors Corporation

64. Reaction plate

65. Snap ring

66. Brake plate

67. Brake disc

68. Pressure plate

69. Wave spring

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Apply automatic transmission fluid to all moving parts before installation.

V5A51 -

Transmission

98±15 Nm

23E-5-5

23±3Nm

19±3Nm

81 80 79

70. Snap ring

71. Center support

72. Thrust race No.8

73. Thrust bearing No.9

74. Direct annulus gear

75. Thrust bearing No.12

76. Direct planetary carrier

77. Seal ring

78. Seal ring

79. Snap ring

80. Reduction brake cover

81. O-ring

82. Snap ring

83. Reduction brake piston nut

84. Reduction brake piston

85. Seal ring

86. Reduction brake piston adjusting rod

87. Reduction brake spring

88. Direct clutch

89. Thrust bearing No.13

90. Reduction brake band

91. Anchor plug

92. O-ring

93. Output shaft support

94. Output shaft support gasket

95. Transmission case

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23E-5-6

V5A51 -

DISASSEMBLY

Caution

Transmission

Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not to scratch or damage these parts during disassembly and reassembly. 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 towel. 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 race and rubber parts should be cleaned with ATF automatic transmission fluid so that they do not become dirty. If the transmission body has been damaged, disassemble and clean the cooler system also.

Manual control lever

1. Remove the input shaft speed sensor.

2. Remove the output shaft speed sensor.

3. Remove the manual control lever, and then remove the park/neutral position switch.

Park/neutral position switch

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Snap ring

Parking gear

MD998727

V5A51 -

4. Remove the snap ring, and remove the parking gear

5. Remove the twenty oil pan mounting bolts and then

Transmission

23E-5-7

using a puller (corresponding load approximately 9,800 N).

NOTE The parking gear may be removed without using a puller.

remove the oil p an using the special tool.

Caution

Carefully hammer the special tool so that the oil pan mounting surface is not damaged.

O-ring

Oil filter

6. Remove the oil filter and O-ring.

7. Remove the detent spring.

8. Disconnect the harness connectors of the valve body.

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23E-5-8

Oil temperature sensor

O-rings

V5A51 -

9. Remove the twenty valve body mounting bolts a n d then

Transmission

remove the valve body, three O-rings and oil temperature sensor.

NOTE The twenty valve body mounting bolts are plated bolts.

NOTE The O-rings are mounted on the transmission case side as shown in the illustration. However there may be cases where they will come off with the valve body.

Oil seals

Oil strainer

Snap ring

10. Remove the snap ring and disconnect the solenoid valve harness.

11. Remove the oil strainer and two oil seals.

12. Remove each accumulator piston, seal ring and spring. Remove the snap ring, then remove the accumulator cover, O-ring and spring.

No. Name

1 For overdrive clutch

2 For second brake

3 For low/reverse brake

4 For underdrive clutch

5 For reduction brake

1234

Mar. 2000Mitsubishi Motors Corporation

6 For direct clutch

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V5A51 -

Transmission

23E-5-9

NOTE To make assembly easier, attach an identification tag on the removed accumulator piston.

Spring pin

Parking roller rod

Manual control shaft

Detent lever

13. Remove the detent lever spring pin.

14. Remove the pin, and then remove the manual control shaft, two O-rings, detent lever an d parking roller rod.

15. Remove the eight converter housing mounting bolts, an d then converter housing.

16. Remove the te n oil pump mounting bolts.

17. Install the special tool into the bolt hole shown in the illustration.

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23E-5-10

MD998333

V5A51 -

18. While screwing in the special tool evenly, remove the

19. Remove the oil pump gasket.

Transmission

oil pump.

Thrust bearing No.2

Reverse and overdrive clutch

Overdrive clutch hub

Thrust race No.1

Thrust bearing No.3

20. Remove t he reverse a nd overdrive clutch, thrust race No.1 an d thrust bearing No.2.

NOTE The thrust race No.1 may be attached to the oil pump.

21. Remove the overdrive clutch hub and thrust bearing No.3.

22. Remove the thrust bearing No.4.

NOTE The thrust bearing No.4 may be attached to the overdrive clutch hub.

23. Remove the reverse sun gear.

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V5A51 -

24. Remove the snap ring.

25. Remove the second brake an d return spring.

Transmission

23E-5-11

Thrust bearing No.7

26. Remove the pressure plate, brake plates and brake discs.

27. Remove the low/reverse annulus gear.

28. Remove the thrust bearing No.7.

NOTE The thrust bearing No.7 may be attached to the low/reverse annulus gear.

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23E-5-12

V5A51 -

29. Remove the snap ring.

30. Remove the reaction plate and one brake disc.

Transmission

31. Remove the snap ring.

32. Remove the brake plates, brake discs, and pressure plate.

33. Remove the wave spring.

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Snap ring

Center support

V5A51 -

34. Remove the snap ring and center support.

Transmission

23E-5-13

Thrust bearing No.9

Direct planetary carrier

35. Remove the thrust race No.8 and thrust bearing No.9.

NOTE The thrust race No.8 may be attached to the center support.

Thrust race No.8

36. Remove the direct annulus gear.

37. Remove the thrust bearing No.12 and direct planetary carrier.

NOTE The thrust bearing No.12 may be attached to the direct annulus gear.

Seal rings

Thrust bearing No.12

Seal rings

Mar. 2000Mitsubishi Motors Corporation

38. Remove the two large and two small seal rings from the direct planetary carrier.

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23E-5-14

V5A51 -

Transmission

Snap ring

Reduction brake piston cover

Snap ring

Reduction brake piston

39. Remove the snap ring and then the reduction brake piston cover and O-ring.

40. Remove the snap ring and then the nut, reduction brake piston, seal ring, adjusting rod and spring.

41. Remove the direct clutch.

42. Remove the thrust bearing No.13.

NOTE The thrust bearing No.13 may be attached to the direct clutch.

43. Remove the reduction brake band.

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Output shaft support

V5A51 -

44. Remove the anchor plug and the O-ring.

45. Remove the eight output shaft support mounting bolts,

Transmission

23E-5-15

and then remove the output shaft support and gasket.

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23E-5-16

V5A51 -

ASSEMBLY

Caution

D D

Transmission

Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling. Never use grease other than blue petrolatum 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 towel. Change the oil in the cooler system.

Output shaft support

1. Install a new gasket and output shaft support.

Caution

Never reuse a gasket.

2. Tighten the eight output shaft support mounting bolts to the specified torque.

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V5A51 -

Transmission

Identification of thrust bearings and thrust races

23E-5-17

No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13

Symbol OD mm ID mm Thickness mm Part No.

No.1 48.9 37 1.4 MD723063

1.6 MD707267

1.8 MD723064

2.0 MD707268

2.2 MD723065

2.4 MD724358

2.6 MD754798

No.2 59 37 2.8 MR305718

No.3 57 38.5 4.12 MD758556

No.4 57 38.5 4.12 MD758556

No.5 54.4 38.5 3.3 MD761683

No.6 57 38.5 4.12 MD758556

No.7 70 48.8 4.0 MR222902

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23E-5-18

Symbol OD mm ID mm Thickness mm Part No.

