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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
  • Do not use grease, use petroleum jelly (i.e. Vaseline).
  • Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch discs or brake discs in ATF for at least two hours before assembling them.
  • When replacing a bushing, replace the assembly which it belongs to.
  • Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.
  1. Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case. Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.
    Fig 1: Installing Transfer Drive Gear Bearing And Gear In Transaxle Case
    G04539027Courtesy of DAIMLERCHRYSLER CORPORATION
  2. Tighten the seven mounting bolts < F4A42 > and eight mounting bolts < F4A51 > of the transfer drive gear bearing to the specified torque.

    Tightening torque: 34 +/- 2 N.m (25 +/- 1 ft-lb) 

    Fig 2: Tightening Mounting Bolts Of Transfer Drive Gear Bearing To Specified Torque
    G04539028Courtesy of DAIMLERCHRYSLER CORPORATION
  3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
    Fig 3: Installing Low-Reverse Brake Piston, Return Spring, And Spring Retainer Into Transaxle Case
    G04539029Courtesy of DAIMLERCHRYSLER CORPORATION
  4. Fit a new O-ring into the groove of one-way clutch inner race.
    Fig 4: Identifying One-Way Clutch Inner Race
    G04539030Courtesy of DAIMLERCHRYSLER CORPORATION
  5. Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.
    Fig 5: Checking Placement Of Identification Notches In One-Way Clutch Inner Race
    G04539031Courtesy of DAIMLERCHRYSLER CORPORATION
  6. Put the snap ring on the inner race.
  7. Set special tools MD998703 < F4A42 > or MD998338 < F4A51 > and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.
    NOTE: This illustration shows F4A51.
    Fig 6: Putting Snap Ring On Inner Race
    G04539032Courtesy of DAIMLERCHRYSLER CORPORATION
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 7: Installing Wave Spring Onto Low-Reverse Brake Piston
    G04539033Courtesy of DAIMLERCHRYSLER CORPORATION
  9. Install the six brake discs, five brake plates and snap ring as shown in the figure.
    NOTE: Do not install the pressure plate at this time.
  10. Install special tool MB991631 < F4A42 > or MB991632 < F4A51 > on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991631 < F4A42 > or MB991632 < F4A51 > to measure the end play of reaction plate. Then replace the snap ring installed in step  11 to adjust the end play to standard value.

    Standard value: 0 - 0.16 mm (0 - 0.0063 inch) 

    Fig 8: Removing Snap Ring
    G04539034Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 9: Installing Snap Ring
    G04539035Courtesy of DAIMLERCHRYSLER CORPORATION
  13. Install the brake discs and brake plates as shown in the figure.

    Number of brake discs and plates 

    NUMBER OF BRAKE DISCS AND PLATES

    A/T MODEL BRAKE DISC BRAKE PLATE
    F4A42 3 2
    F4A51 4 3
  14. Place special tool MB991631 < F4A42 > or MB991632 < F4A51 > on top of the brake disc in place of the pressure plate.
    Fig 10: Installing Brake Discs And Brake Plates
    G04539036Courtesy of DAIMLERCHRYSLER CORPORATION
  15. Install the return spring, second brake piston and snap ring.
    Fig 11: Installing Return Spring, Second Brake Piston And Snap Ring
    G04539037Courtesy of DAIMLERCHRYSLER CORPORATION
  16. Move special tool MB991631 < F4A42 > or MB991632 < F4A51 > and measure its movement.

