2007 Mitsubishi Endeavor Auto Transmission Service Information

2007 Mitsubishi Endeavor LS
2007 TRANSAXLE/TRANSMISSION Automatic Transaxle Overhaul - Endeavor
2007 TRANSAXLE/TRANSMISSION
Automatic Transaxle Overhaul - Endeavor
GENERAL INFORMATION
This automatic transaxle is made up of the following main parts.

The gear train is made up of 3 multi-plate clutches, 2 multi-plate brakes and 2
planetary gears made up of a sun gear, carrier, pinion gear and annulus gear.
The torque converter employs a 3 element, 1 step, 2 phase lock-up clutch.
The cases consist of a converter housing, transaxle case, rear cover and a valve
body cover.
Parts related to oil pressure regulation are the oil pump, which pressurizes the oil;
the regulator, which controls the pressure setting; the solenoid valves, which
changes the oil pressure with electrical signals; the pressure control valve, which
controls the oil pressure coming from the solenoid valve that effects each clutch and
brake; each kind of valve, which carry out the retention of the oil pressure through
the lines; and finally the valve body, which houses all the valves.
SECTIONAL VIEW < F4A5A >
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6:13:06 PM
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2005 Mitchell Repair Information Company, LLC.

Fig. 1: Automatic Transaxle Sectional View (F4A5A)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SECTIONAL VIEW < W4A5A >
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Fig. 2: Automatic Transaxle Sectional View (W4A5A)

HYDRAULIC CIRCUIT
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Fig. 3: Automatic Transaxle Hydraulic Circuit

SPECIAL TOOLS
SPECIAL TOOLS SPECIFICATIONS

TOOL
NUMBER AND
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TOOL
NAME
MD998333
Oil pump
remover
SUPERSESSION
MD998333-01
APPLICATION
Removal of oil
pump
MD998924
Spring
compressor
retainer
MD998924-01
MD998338
Spring
compressor
MD998338
MB990607
Torque wrench
socket
MB990607-01
Removal and
installation of output
shaft nut
MB991625
Special socket
(41)
Removal and
installation of output
shaft jam nut
MD998412
Guide
MD998412
MB991632
MB991632-01
Use with spring

compressor
Removal and
installation of oneway clutch inner
race snap ring
Installation of oil
pump and transfer
drive gear
Measurement of
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Clearance
dummy plate
MD998913
Dial gauge
extension
MD998913-01
MB990938
Handle
MB990938-01
MB990930
MB990930-01 or
Installer adapter General service tool
MD998350
Bearing installer
MD998350-01
reaction plate lowreverse brake and

second brake end
play
Measurement of
low-reverse brake
end play
Installation of
input shaft rear
bearing
Use with
installer adapter
Installation of
output shaft taper
roller bearing outer
race
Installation of
output shaft collar
and taper roller
bearing
MB990931
MB990931-01 or
Installation of cap
MB990936
MB990936-01 or
Installation of
differential taper
roller bearing outer
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race
MD998334
Oil seal installer
MD998334-01
Installation of oil
pump oil seal
MD998907
Spring
compressor
MD998907-01
Removal and
installation of
underdrive clutch
snap ring
MB991629
Spring
compressor
Measurement of
underdrive clutch
and overdrive clutch
end play
MD999575
Spring
compressor
Removal and
installation of
reverse and
overdrive clutch
snap ring
MB991789
Spring
compressor
Measurement of
reverse clutch end
play
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MD998917
General service tool Removal of transfer
Bearing remover or MD998348-01
driven gear
MD998801
Bearing remover
MD998812
Installer cap
MD998814
Installer - 200
MD998348-01
Removal of each
bearing output shaft
taper roller bearing
(differential ball
bearing)
General service tool
Use with installer
and installer adapter
MIT304180
Use with installer

cap and installer
adapter
MB990937
MB990937 or
Installation of
output shaft taper
roller bearing
MD998825
Installer adapter
(52)
Installation of
output shaft taper
roller bearing
MD998813
Use with installer
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Installer - 100
cap and installer

adapter
MD998824
Installation of
Installer adapter
transfer driven gear,
(50)
center differential
taper roller bearing
< W4A5A >
MD998820
Installer adapter
(42)
MIT215013
MD998800
Oil seal installer
Installation of
differential taper
roller bearing
Installation of drive
shaft oil seal
MB990887
Ring
Installation of
transfer oil seal <
W4A5A >
MB990891
Bushing remover
installer base
Installation of
transfer oil seal <
W4A5A >
TRANSAXLE
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DISASSEMBLY AND ASSEMBLY