No.8 73 60 1.6 MR276705

No.9 71.4 57 2.78 MR276587

No.10 71.9 48 4.6 MR263281

No.11 54.1 34 3.83 MR276588

No.12 57 38.5 4.62 MR222936

No.13 58 37.5 4.8 MD758555

V5A51 -

Transmission

1.8 MR276706

2.0 MR276707

2.2 MR276708

2.4 MR276709

Anchor bracket hole

Anchor plug

Apply bracket

Reduction brake piston adjusting rod hole

3. Install a new O-ring on the anchor plug and tighten the anchor plug to the specified torque.

4. Install the reduction brake band.

Fit the anchor bracket hole of the brake band onto the anchor plug tip, and then insert the apply bracket part into the hole for reduction brake piston adjusting rod.

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V5A51 -

Transmission

23E-5-19

Thrust bearing No.13

Direct clutch retainer

Thrust bearing No.13

5. Install the thrust bearing No.13 onto the direct clutch retainer.

Caution

Take care not to mistake the thrust bearing No.13 mounting direction.

6. Install the direct clutch.

Caution

Take care that the reduction brake band does not come off the anchor plug and the hole for the reduction brake piston adjusting rod.

7. Install th e reduction brake spring.

8. Screw the reduction brake piston adjusting rod into the reduction brake piston manually to the full.

9. Install new seal ring on the piston.

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23E-5-20

Snap ring

Reduction brake piston

V5A51 -

10. Press the reduction brake piston into the transmission

11. Tighten the reduction brake piston adjusting rod manually

Transmission

case, and then install the snap ring.

NOTE Set the open of the snap ring at indicated location.

to th e full.

MB991693

MB991633 (Socket)

12 Adjust the reduction brake piston by the following

procedure. (1) Mount the special tool so that the reduction brake

piston does not rotate.

(2) Mount the torque wrench to the special tool (Socket),

and after repeating tightening and turning back with a torque of 10 Nm twice, tighten the reduction brake piston adjusting rod to the specified torque of 5 Nm. Then turn the reduction brake piston adjusting rod

/2to 53/4turns back.

(3) Remove the special tool and tighten the reduction

brake piston nut manually.

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V5A51 -

Transmission

23E-5-21

MB991633 (Socket)

MB991633 (Wrench)

Snap ring

Reduction brake piston cover

Seal rings (small)

(4) Tighten the reduction brake piston nut to the specified

torque of 19 ± 3 Nm using the special tool (Wrench) while fixing the special tool (Socket) so as not to rotate.

13. Install a new O-ring on the reduction brake piston cover, and then install the cover and the snap ring on the transmission case.

14. Install new seal rings (two large pieces) onto the front end of the direct planetary carrier, and new seal rings (two small pieces) onto the shaft of the direct planetary carrier.

15. Insert the direct planetary carrier into the output shaft support.

Seal rings (large)

Thrust bearing No.12

Direct planetary carrier

16. Apply Vaseline or petrolatum jelly on the thrust bearing No.12, and then install on the front end of the direct planetary carrier.

Caution

Take care not to mistake the thrust bearing No.12 mounting direction.

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23E-5-22

V5A51 -

17. Install the direct annulus gear.

18. Apply Vaseline or petrolatum jelly to the thrust bearing

Transmission

Caution

Confirm that the thrust bearing No.10 in the direct annulus gear is still at the specified location.

No.9, and then install on the direct annulus gear.

Thrust bearing No.9

Direct annulus gear

Thrust race No.8

Caution

Take care not to mistake the thrust bearing No.9 mounting direction.

19. Apply Vaseline or blue petrolatum jelly on the thrust race No.8 removed, and then install it on the rear side of the center support.

Caution

Measure and record the thickness of the thrust race No.8 before assembling.

20. Install the center support.

Caution

Install the center support so that the oil hole shown in the illustration faces the lower side of the transmission case.

Use care that the thrust race No.8 attached to the rear side of the center support does not fall off.

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MB991603

Cable end bracket

V5A51 -

21. Using the transfer case adapter bolt, install special tool

Transmission

23E-5-23

MB991603.

Caution

Install the cable end bracket together with the special tool.

Direct planetary carrier

MB991603

Thrust race No.8

End play

MD998304

Direct annulus gear

Thrust bearing No.9

22. Select the thrust race No.8 with the following procedure: (1) Fix a dial gauge to the special tool. (2) Push the direct planetary carrier and direct annulus

gear in alternately, and measure the end play of th e direct planetary carrier.

NOTE (1) When pushing in the direct planetary carrier, make

sure that the center support does not move.

(2) When pushing in the direct annulus gear, use

the special tool.

(3) Replace the thrust race No.8 installed in step 19 with

a suitable one which can bring th e end play of the direct planetary carrier to the standard value. Then, reassemble.

NOTE Refer to the thickness recorded in step 19.

Standard value: 0.25 - 0.55 mm

(4) Measure the end play again, and confirm that it is

within the standard value.

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

Snap ring

23. Using the following steps, select a suitable snap ring for fixing the center support. (1) Install the snap ring which has been used for fixing

the center support.

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23E-5-24

V5A51 -

Transmission

Direct planetary carrier

MB991603

Standard value

Snap ring

Low/reverse brake piston

Center support

(2) Alternately push in the direct planetary carrier an d

center support, and measure the end play of the center support.

NOTE Be sure to push the direct planetary carrier in fully until the center support contacts the snap ring.

(3) Replace the snap ring for fixing the center support

installed in step 23 (1) with a suitable one so that the end play of the center support is at the standard value. Then, reassemble.

Standard value: 0 - 0.16 mm

(4) Measure the end play again, and confirm that it is

within the standard value.

24. Using the following steps, select a snap ring for adjusting the brake reaction plate end play an d second brake end play, and a pressure plate for adjusting the low/reverse brake e nd play. (1) Install the wave spring onto the low/reverse brake

piston.

MB991632

MD998913

Snap ring

End play

Mar. 2000Mitsubishi Motors Corporation

(2) Install the special tool in the position shown in the

illustration instead of the pressure plate for the low/reverse brake. Install the brake discs, brake plates and snap ring.

(3) Install the reaction plate and snap ring that was used.

Caution

Take care to the assembly direction of the reaction plate.

(4) Install a dial gauge onto special tool (MD998913)

so that the tool end contacts the brake reaction plate. Measure the end play by moving special tool (MB991632).

(5) Replace the snap ring installed in step 24 (3) with

a suitable one so that the end play may fall within the standard value. Then, reassemble.

Standard value: 0 - 0.16 mm

(6) Measure the end play again, and confirm that it is

within the standard value.

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Second brake

Snap ring

V5A51 -

Transmission

23E-5-25

(7) Next, install the special tool instead of the pressure

plate for the second brake. Install the four brake discs and three brake plates.

Caution

MB991632

Return spring

(8) Install the return spring, second brake and snap ring.