    Standard value of end play (Reference): 

    0.79 - 1.25 mm (0.0311 - 0.0492 inch) < F4A42 > 

    1.09 - 1.55 mm (0.0429 - 0.0610 inch) < F4A51 > 

  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
    Fig 12: Checking Movement Using Special Tool
    G04539038Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 13: Checking Movement Of Pressure Plate Thickness
    G04539039Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 14: Checking Movement Of Pressure Plate Thickness
    G04539040Courtesy of DAIMLERCHRYSLER CORPORATION

    PRESSURE PLATE FOR SECOND BRAKE < F4A42 > 

    PRESSURE PLATE FOR SECOND BRAKE

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    0.6 - 0.8 (0.024 - 0.031) 1.6 (0.063) L MD759567
    0.8 - 1.0 (0.031 - 0.039) 1.8 (0.071) 1 MD759414
    1.0 - 1.2 (0.039 - 0.047) 2.0 (0.079) 0 MD759415
    1.2 - 1.4 (0.047 - 0.055) 2.2 (0.087) 2 MD759416
    1.4 - 1.6 (0.055 - 0.063) 2.4 (0.094) 4 MD759417
    1.6 - 1.8 (0.063 - 0.071) 2.6 (0.102) 6 MD759418

    PRESSURE PLATE FOR SECOND BRAKE < F4A51> 

    PRESSURE PLATE FOR SECOND BRAKE

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.1 - 1.3 (0.043 - 0.051) 1.8 (0.071) E MD759425
    1.3 - 1.5 (0.051 - 0.059) 2.0 (0.079) D MD759426
    1.5 - 1.7 (0.059 - 0.067) 2.2 (0.087) C MD759427
    1.7 - 1.9 (0.067 - 0.075) 2.4 (0.094) B MD759428
    1.9 - 2.1 (0.075 - 0.083) 2.6 (0.102) A MD759429
    2.1 - 2.3 (0.083 - 0.091) 2.8 (0.110) 0 MD759430
  18. Turn the transaxle over so that the installation surface of the torque converter housing is facing up.

    Install special tool MD998913 in a dial gauge, and then move special tool MB991631 < F4A42 > or MB991632 < F4A51 > and measure its movement.

    Standard value of end play (Reference): 

    1.65 - 2.11 mm (0.065 - 0.083 inch) 

    Fig 15: Identifying Special Tool MD998913 In Dial Gauge
    G04539041Courtesy of DAIMLERCHRYSLER CORPORATION
  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.
    NOTE: This illustration shows F4A51.
    Fig 16: Identifying Special Tool MD998913 In Dial Gauge
    G04539042Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 17: Identifying Special Tool MD998913 In Dial Gauge
    G04539043Courtesy of DAIMLERCHRYSLER CORPORATION

    PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A42 > 

    PRESSURE PLATE FOR LOW-REVERSE BRAKE

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.3 - 1.5 (0.051 - 0.059) 1.6 (0.063) L MD759567
    1.5 - 1.7 (0.059 - 0.067) 1.8 (0.071) 1 MD759414
    1.7 - 1.9 (0.067 - 0.075) 2.0 (0.079) 0 MD759415
    1.9 - 2.1 (0.075 - 0.083) 2.2 (0.087) 2 MD759416
    2.1 - 2.3 (0.083 - 0.091) 2.4 (0.094) 4 MD759417
    2.3 - 2.5 (0.091 - 0.098) 2.6 (0.102) 6 MD759418
    2.5 - 2.7 (0.098 - 0.106) 2.8 (0.110) 8 MD759419
    2.7 - 2.9 (0.106 - 0.114) 3.0 (0.118) D MD759420

    PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A51 > 

    PRESSURE PLATE FOR LOW-REVERSE BRAKE

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.0 - 1.2 (0.039 - 0.047) 1.6 (0.063) F MD759568
    1.2 - 1.4 (0.047 - 0.055) 1.8 (0.071) E MD759425
    1.4 - 1.6 (0.055 - 0.063) 2.0 (0.079) D MD759426
    1.6 - 1.8 (0.063 - 0.071) 2.2 (0.087) C MD759427
    1.8 - 2.0 (0.071 - 0.079) 2.4 (0.094) B MD759428
    2.0 - 2.2 (0.079 - 0.087) 2.6 (0.102) A MD759429
    2.2 - 2.4 (0.087 - 0.094) 2.8 (0.110) 0 MD759430
    2.4 - 2.6 (0.094 - 0.102) 3.0 (0.118) 1 MD759431
    CAUTION: If necessary, take the measurements in steps  9 to  18 after replacing the pressure plate, brake plate and brake disc.
  20. Remove all parts and special tools that were installed to take the measurements in steps  9 to  18. Remove and separate the pressure plate and snap ring chosen in steps  12,  16 and  18.
  21. Install the snap ring into the groove of transaxle case output shaft bore.
  22. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.
    Fig 18: Installing Snap Ring Into Groove Of Transaxle Case Output Shaft Bore
    G04539044Courtesy of DAIMLERCHRYSLER CORPORATION
    CAUTION: Do not reuse the bolt, as it has had sealant applied.
  23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.

    Tightening torque: 

    23 +/- 3 N.m (17 +/- 2 ft-lb) < F4A42 > 

    54 +/- 5 N.m (40 +/- 4 ft-lb) < F4A51 > 

    Fig 19: Tightening Mounting Bolts
    G04539045Courtesy of DAIMLERCHRYSLER CORPORATION
  24. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft. 
    Fig 20: Installing Collar Using Special Tool MD998350
    G04539046Courtesy of DAIMLERCHRYSLER CORPORATION
  25. Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.

    Tightening torque: 167 +/- 10 N.m (123 +/- 7 ft-lb) 

    NOTE: The jam nut is reverse threaded.
    Fig 21: Applying ATF To Jam Nut, And Using Special Tools MB990607 And MB991625
    G04539047Courtesy of DAIMLERCHRYSLER CORPORATION
  26. Move the output shaft to measure the end play and record the measurement value.
  27. Remove the parts that were installed in steps  22 to  25.
  28. Select a spacer whose thickness corresponds to the measured amount of movement from the following table.
    Fig 22: Measuring End Play And Record Measurement Value