< F4A5A >
Fig. 4: Disassembling/Assembling Transaxle (1 Of 2) (With Torque

Specifications)
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Specifications)
< W4A5A >

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Specifications)
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Specifications)
Required Special Tools:

MB990607: Torque Wrench Socket

MB990930: Installer Adapter
MB990938: Handle
MB991625: Special Socket (41)
MB991632: Clearance Dummy Plate
MD998323: Bearing Installer
MD998333: Oil Pump Remover
MD998338: Oil Pump Remover
MD998412: Guide
MD998913: Dial Gauge Extension
MD998924: Spring Compressor Retainer
DISASSEMBLY
CAUTION:
Because the automatic transaxle is manufactured

from high-precision parts, care must be taken not
to scratch or damage these parts during
disassembly and assembly.
The working area should be covered with a
rubber mat to keep it clean at all times.
Do not wear any cloth gloves and do not use any
shop towels during disassembly. Use only nylon
cloth, paper towels or any other lint-free material.
Parts which have been disassembled should all
be cleaned. Metal parts can be cleaned with
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1.
2.
3.
4.
5.
6.
normal detergent, but they should be dried

completely using compressed air.
Clutch discs, plastic thrust plates and rubber
parts should be cleaned with automatic
transmission fluid (ATF).
If the transaxle body has been damaged,
disassemble and clean the cooler system.
Remove the transfer and O-ring < W4A5A >

Use a dial gauge to measure the input shaft end play.
Remove the torque converter.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt, gaskets and the oil cooler feed tube.
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Fig. 8: Measuring Input Shaft End Play

7. Remove the air breather by inserting a screw driver into the air breather and
prying it up.
Fig. 9: Removing Air Breather

8. Remove the input shaft speed sensor and output shaft speed sensor.
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Fig. 10: Removing Input Shaft Speed Sensor And Output Shaft Speed
Sensor
CAUTION: The manual control lever tightening nut must be
removed before removing the valve body. If the
valve body is removed before the nut, the
park/neutral position switch will be damaged.
9. Loosen the manual control lever tightening nut, and then remove the manual
control lever, and the park/neutral position switch.
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Fig. 11: Removing Manual Control Lever

10. Remove the sealing cap and o-ring. < Type with sealing cap >
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Fig. 12: Removing Sealing Cap

11. Remove the valve body cover.
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Fig. 13: Removing Valve Body Cover

12. Remove the manual control shaft detent.
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Fig. 14: Removing Manual Control Shaft Detent

13. Disconnect the solenoid valve harness from the valve body by undoing the
fluid temperature sensor and all the connectors.
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Fig. 15: Disconnecting Connectors

CAUTION:
Make sure that the manual control lever and

the park/neutral position switch are removed.
See step 8.
Do not remove the bolts (four pieces) shown
in the illustration.
14. Remove the valve body mounting bolts (twenty seven pieces).
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Fig. 16: Removing Valve Body Mounting Bolts

CAUTION: Do not lose the two steel balls.
15. Remove the valve body, gasket and the two steel balls.
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Fig. 17: Removing Valve Body

16. Remove the snap ring from the connector and then push the connector into the
transaxle case and remove the solenoid valve harness.
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Fig. 18: Removing Snap Ring

17. Remove the strainer and the second brake retainer oil seal.
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Fig. 19: Removing Strainer And Second Brake Retainer Oil Seal
18. Remove each accumulator piston and spring.
ACCUMULATOR NUMBER REFERENCE
NUMBER NAME
1
For low-reverse brake
2
For underdrive clutch
3
For second brake
4
For overdrive clutch
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Fig. 20: Removing Accumulator Piston And Spring

19. Remove the manual control lever shaft roller.
20. Remove the manual control lever shaft and the parking pawl rod.
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Fig. 21: Removing Manual Control Lever Shaft Roller