(9) Install a dial gauge onto special tool (MD998913)

MD998913

so that the end contacts the special tool (MB991632). Move special tool (MB991632) and measure the moving amount. Select a pressure plate with a thickness that

MB991632

Moving amount

corresponds to the measured moving amount from the following table.

End play standard value (reference):

Moving amount mm Pressure plate

Thickness mm ID Symbol Part No.

Take care to the shape and assembly direction of the brake plates installed at section “A” shown in the illustration.

1.49 - 1.95 mm

1.2 or more - less than 1.4 1.6 F MR336390

1.4 or more - less than 1.6 1.8 E MR336391

1.6 or more - less than 1.8 2.0 D MR336392

1.8 or more - less than 2.0 2.2 C MR336393

2.0 or more - less than 2.2 2.4 B MR336394

2.2 or more - less than 2.4 2.6 A MR336395

2.4 or more - less than 2.6 2.8 0 MR336396

2.6 or more - less than 2.8 3.0 1 MR336397

(10)Remove the snap ring, second brake, return spring

and special tool 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)

MD998913

so that the end contacts the special tool (MB991632). 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.

MB991632

End play standard value (reference):

1.65 - 2.11 mm

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23E-5-26

Moving amount mm Pressure plate

1.5 or more - less than 1.7 1.8 E MD759425

1.7 or more - less than 1.9 2.0 D MD759426

1.9 or more - less than 2.1 2.2 C MD759427

2.1 or more - less than 2.3 2.4 B MD759428

2.3 or more - less than 2.5 2.6 A MD759429

2.5 or more - less than 2.7 2.8 0 MD759430

2.7 or more - less than 2.9 3.0 1 MD759431

V5A51 -

Thickness mm ID symbol Part No.

Transmission

(13)Remove the parts installed in steps 24 (1) to (12).

Thrust bearing No.7

25. Apply Vaseline or petrolatum jelly on the thrust bearing No.7, a n d then install the bearing on the rear side of the low/reverse annulus gear.

Caution

Take care not to mistake the thrust bearing No.7 mounting direction.

26. Install the low/reverse annulus gear.

Caution

Make sure that the thrust bearing No.7 attached to the rear side of the low/reverse annulus gear does not fall off.

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V5A51 -

27. Install the reverse sun gear.

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

Transmission

23E-5-27

29. Install the pressure plate selected in step 24 (12), brake discs and brake plates.

30. Install the snap ring.

31. Install the reaction plate.

Caution

Take care not to mistake the reaction plate installation direction.

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23E-5-28

Reaction plate

Pressure plate

Brake plate

V5A51 -

32. Install the snap ring selected in step 24 (5).

33. Install the brake discs, brake plates and pressure plate

Transmission

selected in step 24 (9).

Caution

Take care not to mistake the brake plate (reaction plate side) installation direction.

Second brake

Return spring

Flat side

34. Install the return spring a n d second brake.

Caution

Install the return spring so that the flat side faces the back of the transmission.

35. Install the snap ring.

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V5A51 -

Transmission

23E-5-29

Thrust bearing No.4

Overdrive clutch hub

Thrust bearing No.3

36. Apply Vaseline or petrolatum jelly on the thrust bearing No.4, and then install on the reverse sun gear.

Caution

Take care not to mistake the thrust bearing No.4 installation direction.

37. Apply Vaseline or petrolatum jelly on the thrust bearing No.3, and then install on the overdrive clutch hub.

38. Install the overdrive clutch hub.

Thrust bearing No.3

Reverse and overdrive clutch

Thrust bearing No.2

Caution

Take care not to mistake the thrust bearing No.3 mounting direction.

39. Install the reverse and overdrive clutch.

40. Apply Vaseline or petrolatum jelly on the thrust bearing No.2, and then install on the reverse and overdrive clutch.

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23E-5-30

Thrust bearing No.2

V5A51 -

Transmission

Caution

Take care not to mistake the thrust bearing No.2 mounting direction.

MD998316

Thrust race No.1

MD998412

41. Apply Vaseline or petrolatum jelly on the thrust race No.1, and then install on the oil pump.

42. Install the special tool at the position shown in the illustration, and using this as a guide, install the oil pump and gasket.

Caution

Never reuse the gasket.

43. Tighten the ten oil pump mounting bolts to the specified torque.

44. Using the special tool, set a dial gauge as shown in the illustration. Measure the end play of the input shaft, and replace the thrust race installed in step 41 with a suitable one so that the end play may meet the standard value. Then, reassemble.

Standard value: 0.25 - 0.81 mm

45. Measure the end play again, and confirm that it is within the standard value.

46. Install the converter housing.

47. Tighten the eight converter housing mounting bolts to the specified torque.

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Parking roller rod

O-rings

Detent lever

V5A51 -

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

49. Install two new O-rings to the manual control shaft, and

Transmission

23E-5-31

assemble onto the transmission case together with the detent lever and parking roller rod.

Manual control shaft

50. Install the pin.

51. Hammer in the spring pin so that its slit is perpendicular to the axial direction of the manual control shaft.

Spring pin

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23E-5-32

Inner springs

Outer springs

V5A51 -

Transmission

52. Install a new seal ring onto each accumulator piston.

53. Install each accumulator piston a nd spring, then install accumulator cover with O-ring and snap ring.

NOTE (1) Install the accumulator pistons to the original positions

following the identification tags attached when they were removed.

1, 5, 6234

(2) The springs are identified by paint application position

as shown below. Assemble following this table.

No. Name Identification paint

application position

1 For overdrive

clutch

2 For second

brake

1234

3 For

low/reverse brake

4 For underdrive

clutch

5 For reduction

brake

6 For direct

clutch

None

Inner Applied on all surfaces

including both ends

Outer Applied on half of surface

including both ends

Inner Applied on half of surface

including both ends

Outer Applied on entire surface

of one side

Inner Applied on half of surface

including both ends

Outer Applied on half of surface

including both ends

None

54. Install the oil strainer an d two new oil seals. Install the

Oil seals

oil seals so that the notched section is oriented as shown in the illustration.

Caution

Take care to the installation direction of the oil seal.

Oil strainer

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V5A51 -

Transmission

23E-5-33

Manual valve pin

O-ring

Snap ring

55. Install the solenoid valve harness, and then secure the snap ring to connector groove.

NOTE Install the harness so that it is oriented as shown in the illustration.

56. Install new three O-rings onto the transmission case at the positions shown in the illustration.

57. Install the valve body while inserting the manual valve pin into the detent lever groove.

Oil temperature sensor

Detent lever

58. Install the oil temperature sensor.

59. Tighten the twenty valve body mounting bolts to the specified torque.

Bolt Length mm

A 25

B 30

Mar. 2000Mitsubishi Motors Corporation

C 40

D 45

E 55

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23E-5-34

V5A51 -

60. Connect the connector to the valve body.

61. Install the detent spring.

62. Tighten the detent spring mounting bolt to the specified

Transmission

torque.