    G04539048Courtesy of DAIMLERCHRYSLER CORPORATION

    SPACER FOR OUTPUT SHAFT 

    SPACER FOR OUTPUT SHAFT

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.81 - 1.85 (0.0713 - 0.0728) 1.88 (0.0740) 88 MD756579
    1.85 - 1.89 (0.0728 - 0.0744) 1.92 (0.0756) 92 MD756580
    1.89 - 1.93 (0.0744 - 0.0760) 1.96 (0.0772) 96 MD756581
    1.93 - 1.97 (0.0760 - 0.0776) 2.00 (0.0787) 00 MD756582
    1.97 - 2.01 (0.0776 - 0.0791) 2.04 (0.0803) 04 MD756583
    2.01 - 2.05 (0.0791 - 0.0807) 2.08 (0.0819) 08 MD756584
    2.05 - 2.09 (0.0807 - 0.0823) 2.12 (0.0835) 12 MD756585
    2.09 - 2.13 (0.0823 - 0.0839) 2.16 (0.0850) 16 MD756586
    2.13 - 2.17 (0.0839 - 0.0854) 2.20 (0.0866) 20 MD756587
    2.17 - 2.21 (0.0854 - 0.0870) 2.24 (0.0882) 24 MD756588
    2.21 - 2.25 (0.0870 - 0.0886) 2.28 (0.0898) 28 MD756589
    2.25 - 2.29 (0.0886 - 0.0902) 2.32 (0.0913) 32 MD756590
    2.29 - 2.33 (0.0902 - 0.0917) 2.36 (0.0929) 36 MD756591
    2.33 - 2.37 (0.0917 - 0.0933) 2.40 (0.0945) 40 MD756592
    2.37 - 2.41 (0.0933 - 0.0949) 2.44 (0.0961) 44 MD756593
    2.41 - 2.45 (0.0949 - 0.0965) 2.48 (0.0976) 48 MD756594
    2.45 - 2.49 (0.0965 - 0.0980) 2.52 (0.0992) 52 MD756595
    2.49 - 2.53 (0.0980 - 0.0996) 2.56 (0.1008) 56 MD756596
    2.53 - 2.57 (0.0996 - 0.1012) 2.60 (0.1024) 60 MD756597
    2.57 - 2.61 (0.1012 - 0.1028) 2.64 (0.1039) 64 MD756598
    2.61 - 2.65 (0.1028 - 0.1043) 2.68 (0.1055) 68 MD756599
    2.65 - 2.69 (0.1043 - 0.1059) 2.72 (0.1071) 72 MD760685
    2.69 - 2.73 (0.1059 - 0.1075) 2.76 (0.1087) 76 MD760686
  29. Repeat steps  22 to  25 again, installing each part and using the appropriate adjustment spacer determined in step  28.
  30. Stake the jam nut with a punch (two places).
    Fig 23: Identifying Stake Jam Nut With Punch (Two Places)
    G04539049Courtesy of DAIMLERCHRYSLER CORPORATION
  31. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 24: Installing Cap Using Special Tools MB990931 And MB990938
    G04539050Courtesy of DAIMLERCHRYSLER CORPORATION
  32. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 25: Inserting Parking Pawl Shaft
    G04539051Courtesy of DAIMLERCHRYSLER CORPORATION
  33. Install the parking roller support, and then insert the two parking roller support shafts.
    Fig 26: Inserting Parking Roller Support Shafts
    G04539052Courtesy of DAIMLERCHRYSLER CORPORATION

    IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

    Fig 27: Locating Identification Of Thrust Bearing, Thrust Races, And Thrust Washers
    G04539053Courtesy of DAIMLERCHRYSLER CORPORATION
    THRUST BEARING, THRUST RACES, AND THRUST WASHERS THICKNESS SPECIFICATION

    SYMBOL OD mm (in) ID mm (in) THICKNESS mm (in) PART NO. APPLICATION
    No.1 59 (2.32) 47 (1.85) 1.8 (0.071) MD754509  
    59 (2.32) 47 (1.85) 2.0 (0.079) MD754508  
    59 (2.32) 47 (1.85) 2.2 (0.087) MD754507  
    59 (2.32) 47 (1.85) 2.4 (0.094) MD753793  
    59 (2.32) 47 (1.85) 2.6 (0.102) MD753794  
    59 (2.32) 47 (1.85) 2.8 (0.110) MD753795  
    No.2 49 (1.93) 34 (1.34) 3.6 (0.142) MD756846  
    No.3 49 (1.93) 34 (1.34) 3.6 (0.142) MD756846 F4A42
    57 (2.24) 38.5 (1.516) 4.12 (0.1622) MD758556 F4A51
    No.4 45.3 (1.783) 31 (1.22) 3.3 (0.130) MD757647 F4A42
    55.4 (2.181) 38.5 (1.516) 3.3 (0.130) MD761683 F4A51
    No.5 49 (1.93) 34 (1.34) 3.6 (0.142) MD756846 F4A42
    57 (2.244) 38.5 (1.516) 4.1 (0.161) MD758556 F4A51
    No.6 49 (1.93) 34 (1.34) 3.6 (0.142) MD756846 F4A42
    57 (2.244) 38.5 (1.516) 4.1 (0.161) MD758556 F4A51
    No.7 59 (2.32) 37 (1.46) 2.8 (0.110) MR305718  
    No.8 48.9 (1.925) 37 (1.46) 1.6 (0.063) MD707267  
    48.9 (1.925) 37 (1.46) 1.7 (0.067) MD759681  
    48.9 (1.925) 37 (1.46) 1.8 (0.071) MD723064  
    48.9 (1.925) 37 (1.46) 1.9 (0.075) MD754794  
    48.9 (1.925) 37 (1.46) 2.0 (0.079) MD707268  
    48.9 (1.925) 37 (1.46) 2.1 (0.083) MD754795  
    48.9 (1.925) 37 (1.46) 2.2 (0.087) MD723065  
    48.9 (1.925) 37 (1.46) 2.3 (0.091) MD754796  
    48.9 (1.925) 37 (1.46) 2.4 (0.094) MD724358  
    48.9 (1.925) 37 (1.46) 2.5 (0.098) MD754797  
    48.9 (1.925) 37 (1.46) 2.6 (0.102) MD754798  
  34. Install the planetary carrier assembly.
    Fig 28: Installing Planetary Carrier Assembly
    G04539054Courtesy of DAIMLERCHRYSLER CORPORATION
  35. Install the planetary reverse sun gear.
    Fig 29: Installing Planetary Reverse Sun Gear
    G04539055Courtesy of DAIMLERCHRYSLER CORPORATION
  36. Install the wave spring on the low-reverse brake piston.
    Fig 30: Installing Wave Spring On Low-Reverse Brake Piston
    G04539056Courtesy of DAIMLERCHRYSLER CORPORATION
  37. Install the pressure plate that was selected in step  19. Next, install six brake discs and five brake plates, one on top of the other.
    Fig 31: Installing Pressure Plate
    G04539057Courtesy of DAIMLERCHRYSLER CORPORATION
  38. Install the snap ring.
    Fig 32: Installing Snap Ring
    G04539058Courtesy of DAIMLERCHRYSLER CORPORATION
  39. Install the reaction plate.
    Fig 33: Installing Reaction Plate
    G04539059Courtesy of DAIMLERCHRYSLER CORPORATION
  40. Install the snap ring that was selected in step  12.
    Fig 34: Installing Snap Ring
    G04539060Courtesy of DAIMLERCHRYSLER CORPORATION
  41. Install three brake discs < F4A42 > or four brake discs < F4A51 > and two brake plates < F4A42 > or three brake plates < F4A51 >, one on top of the other. Next, install the pressure plate that was selected in step  17.
    Fig 35: Identifying Three And Four Brake Discs
    G04539061Courtesy of DAIMLERCHRYSLER CORPORATION
  42. Install the return spring and second brake piston.
    Fig 36: Installing Return Spring And Second Brake Piston
    G04539062Courtesy of DAIMLERCHRYSLER CORPORATION
  43. Install the snap ring.
    Fig 37: Installing Snap Ring
    G04539063Courtesy of DAIMLERCHRYSLER CORPORATION
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  44. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
    Fig 38: Installing Direction Of Thrust Bearing Number 5
    G04539064Courtesy of DAIMLERCHRYSLER CORPORATION
    CAUTION: Use care to install the thrust bearing in the proper direction.
  45. Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.
    Fig 39: Attaching Thrust Bearing Number 6 To Inside Of Overdrive Clutch Hub
    G04539065Courtesy of DAIMLERCHRYSLER CORPORATION
  46. Install the reverse and overdrive clutch.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  47. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
    Fig 40: Installing Direction Of Thrust Bearing Number 7
    G04539066Courtesy of DAIMLERCHRYSLER CORPORATION
  48. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
  49. Install the four seal rings in the grooves of the rear cover.
    Fig 41: Installing Four Seal Rings In Grooves Of Rear Cover
    G04539067Courtesy of DAIMLERCHRYSLER CORPORATION
  50. Measure the end play of the under drive sun gear by the following procedures:
    1. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7.
    2. Install the rear cover on the transaxle case and tighten the bolts to the specified torque.

      Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

    3. Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.
    4. Install the under drive clutch hub on the under drive sun gear.
    5. Measure end play of the underdrive sun gear and record the measurement value.