O-ring

3 mm diameter

Oil filter

63. Install the oil filter and a new O-ring.

64. Apply sealant on the oil pan.

Specified sealant:

MITSUBISHI genuine sealant part No. MR166584 or equivalent

Caution

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

65. Install the oil pan.

66. Tighten the oil pan mounting bolts to the specified torque.

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Transmission side

Snap ring

Parking gear

V5A51 -

67. Install the parking gear and snap ring.

Transmission

23E-5-35

Caution

Install the parking gear so that the side without the spline cut faces the transmission side.

Heat the parking gear to 160 - 180_C, and shrink fit up to the stepped section of the output shaft.

Manual control lever

Park/neutral position switch

68. Install the park/neutral position switch and manual control lever.

69. Install the output shaft speed sensor.

70. Install the input shaft speed sensor.

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V5A51 -

Reverse and Overdrive Clutch

6. REVERSE AND OVERDRIVE CLUTCH

DISASSEMBLY AND ASSEMBLY

23E-6-1

Apply automatic transmission fluid to all moving parts before installation.

Disassembly steps

1. Seal ring

2. Snap ring

3. Input shaft

"HA 4. Snap ring "GA 5. Reaction plate "GA 6. Clutch disc "GA 7. Clutch plate "FA 8. Snap ring "EA 9. Reaction plate "EA 10. Clutch disc "EA 11. Clutch plate

22 21

AA""DA 12. Snap ring

13. Spring retainer

"AA 14. D-ring "CA 15. Return spring

16. Overdrive clutch piston

"AA 17. D-ring "BA 18. Reverse clutch piston "AA 19. D-ring "AA 20. D-ring "AA 21. D-ring

22. Reverse clutch retainer

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23E-6-2

V5A51 -

Reverse and Overdrive Clutch

MD999590

Hole “A”

MD998924

Snap ring

Hole “B”

DISASSEMBLY SERVICE POINT

AA"

1. Set the special tools as shown in t he illustration.

2. Compress the return spring, and remove the snap ring.

SNAP RING REMOVAL

ASSEMBLY SERVICE POINTS

"AA

1. Apply ATF to the D-ring.

2. Install the D-rings in the reverse clutch retainer, piston,

"BA

Align the holes (“A” and “B”) in t he reverse clutch piston and reverse clutch retainer and then assemble.

D-RING INSTALLATION

overdrive clutch piston and spring retainer grooves. Make sure that they are not twisted or damaged when installing.

REVERSE CLUTCH PISTON INSTALLATION

MD999590

MD998924

Snap ring

Mar. 2000Mitsubishi Motors Corporation

"CA

RETURN SPRING INSTALLATION

Align the two return spring holes with the two projections on the overdrive clutch piston, and then assemble the return springs.

"DA

SNAP RING INSTALLATION

1. Set the special tools as shown in t he illustration.

2. Tighten the special tool nut, and press the spring retainer against the reverse clutch retainer.

3. Install the thickest snap ring that can be fitted in the snap ring groove of the reverse clutch retainer.

4. Confirm that clearance between the snap ring and spring retainer is the standard value.

Standard value: 0 - 0.09 mm

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V5A51 -

Reverse and Overdrive Clutch

23E-6-3

Clutch plates

Clutch discs

MD998924

Rounded edge

Reaction plate

“R1” stamp

MB991629

"EA

CLUTCH PLATE / CLUTCH DISC / REACTION PLATE INSTALLATION

1. Alternately assemble the clutch discs and clutch plates in the reverse clutch piston.

2. Install the reaction plate so that it is oriented as shown in the illustration.

"FA

SNAP RING INSTALLATION

1. Install the snap ring in the reverse clutch piston groove.

2. Set the special tools as shown in the illustration, and compress the clutch element.

3. Confirm that the clearance between the snap ring and reaction plate (overdrive clutch end play) is the standard value. If the clearance is not at the standard value, select a suitable snap ring and adjust so that the clearance is within the standard value.

Standard value: 2.0 - 2.2 mm

Clutch plates

Reaction plate

Rounded edge

Snap ring

End play

Reaction plate

“R” stamp

"GA

CLUTCH PLATE / CLUTCH DISC/REACTION PLATE INSTALLATION

1. Alternately assemble the clutch plates and clutch discs in the reverse clutch retainer. When assembling th e clutch plates, align the section having no teeth (A in the illustration) with the reverse clutch retainer hole (B in the illustration).

2. Install the reaction plate so that it is oriented as shown in the illustration. Assemble in the same manner as the clutch plate so that the section with no teeth (“A” in the illustration) matches the retainer hole (“B” in the illustration).

Clutch discs

Mar. 2000Mitsubishi Motors Corporation

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23E-6-4

V5A51 -

Reverse and Overdrive Clutch

End play

MB991789

MD998924

"HA

SNAP RING INSTALLATION

1. Install the snap ring in the reverse clutch retainer groove.

2. Set the special tools as shown in the illustration, and compress the clutch element.

3. Check that the clearance between the snap ring and reaction plate (reverse clutch end play) is the standard value. If the clearance is not at the standard value, select a suitable snap ring an d adjust so that the clearance is within the standard value.

Standard value: 1.5 - 1.7 mm

Mar. 2000Mitsubishi Motors Corporation

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V5A51 -

7. SECOND BRAKE

DISASSEMBLY AND ASSEMBLY

Second Brake

23E-7-1

Disassembly steps

1. Second brake retainer

2. Second brake piston

"AA 3. D-ring "AA 4. D-ring

ASSEMBLY SERVICE POINT

"AA

1. Apply ATF to the D-ring.

2. Install the D-ring in the groove on the outer an d inner

Mar. 2000Mitsubishi Motors Corporation

D-RING INSTALLATION

periphery of the piston. Make sure that the D-ring is not twisted or damaged when installing.

AddedPWEE8920-I

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V5A51 -

Low/reverse Annulus Gear

8. LOW/REVERSE ANNULUS GEAR

DISASSEMBLY AND ASSEMBLY

Apply automatic transmission fluid to all moving parts before installation.

23E-8-1

Disassembly steps

1. Snap ring

2. Overdrive planetary carrier

"DA 3. Thrust bearing No.5

4. Underdrive sun gear

"CA 5. Thrust bearing No.6

6. Output planetary carrier

"BA 7. Stopper plate "AA 8. One-way clutch

9. Snap ring

10. Low/reverse annulus gear

ASSEMBLY SERVICE POINTS

"AA

Install the one-way clutch so that the arrow stamp is oriented as shown in the illustration.

Arrow

Mar. 2000Mitsubishi Motors Corporation

ONE-WAY CLUTCH INSTALLATION

AddedPWEE8920-I

Page 68

23E-8-2

V5A51 -

Low/reverse Annulus Gear

Stopper plate

Claw

Groove

Output planetary carrier side

"BA

STOPPER PLATE INSTALLATION

Install the stopper plate onto the low/reverse annulus gear. Make sure that the stopper plate claws are securely engaged in the annulus gear groove.

"CA

THRUST BEARING NO.6 INSTALLATION

Apply Vaseline or petrolatum jelly on the thrust bearing No.6, and then install on the output planetary carrier.

Caution

Take care not to mistake the thrust bearing No.6 mounting direction.

"DA

THRUST BEARING NO.5 INSTALLATION

Overdrive planetary carrier side

Apply Vaseline or petrolatum jelly on the thrust bearing No.5, and then install on the overdrive planetary carrier.

Caution

Take care not to mistake the thrust bearing No.5 mounting direction.

Mar. 2000Mitsubishi Motors Corporation

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V5A51 -

9. CENTER SUPPORT

DISASSEMBLY AND ASSEMBLY

Apply automatic transmission fluid to all moving parts before installation.

Center Support

23E-9-1

Disassembly steps

AA""CA 1. Snap ring

2. Plate

3. One-way clutch inner race

"BA 4. O-ring

5. Spring retainer

6. Return spring

7. Low/reverse brake piston

"AA 8. D-ring "AA 9. D-ring

10. Center support

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Page 70

23E-9-2

V5A51 -

Center Support

MD998924

MB991630

Snap ring

DISASSEMBLY SERVICE POINT

AA"

1. Set the special tools as shown in the illustration so that

2. Screw in the special tool nut, and lightly press against

3. Remove the snap ring.

SNAP RING REMOVAL

they are pressed against the inner race of the one-way clutch.

the inner race of the one-way clutch.

ASSEMBLY SERVICE POINTS

"AA

1. Apply ATF to the D-ring.

2. Install the D-ring in the groove on the outer an d inner

"BA

Install the O-ring onto the center support at the position shown in the illustration.

D-RING INSTALLATION

periphery of the piston. Make sure that the D-ring is not twisted or damaged when installing.

O-RING INSTALLATION

O-ring

MD998924

MB991630

Snap ring

"CA

SNAP RING INSTALLATION

1. Set the special tools as shown in t he illustration.

2. Screw in the special tool nut, and lightly press against the inner race of the one-way clutch.

3. Install the snap ring.

Mar. 2000Mitsubishi Motors Corporation

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V5A51 -

10. UNDERDRIVE CLUTCH

DISASSEMBLY AND ASSEMBLY

Apply automatic transmission fluid to all moving parts before installation.

Underdrive Clutch

23E-10-1

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Page 72

23E-10-2

Disassembly steps

"EA 1. Snap ring "DA 2. Reaction plate "DA 3. Clutch disc "DA 4. Clutch plate

AA""CA 5. Snap ring

6. Snap retainer

"AA 7. D-ring

V5A51 -

Underdrive Clutch

"BA 8. Return spring

9. Underdrive clutch piston

"AA 10. D-ring "AA 11. D-ring "AA 12. D-ring

13. Underdrive clutch retainer

MD998924

Snap ring

MD998907

DISASSEMBLY SERVICE POINT

AA"

1. Set the special tools as shown in t he illustration.

2. Compress the return spring, and remove the snap ring.

SNAP RING REMOVAL

ASSEMBLY SERVICE POINTS

"AA

1. Apply ATF to the D-ring.

2. Install th e D-ring in the groove of the underdrive clutch

"BA

Align the two return spring holes with the two projections on the underdrive clutch piston, and then assemble the return springs.

D-RING INSTALLATION

retainer and spring retainer. Make sure that the D-ring is not twisted or damaged when installing.

RETURN SPRING INSTALLATION

MD998924

MD998907

"CA

SNAP RING INSTALLATION

1. Set the special tools as shown in t he illustration.

2. Compress the return spring, and install the snap ring.

Snap ring

Mar. 2000Mitsubishi Motors Corporation

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V5A51 -

Underdrive Clutch

23E-10-3

“W” stamp

Reaction plate

MD998924

MB991629

Clutch discs

"DA

CLUTCH PLATE / CLUTCH DISC / REACTION PLATE INSTALLATION

1. Alternately assemble the clutch plates and clutch discs in the underdrive clutch retainer. When assembling the four clutch plates, align the seciton having no teeth (A in the illustration) with the underdrive clutch retainer hole (B in the illustration).

Clutch platesRounded edge

"EA

SNAP RING INSTALLATION

1. Install the snap ring in the groove of the underdrive clutch retainer.

2. Set the special tools as shown in the illustration, and compress the clutch element.

3. Confirm that the clearance between the snap ring and reaction plate (underdrive clutch end play) is the standard value. If the clearance is not at the standard value, select a suitable snap ring and adjust so that the clearance is within the standard value.

Snap ring

End play

Standard value: 1.6 - 1.8 mm

Reaction plate

Mar. 2000Mitsubishi Motors Corporation

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Page 74

11. VALVE BODY

DISASSEMBLY AND ASSEMBLY

V5A51 -

Valve Body

23E-11-1

11±1Nm

Apply automatic transmission fluid to all moving parts before installation.

6±1Nm

11±1Nm

11 12

Disassembly steps

"GA 1. Manual valve pin "FA 2. Damping valve "FA 3. Seal ring "FA 4. Damping valve spring "FA 5. Ball (orifice check ball) "FA 6. Steel ball (orifice check ball) "FA 7. Spring

8. Upper valve body gasket

11±1Nm

9. Separating plate

10. Lower valve body gasket

"EA 11. Steel ball (line relief) "EA 12. Spring "DA 13. Knock bushing "CA 14. Knock bushing "BA 15. Dowel pin

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23E-11-2

6±1Nm

V5A51 -

Valve Body

Apply automatic transmission fluid to all moving parts before installation.

Disassembly steps

16. Solenoid support

AA""AA 17. Low/reverse brake solenoid valve AA""AA 18. Reduction brake solenoid valve AA""AA 19. Second brake solenoid valve AA""AA 20. Underdrive clutch solenoid valve AA""AA 21. Overdrive clutch solenoid valve AA""AA 22. Torque converter clutch control sole-

noid valve

23. Stopper plate

24. Stopper plug

25. Switching valve

26. Stopper plate

27. Fail-safe valve A sleeve

28. Fail-safe valve A

29. Fail-safe valve A spring

30. Fail-safe valve A

31. Stopper plate

32. Fail-safe valve B sleeve

33. Fail-safe valve B

34. Stopper plate

35. Stopper plug

36. Torque converter pressure control valve

37. Torque converter pressure control valve spring

38. Upper valve body

Mar. 2000Mitsubishi Motors Corporation

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V5A51 -

Valve Body

23E-11-3

Apply automatic transmission fluid to all moving parts before installation.