      Standard value (Reference): 

      0.25 - 0.45 mm (0.0098 - 0.0177 inch) 

    6. After taking the measurement in steps (5), take out the installed parts in steps (1) through (4).
      Fig 42: Measuring End Play Of Underdrive Sun Gear
      G04539068Courtesy of DAIMLERCHRYSLER CORPORATION
  51. Install the three O-rings.
    Fig 43: Installing Three O-Rings
    G04539069Courtesy of DAIMLERCHRYSLER CORPORATION
  52. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step  50 from the table below. Install it on thrust bearing number 7.
    Fig 44: Installing Thrust Bearing Number 7
    G04539070Courtesy of DAIMLERCHRYSLER CORPORATION
    THRUST RACE NUMBER 8 THICKNESS SPECIFICATION

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) PART NO.
    0.3 - 0.4 (0.012 - 0.016) 1.6 (0.063) MD707267
    0.4 - 0.5 (0.016 - 0.020) 1.7 (0.067) MD759681
    0.5 - 0.6 (0.020 - 0.024) 1.8 (0.071) MD723064
    0.6 - 0.7 (0.024 - 0.028) 1.9 (0.075) MD754794
    0.7 - 0.8 (0.028 - 0.031) 2.0 (0.079) MD707268
    0.8 - 0.9 (0.031 - 0.035) 2.1 (0.083) MD754795
    0.9 - 1.0 (0.035 - 0.039) 2.2 (0.087) MD723065
    1.0 - 1.1 (0.039 - 0.043) 2.3 (0.091) MD754796
    1.1 - 1.2 (0.043 - 0.047) 2.4 (0.094) MD724358
    1.2 - 1.3 (0.047 - 0.051) 2.5 (0.098) MD754797
    1.3 - 1.4 (0.051 - 0.055) 2.6 (0.102) MD754798
  53. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the illustrated position of the rear cover.
    NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.
    Fig 45: Installing Rear Cover
    G04539071Courtesy of DAIMLERCHRYSLER CORPORATION
  54. Install the rear cover, and tighten its mounting bolts to the specified torque.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

    NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
    Fig 46: Tightening Mounting Bolts To Specified Torque
    G04539072Courtesy of DAIMLERCHRYSLER CORPORATION
  55. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 47: Installing Underdrive Clutch Hub
    G04539073Courtesy of DAIMLERCHRYSLER CORPORATION
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  56. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
    Fig 48: Installing Direction Of Thrust Bearing Number 2
    G04539074Courtesy of DAIMLERCHRYSLER CORPORATION
  57. Hold the input shaft, and install the underdrive clutch.
    Fig 49: Holding Input Shaft
    G04539075Courtesy of DAIMLERCHRYSLER CORPORATION
  58. Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14 inch) in diameter] on the underdrive clutch retainer as shown in the illustration.
    Fig 50: Placing Two Beads Of Solder On Underdrive Clutch Retainer
    G04539076Courtesy of DAIMLERCHRYSLER CORPORATION
  59. Install special tool MD998412 as shown.
  60. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
  61. Tighten the oil pump mounting bolts (six pieces) to the specified torque.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

    Fig 51: Installing Oil Pump To Transaxle Case
    G04539077Courtesy of DAIMLERCHRYSLER CORPORATION
  62. Remove the oil pump mounting bolts.
  63. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 52: Removing Oil Pump And Crushed Solders
    G04539078Courtesy of DAIMLERCHRYSLER CORPORATION
  64. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
  65. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.
    Fig 53: Measuring Thickness Of Crushed Solder Beads And Using Micrometer
    G04539079Courtesy of DAIMLERCHRYSLER CORPORATION
    THRUST WASHER NUMBER 1 THICKNESS SPECIFICATION

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) ID SYMBOL PART NO.
    2.25 - 2.45 (0.089 - 0.096) 1.8 (0.071) 18 MD754509
    2.45 - 2.65 (0.096 - 0.104) 2.0 (0.079) 20 MD754508
    2.65 - 2.85 (0.104 - 0.112) 2.2 (0.087) 22 MD754507
    2.85 - 3.05 (0.112 - 0.120) 2.4 (0.094) 24 MD753793
    3.05 - 3.25 (0.120 - 0.128) 2.6 (0.102) 26 MD753794
    3.25 - 3.45 (0.128 - 0.136) 2.8 (0.110) 28 MD753795
  66. Install thrust washer number 1 that was selected in step 66 on the underdrive clutch retainer.
    Fig 54: Installing Thrust Washer Number 1 On Underdrive Clutch Retainer
    G04539080Courtesy of DAIMLERCHRYSLER CORPORATION
  67. Install special tool MD998412 as shown.
  68. Install the new oil pump gasket on the transaxle case.
  69. Install the oil pump and tighten the mounting bolts (six pieces) to the specified torque.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