Disassembly steps

39. Manual valve

40. Roller

41. Low/reverse brake pressure control valve sleeve

42. Low/reverse brake pressure control valve

43. Low/reverse brake pressure control valve spring

44. Stopper plate

45. Fail-safe valve C sleeve

46. Fail-safe valve C

47. Roller

48. Reduction brake pressure control valve sleeve

49. Reduction brake pressure control valve

50. Reduction brake pressure control valve spring

51. Roller

52. Second brake pressure control valve sleeve

53. Second brake pressure control valve

54. Second brake pressure control valve spring

55. Roller

56. Underdrive clutch pressure control valve sleeve

11±1Nm

57. Underdrive clutch pressure control valve

58. Underdrive clutch pressure control valve spring

59. Roller

60. Overdrive clutch pressure control valve sleeve

61. Overdrive clutch pressure control valve

62. Overdrive clutch pressure control valve spring

63. Stopper plate

64. Regulator valve adjusting screw

65. Regulator valve sleeve

66. Regulator valve spring

67. Regulator valve

68. Roller

69. Torque converter clutch control valve sleeve

70. Torque converter clutch control valve

71. Torque converter clutch control valve spring

72. Cover

73. Cover gasket

74. Lower valve body

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Page 77

23E-11-4

V5A51 -

Valve Body

DISASSEMBLY SERVICE POINT

AA"

Before removing the solenoid valves, make marks with white paint, etc., so that these valves can be reinstalled in the original positions.

SOLENOID VALVE REMOVAL

ASSEMBLY SERVICE POINTS

"AA

1. Apply ATF, petrolatum jelly or Vaseline to O-rings, and

2. Following the marks made during removal, install each

SOLENOID VALVE INSTALLATION

install them to solenoid valves.

solenoid valve.

Dowel pin

6mm

"BA

DOWEL PIN INSTALLATION

Install the dowel pin at the specified position on the lower valve body.

"CA

KNOCK BUSHING INSTALLATION

Install the knock bushing onto the lower valve body position shown in the illustration.

9mm

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Page 78

V5A51 -

Valve Body

23E-11-5

4.5 mm

Steel ball

"DA

KNOCK BUSHING INSTALLATION

Install the knock bushing onto the lower valve body position shown in the illustration.

"EA

SPRING / STEEL BALL (LINE RELIEF) INSTALLATION

Install the spring (7 mm in diameter, 17.3 mm in length) and the steel ball (6.4 mm in diameter) onto the lower valve body position shown in the illustration.

Seal ring

Spring

Ball (rubber)

Steel ball

"FA

SPRING / STEEL BALL (ORIFICE CHECK BALL) / BALL (ORIFICE CHECK BALL) / DAMPING VALVE SPRING / SEAL RING / DAMPING VALVE INSTALLATION

1. Install the spring (4.5 mm in diameter, 15.4 mm in length) and the steel ball (6.4 mm in diameter) onto the upper valve body position shown in the illustration.

2 Install the ball (rubber) (6.4 mm in diameter) onto the

upper valve body position shown in the illustration.

3. After installing the seal ring onto the damping valve, install together with the damping valve spring (7.7 mm in diameter, 35.8 mm in length) onto the upper valve body position shown in the illustration.

Damping valve

Damping spring

Spring

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23E-11-6

V5A51 -

Valve Body

Manual valve

Manual valve pin

"GA

MANUAL VALVE INSTALLATION

Fit the manual valve pin into the groove of the manual valve.

Mar. 2000Mitsubishi Motors Corporation

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Page 80

V5A51 -

12. DIRECT ANNULUS GEAR

DISASSEMBLY AND ASSEMBLY

Apply automatic transmission fluid to all moving parts before installation.

Direct Annulus Gear

23E-12-1

Disassembly steps

1. Snap ring

2. Output flange

"BA 3. Thrust bearing No.10

4. Underdrive clutch hub

"AA 5. Thrust bearing No.11

6. Underdrive clutch

7. Direct annulus gear

Thrust bearing No.11

ASSEMBLY SERVICE POINTS

"AA

Apply vaseline or petrolatum jelly on the thrust bearing No.11, and then install on the underdrive clutch.

Caution

Mar. 2000Mitsubishi Motors Corporation

THRUST BEARING NO.11 INSTALLATION

Take care not to mistake the thrust bearing No.11 mounting direction.

AddedPWEE8920-I

Page 81

23E-12-2

V5A51 -

Direct Annulus Gear

Thrust bearing No.10

"BA

THRUST BEARING NO.10 INSTALLATION

Apply vaseline or petrolatum jelly on the thrust bearing No.10, and then install on the underdrive clutch hub.

Caution

Take care not to mistake the thrust bearing No.10 mounting direction.

Mar. 2000Mitsubishi Motors Corporation

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Page 82

V5A51 -

13. DIRECT CLUTCH

DISASSEMBLY AND ASSEMBLY

Apply automatic transmission fluid to all moving parts before installation.

Direct Clutch

23E-13-1

Disassembly steps

"DA 1. Snap ring "CA 2. Reaction plate "CA 3. Clutch disc "CA 4. Clutch plate

AA""BA 5. Snap ring

6. Spring retainer

"AA 7. D-ring

8. Return spring

9. Direct clutch piston

"AA 10. D-ring "AA 11. D-ring

12. Direct clutch retainer

10 11

678

Mar. 2000Mitsubishi Motors Corporation

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Page 83

23E-13-2

V5A51 -

Direct Clutch

MB991630 MD998924

Snap ring

MB991630 MD998924

DISASSEMBLY SERVICE POINT

AA"

1. Set the special tools as shown in t he illustration.

2. Compress the return spring, and remove the snap ring.

SNAP RING REMOVAL

ASSEMBLY SERVICE POINTS

"AA

1. Apply ATF to the D-ring.

2. Install the D-ring in the direct clutch piston and spring

"BA

1. Set the special tools as shown in t he illustration.

2. Compress the return spring, and install the snap ring.

D-RING INSTALLATION

retainer groove. Make sure that the D-ring is not twisted or damaged when installing.

SNAP RING INSTALLATION

Clutch plates

Rounded edge

Snap ring

Reaction plate

“R” stamp

"CA

CLUTCH PLATE / CLUTCH DISC / REACTION PLATE INSTALLATION

1. Alternately assemble the clutch plates and clutch discs in the reverse clutch retainer. Align the section having no teeth of the clutch plates (A in t he illustration) with the reverse clutch retainer hole (B in the illustration).

2. Install the reaction plate so that it is oriented as shown in the illustration. Assemble in the same manner as the clutch plate so that the section with no teeth (A in the illustration) matches the retainer hole (B in the illustration).

Clutch discs

Mar. 2000Mitsubishi Motors Corporation

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V5A51 -

Direct Clutch

23E-13-3

Snap ring

Standard value

Reaction plate

"DA

SNAP RING INSTALLATION

1. Install the snap ring in the direct clutch retainer groove.

2. Press the entire periphery of the reaction plate with a force of 49 N, a n d confirm that the clearance between the snap ring and reaction plate (direct clutch e nd play) is the standard value. If the clearance is not at the standard value, select a suitable snap ring and adjust so that the clearance is within the standard value.

Standard value: 1.0 - 1.2 mm

Mar. 2000Mitsubishi Motors Corporation

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Page 85

V5A51 -

Output Shaft Support

14. OUTPUT SHAFT SUPPORT

DISASSEMBLY AND ASSEMBLY

Apply automatic transmission fluid to all moving parts before installation.

23E-14-1

Disassembly steps

1. Snap ring

"AA 2. One-way clutch

3. Seal ring

4. Output shaft support

Output shaft support

Identification groove

One-way clutch

ASSEMBLY SERVICE POINT

"AA

Install the one-way clutch in such a way that it will be oriented in the direction shown.

Mar. 2000Mitsubishi Motors Corporation

ONE-WAY CLUTCH INSTALLATION

AddedPWEE8920-I

Page 86

15. TRANSFER

DISASSEMBLY AND ASSEMBLY

V5A51 -

Transfer

23E-15-1

35±6Nm

19±2Nm

11±1Nm

35±6Nm

Apply gear oil to all moving parts before installation.

11±1Nm

12 13

35±6Nm

11±1Nm

35±6Nm

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Page 87

23E-15-2

"WA 2. 4LLC switch

"WA 5. 2WD switch

"WA 8. Center differential lock switch

"WA 11. 4H switch

"WA 14. 2WD-4WD switch

Disassembly steps

1. Vacuum hose

3. Gasket

4. Steel ball

6. Gasket

7. Steel ball

9. Gasket

10. Steel ball

12. Gasket

13. Steel ball

15. Gasket

16. Steel ball

V5A51 -

Transfer

"VA 17. Transfer case cover "UA 18. Shift rail drive gear "UA 19. Shift rail drive gear

20. Dust seal guard

21. Dynamic damper

22. Vehicle speed sensor

23. O-ring

24. Rear output sensor

25. O-ring

26. Front output sensor

27. O-ring

"TA 28. Shift actuator

29. O-ring

"TA 30. Main shift rail

31. Under guard (EXP)

Mar. 2000Mitsubishi Motors Corporation

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Page 88

Apply gear oil to all moving parts before installation.

V5A51 -

Transfer

35±6Nm

23E-15-3

35±6Nm

Disassembly steps

"SA 32. Rear cover "RA 33. Oil seal

34. Snap ring

35. Sensor rotor

36. Steel ball

37. Oil guide

"QA 38. Spacer

39. Snap ring

"PA 40. Snap ring "OA 41. Chain cover "NA 42. Rear output shaft

43. O-ring

44. Bearing

45. Snap ring

46. Center differential planetary carrier

47. Viscous coupling

AA""MA 48. Chain AA""MA 49. Front output shaft

"MA 50. Drive sprocket

51. Bearing

"LA 52. Synchronizer inner ring "LA 53. Synchronizer cone "LA 54. Synchronizer outer ring

55. Synchronizer spring

"KA 56. Snap ring

57. 2-4WD clutch hub

AA" 58. Sun gear

59. Bearing

60. Wave spring

"JA 61. 2-4WD clutch sleeve "JA 62. 2-4WD shift fork "IA 63. Spacer "IA 64. Steel ball "HA 65. Snap ring

66. Differential lock hub

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Page 89

23E-15-4

Apply gear oil to all moving parts before installation.

35±6Nm

V5A51 -

Transfer

20±2Nm

35±6Nm

Disassembly steps

"GA 67. Transfer case plate

68. Bearing

69. Counter shaft gear

"FA 70. Spacer "EA 71. H-L clutch sleeve "EA 72. H-L shift fork "DA 73. Snap ring

74. H-L clutch hub

75. Low speed gear

76. Bearing

"CA 77. Rear bearing retainer

78. Transfer drive shaft

79. Dust seal guard

"BA 80. Oil seal

AB""AA 81. Oil pool cover

82. Oil guide

83. Transfer case

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Page 90

V5A51 -

Transfer

23E-15-5

DISASSEMBLY SERVICE POINTS

AA"

Remove the chain, front output shaft and sun gear as a set from the transfer case.

CHAIN / FRONT OUTPUT SHAFT / SUN GEAR REMOVAL

MB990932

2mm

MB990938

5mm

AB"

OIL POOL COVER REMOVAL

Unstake the positions shown in the illustration to remove the oil pool cover.

Caution

The oil pool cover normally does not require disassembly. Once it is removed, the transfer case cannot be reused.

ASSEMBLY SERVICE POINTS

"AA

Install the oil pool cover on a new transfer case. Stake the projecting portions of the transfer so that the dimensions will be as illustrated.

"BA

1. Use the special tools to install the oil seal on the transfer

2. Apply grease to the lip of t he oil seal.

OIL POOL COVER INSTALLATION

OIL SEAL INSTALLATION

case.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

"CA

REAR BEARING RETAINER INSTALLATION

The bolts used for mounting the rear bearing retainer are pre-coated ones. When they are to be reused, apply sealant to the threaded portion before installation.

Specified sealant:

MITSUBISHI genuine sealant part No. MD997740 or equivalent

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Page 91

23E-15-6

V5A51 -

Transfer

Solder

"DA

SNAP RING INSTALLATION

Select a proper snap ring so that the end play of the H-L clutch hub will have the standard value, and install the snap ring on the transfer drive shaft.

Standard value: 0 - 0.08 mm

"EA

H-L SHIFT FORK / H-L CLUTCH SLEEVE INSTALLATION

Apply grease to the H-L shift fork shaft inserting portion, and install the H-L shift fork and H-L clutch sleeve in combined state in the transfer case.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

"FA

SPACER INSTALLATION

1. Put pieces of solder (approx. 10 mm long and 1.6 mm in diameter) at th e illustrated positions of the transfer case.

2. Install the countershaft gear and transfer case plate an d tighten the bolts to the specified torque.

3. If the pieces of solder are not crushed, pu t thicker pieces of solder and perform Steps 1 and 2.

4. Measure the thickness of the crushed pieces of solder with a micrometer, and select a spacer of proper thickness so that the end play will have the standard value.

Standard value: 0 - 0.15 mm

"GA

TRANSFER CASE PLATE INSTALLATION

1. Apply grease to t he illustrated position of the high/low shift rail inserting portion of the transfer case plate.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

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V5A51 -

Transfer

23E-15-7

2. Face the notched portion of the input gear in the illustrated direction (in the direction of the countershaft gear bearing hole).

3. Apply sealant to the illustrated position of the transfer case.

Specified sealant:

MITSUBISHI genuine sealant part No. MD997740 or equivalent

Caution

Squeeze sealant out evenly to make sure that it is not broken or excessively supplied.

4. While making sure that the notched portion of the input gear positioned in Step 2 is in alignment with the gear portion of the countershaft, install the transfer case plate.

Caution

If the sub gear does not readily come in mesh with the countershaft gear, rotate the transfer drive shaft, etc. to securely engage it.

"HA

SNAP RING INSTALLATION

Select a proper snap ring so that the end play of the differential lock h u b will have the standard value, an d install it on the transfer drive shaft.

Standard value: 0 - 0.08 mm

Steel ball

"IA

Install the steel ball in the illustrated position of the transfer

STEEL BALL / SPACER INSTALLATION

drive shaft and install the spacer with its oil groove toward the chain cover.

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23E-15-8

V5A51 -

Transfer

"JA

2-4WD SHIFT FORK / 2-4WD CLUTCH SLEEVE INSTALLATION

Apply grease to the 2-4WD shift fork shaft inserting portion and install the 2-4WD shift fork and 2-4WD clutch sleeve in combined state in the transfer case.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

"KA

SNAP RING INSTALLATION

Select a proper snap ring so that the end play of the 2-4WD clutch hub will have the standard value, and install it on the sun gear.