    Fig 55: Installing Oil Pump Gasket On Transaxle Case
    G04539081Courtesy of DAIMLERCHRYSLER CORPORATION
  70. Make sure that the input shaft end play meets the standard value.

    Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch) 

    Fig 56: Installing Input Shaft End Play Meets Standard Value
    G04539082Courtesy of DAIMLERCHRYSLER CORPORATION
  71. Install the oil filter.
    Fig 57: Installing Oil Filter
    G04539083Courtesy of DAIMLERCHRYSLER CORPORATION
  72. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 58: Taping Differential Bearing Outer Race In Transaxle Case
    G04539084Courtesy of DAIMLERCHRYSLER CORPORATION
  73. Install the differential.
    Fig 59: Installing Differential
    G04539085Courtesy of DAIMLERCHRYSLER CORPORATION
  74. Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter] on the torque converter housing as shown in the illustration.
    Fig 60: Placing Two Beads Of Solder On Torque Converter Housing
    G04539086Courtesy of DAIMLERCHRYSLER CORPORATION
  75. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to press in the differential bearing outer race into the torque converter housing.
    Fig 61: Pressing Differential Bearing Outer Race Into Torque Converter Housing
    G04539087Courtesy of DAIMLERCHRYSLER CORPORATION
  76. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.

    Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb) 

  77. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
    Fig 62: Loosening Bolts
    G04539088Courtesy of DAIMLERCHRYSLER CORPORATION
  78. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to the measured value and select a spacer with the corresponding thickness. Adjustment spacer sizes are all listed on VALVE BODY SPRING IDENTIFICATION TABLE  . Select the most suitable one from among those listed.
    NOTE: * is the thickness for the differential case preload.
    Fig 63: Measuring Thickness Of Crushed Solder Beads
    G04539089Courtesy of DAIMLERCHRYSLER CORPORATION
  79. Install the spacer selected in step 79 to the torque converter housing.
  80. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to press the outer race into housing.
    Fig 64: Identifying Torque Converter Housing
    G04539090Courtesy of DAIMLERCHRYSLER CORPORATION
  81. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the torque converter housing in the area shown.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.
    NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
    Fig 65: Identifying Area For Applying Sealant
    G04539091Courtesy of DAIMLERCHRYSLER CORPORATION
  82. Install the two O-rings.
    Fig 66: Installing Two O-Rings
    G04539092Courtesy of DAIMLERCHRYSLER CORPORATION
  83. Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque.

    Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb) 

    Fig 67: Tightening Mounting Bolts To Specified Torque
    G04539093Courtesy of DAIMLERCHRYSLER CORPORATION
  84. Insert the two O-rings into the grooves of the manual control lever shaft.
  85. Install the manual control lever shaft and parking pawl rod.
  86. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A."
    Fig 68: Installing Manual Control Lever Shaft And Parking Pawl Rod
    G04539094Courtesy of DAIMLERCHRYSLER CORPORATION
  87. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
  88. Identify the accumulator spring and insert it and the accumulator piston into each hole of the transaxle case.
    NOTE: Accumulator springs are identified as shown in the illustration.
    Fig 69: Inserting Seal Rings In Grooves Of Accumulator Pistons
    G04539095Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 70: Identifying Accumulator Spring
    G04539096Courtesy of DAIMLERCHRYSLER CORPORATION
  89. Install the strainer and second brake retainer oil seal.
    Fig 71: Installing Strainer And Second Brake Retainer Oil Seal
    G04539097Courtesy of DAIMLERCHRYSLER CORPORATION
  90. Insert a new O-ring to the groove of the solenoid valve harness connector.
  91. Insert the solenoid valve harness connector into the hole from the inside of the transaxle case so it is oriented as shown in the illustration. Then secure the snap ring to the connector groove.
    Fig 72: Inserting O-Ring To Groove Of Solenoid Valve Harness Connector
    G04539098Courtesy of DAIMLERCHRYSLER CORPORATION
  92. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
    Fig 73: Installing Steel Ball Into Each Of Two Holes
    G04539099Courtesy of DAIMLERCHRYSLER CORPORATION
  93. Install the valve body and gasket to the transaxle case. Make sure that the manual valve's pin is in the groove in the detent plate of the manual control lever.
  94. Install the 27 valve body mounting bolts, and tighten to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 74: Installing Valve Body Mounting Bolts
    G04539100Courtesy of DAIMLERCHRYSLER CORPORATION
  95. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
    Fig 75: Attaching Solenoid Valve Harness
    G04539101Courtesy of DAIMLERCHRYSLER CORPORATION
    PARTS TO BE CONNECTED AND SOLENOID VALVE HARNESS

    NO. PARTS TO BECONNECTED SOLENOID VALVE HARNESS
    CABLECOLOR CONNECTORHOUSING COLOR
    1 Underdrive solenoid valve White, red, red Black
    2 Overdrive solenoid valve Orange, red Black
    3 Low-reverse solenoid valve Brown, yellow Milky white
    4 Second solenoid valve Blue, red, red Milky white
    5 Torque converter clutch control solenoid valve Blue, yellow, yellow Black
  96. Install the manual control shaft detent and tighten the bolt to the specified torque.

    Tightening torque: 6 +/- 1 N.m (52 +/- 9 in-lb) 

    Fig 76: Installing Manual Control Shaft Detent
    G04539102Courtesy of DAIMLERCHRYSLER CORPORATION
  97. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.
    NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
    Fig 77: Identifying Area For Applying Sealant
    G04539103Courtesy of DAIMLERCHRYSLER CORPORATION
  98. Install the valve body cover, and then tighten its mounting bolts to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 78: Installing Valve Body Cover
    G04539104Courtesy of DAIMLERCHRYSLER CORPORATION
  99. Install the Sealing cap and tighten the bolt to the specified torque.

    Tightening torque: 5 +/- 1 N.m (43 +/- 9 in-lb) 

    Fig 79: Installing Sealing Cap
    G04539105Courtesy of DAIMLERCHRYSLER CORPORATION
  100. Install the park/neutral position switch and tighten the bolt to specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

  101. Install the manual control lever and tighten the nut to specified torque.

    Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb) 

    Fig 80: Identifying Park/Neutral Position Switch
    G04539106Courtesy of DAIMLERCHRYSLER CORPORATION
  102. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

  103. Apply ATF on the both sides of the new gasket and threads of the eyebolts.
  104. Install the oil cooler feed tube together with new gaskets and tighten the eye bolts to the specified torque.

    Tightening torque: 30 +/- 3 N.m (22 +/- 2 ft-lb) 

  105. Tighten the oil cooler feed pipe clamp bolt.
    Fig 81: Installing Input And Output Shaft Speed Sensor
    G04539107Courtesy of DAIMLERCHRYSLER CORPORATION

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

  106. Install the oil dipstick.
  107. Install the cable support bracket.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

  108. Install the roll stopper brackets.

    Tightening torque: 69 +/- 10 N.m (51 +/- 7 ft-lb) 

    CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.
  109. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value.

    Reference value: 

    Approximately 12.2 mm (0.48 inch) < F4A42 > 

    Approximately 9.4 mm (0.37 inch) < F4A51 > 

    Fig 82: Identifying Torque Converter
    G04539108Courtesy of DAIMLERCHRYSLER CORPORATION
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