Standard value: 0 - 0.08 mm

"LA

SYNCHRONIZER OUTER RING / SYNCHRONIZER CONE / SYNCHRONIZER INNER RING INSTALLATION

1. Combine the synchronizer outer ring, synchronizer cone and synchronizer inner ring, press them against the drive sprocket, and measure the dimension shown in the illustration.

Limit: 0.3 mm

2. If the dimension is out of the limit value, replace them with a synchronizer ring set.

3. Apply gear oil to the synchronizer outer ring and synchronizer inner ring.

4. Line up the notched portion of the 2-4WD clutch hub with t he projecting portion of the synchronizer ring and install the ring on the 2-4WD clutch hub.

"MA

DRIVE SPROCKET / FRONT OUTPUT SHAFT / CHAIN INSTALLATION

1. Set the chain in mesh with the drive sprocket a nd front output shaft sprocket and install them in the transfer case.

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23E-15-9

2. Install the drive sprocket so that its illustrated holes will match the projecting portions of the synchronizer cone.

"NA

REAR OUTPUT SHAFT INSTALLATION

Apply grease to the O-ring at the illustrated position and install the rear output shaft.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

"OA

CHAIN COVER INSTALLATION

1. Apply grease to the indicated 2-4WD shift rail inserting portion.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

2. Apply a bead of sealant to the illustrated position of the chain cover.

Specified sealant:

MITSUBISHI genuine sealant part No. MD997740 or equivalent

Caution

Squeeze the sealant out evenly to make sure that it is not broken or excessively supplied.

"PA

SNAP RING ISNTALLATION

1. Install the snap ring in the bearing groove of the rear output shaft.

2. With the rear output shaft pressed against the chain cover, measure the clearance between the chain cover and snap ring.

3. Select a snap ring whose thickness is the dimension of the measured clearance plus the standard value.

Standard value: 0.12 - 0.24 mm

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Transfer

4. Remove the snap ring from the bearing groove of the rear output shaft, install the selected snap ring, and reinstall the removed snap ring in the bearing groove of the rear output shaft.

Concave portion

Projection

MB990938

MB990932

"QA

SPACER INSTALLATION

1. With the rear output shaft pressed toward the chain cover, measure the projection of the bearing from the chain cover.

Caution

Measure the projection with the snap ring installed.

2. Measure the dimension of the rear cover concave portion at the illustrated position.

3. Subtract the measured value in Step 1 from the measured value in Step 2 to calculate the clearance between the bearing and rear cover. Select a proper spacer so that the clearance will have the standard value.

Standard value: 0 - 0.12 mm

"RA

OIL SEAL INSTALLATION

1. Use the special tools to install the oil seal in the rear cover.

2. Apply grease to the lip of t he oil seal.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

"SA

REAR COVER INSTALLATION

Apply sealant to the illustrated position of the chain cover.

Specified sealant:

MITSUBISHI genuine sealant part No. MD997740 or equivalent

Caution

Squeeze the sealant out evenly to make sure that it is not broken or excessively supplied.

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Transfer

23E-15-11

Mark

Third gear

"TA

MAIN SHIFT RAIL / SHIFT ACTUATOR INSTALLATION

1. Apply grease to the O-ring.

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

2. Combine the main shift rail key with actuator key and insert them in the transfer case.

"UA

SHIFT RAIL DRIVE GEAR INSTALLATION

Install the shift rail drive gear with its marked tooth in mesh with the third gear groove of each shift rail.

"VA

TRANSFER CASE COVER INSTALLATION

Apply sealant to the illustrated position of the transfer case cover.

Specified sealant:

MITSUBISHI genuine sealant part No. MD997740 or equivalent

Caution

Squeeze the sealant out evenly to make sure that it is not broken or excessively supplied.

"WA

Install th e switches in the right positions.

SWITCH INSTALLATION

Switch name

A 4LLC switch Black Brown

B 2WD switch Black Black

C Center differential

lock switch

D 4H switch Blue White

E 2-4WD switch Blue Black

Tube color Connector color

Blue Brown

INSPECTION

SWITCHES

Check for the continuity between the connector terminal and switch body. Replace the switch if found faulty.

Switch state Continuity

Switch end pressed No

Switch end released Yes

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16. TRANSFER CASE PLATE

DISASSEMBLY AND ASSEMBLY

Apply gear oil to all moving parts before installation.

Transfer Case Plate

23E-16-1

20±2Nm

Disassembly steps

"BA 1. Bolt

2. Bearing retainer

3. Transfer input gear

"AA 4. Oil seal

5. Baffle plate

6. Transfer case plate

MB990938

MB990936

ASSEMBLY SERVICE POINTS

"AA

1. Use the special tool to install the oil seal.

2. Apply grease to the lip of t he oil seal.

OIL SEAL INSTALLATION

Specified grease:

MITSUBISHI genuine grease part No. 0101011 or equivalent

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Transfer Case Plate

"BA

BOLT INSTALLATION

Apply sealant to the threads.

Specified sealant:

MITSUBISHI genuine sealant part No. MD997740 or equivalent

NOTE New bolts are precoated with sealant, so sealant does not need to be applied.

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17. INPUT GEAR

DISASSEMBLY AND ASSEMBLY

V5A51 -

Input Gear

23E-17-1

Apply gear oil to all moving parts before installation.

Disassembly steps

"BA 1. Snap ring

AA""AA 2. Ball bearing

3. Snap ring (some model)

4. Cone spring (some model)

5. Sub gear (some model)

6. Transfer input gear

DISASSEMBLY SERVICE POINT

MD998801

AA"

Use the special tool to remove the ball bearing.

BALL BEARING REMOVAL

ASSEMBLY SERVICE POINTS

MD998812

"AA

Use the special tools to install the ball bearing.

MD998826

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"BA

SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the snap ring groove of the input gear.

2. Make sure that the ball bearing end play meets the standard value.

Standard value: 0 - 0.06 mm

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Mitsubishi V5A51, V5A51-7-ACA, V5A51-7-SDA, V5A51-7-CCA1, V5A51-7-CCA2 USER MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

1. SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

VALVE BODY SPRING IDENTIFICATION

TORQUE SPECIFICATIONS

SNAP RING, THRUST RACE, SPACER AND PRESSURE PLATE FOR ADJUSTMENT

SEALANTS

LUBRICANTS

2. SPECIAL TOOLS

3. TRANSMISSION AND TRANSFER

4. TRANSFER CASE ADAPTER

5. TRANSMISSION

6. REVERSE AND OVERDRIVE CLUTCH

7. SECOND BRAKE

8. LOW/REVERSE ANNULUS GEAR

9. CENTER SUPPORT

10. UNDERDRIVE CLUTCH

11. VALVE BODY

12. DIRECT ANNULUS GEAR

13. DIRECT CLUTCH

14. OUTPUT SHAFT SUPPORT

15. TRANSFER

16. TRANSFER CASE PLATE

17. INPUT GEAR