21. Remove the torque converter housing mounting bolts (18 pieces), and then
remove the torque converter housing.
22. Remove the differential bearing outer race and spacer from the torque
converter housing.
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Fig. 22: Removing Torque Converter Housing Mounting Bolts

23. Remove the O-rings (two pieces).
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Fig. 23: Removing O-rings

24. Remove the differential.
25. Remove the differential bearing outer race from the transaxle case.
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Fig. 24: Removing Differential

26. Remove the oil filter.
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Fig. 25: Removing Oil Filter

27. Remove the oil pump mounting bolts (six pieces).
28. Install special tool MD998333 in hole "A."
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Fig. 26: Removing Oil Pump Mounting Bolts

29. Turn special tools MD998333 to remove the oil pump.
30. Remove the oil pump gasket.
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Fig. 27: Removing Oil Pump

31. Remove thrust washer number 1.
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Fig. 28: Removing Thrust Washer Number 1

32. Holding the input shaft, remove the underdrive clutch and input shaft.
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Fig. 29: Removing Underdrive Clutch And Input Shaft

33. Remove thrust bearing number 2.
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Fig. 30: Removing Thrust Bearing Number 2

34. Remove the underdrive clutch hub.
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Fig. 31: Removing Underdrive Clutch Hub

35.
36.
37.
38.
Remove the rear cover.

Remove thrust race number 8.
Remove the seal rings (four pieces).
Remove the input shaft rear bearing.
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Fig. 32: Removing Rear Cover

39. Remove the O-rings (three pieces).
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Fig. 33: Removing O-rings

40. Remove the reverse and overdrive clutch and thrust bearing number 7.
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41. Remove overdrive clutch hub and thrust bearing number 6.
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42. Remove thrust bearing number 5.
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43. Remove the planetary reverse sun gear.
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Fig. 37: Removing Planetary Reverse Sun Gear

44. Remove the snap ring.
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45. Remove the second brake piston and the return spring.
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Fig. 39: Removing Return Spring

46. Remove the pressure plate, brake discs and brake plates.
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Fig. 40: Removing Pressure Plate

47. Remove the planetary carrier assembly.
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Fig. 41: Removing Planetary Carrier Assembly

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49. Remove the reaction plate and the brake disc.
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Fig. 43: Removing Reaction Plate

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51. Remove the brake plates (five pieces), brake discs (six pieces) and pressure
plate.
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Fig. 45: Removing Brake Plates

52. Remove the wave spring.
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Fig. 46: Removing Wave Spring

53. Remove the parking pawl shaft, and then remove the spacer and spring.
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Fig. 47: Removing Parking Pawl Shaft

54. Remove the two parking roller support shafts, and then remove the parking
roller support.
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Fig. 48: Removing Parking Roller Support Shafts

55. Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998338 and MD998924, compress the one-way
clutch inner race.
NOTE:
This illustration shows F4A5A.

3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return
spring and low-reverse brake piston.
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Fig. 49: Using Special Tools MD998338 & MD998924

56. Remove the four transfer drive gear bearing mounting bolts. Then, turn the
gear 1/8 turn (45 degree angle) and remove the remaining bolts.
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Fig. 50: Removing Mounting Bolts

57. Remove the transfer drive gear.
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Fig. 51: Removing Transfer Drive Gear

58. Remove the cap by inserting a screw driver into the center of the cap and
prying it up.
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Fig. 52: Removing Cap With Screw Driver

59. Using a chisel, remove the staked nut from the output shaft.
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Fig. 53: Removing Staked Nut

CAUTION: The jam nut is reverse threaded.
60. Use special tools MB991625 and MB990607 to remove the output shaft jam
nut.
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Fig. 54: Removing Output Shaft Jam Nut

61. Remove the output shaft mounting bolts.
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Fig. 55: Removing Output Shaft Mounting Bolts

62. Tap on the rear end of the output shaft to remove the output shaft, taper roller
bearing and collar.
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Fig. 56: Removing Output Shaft

63. Remove the outer race and the spacer.
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Fig. 57: Removing Outer Race & Spacer

ASSEMBLY
CAUTION:
Do not reuse the gasket, O-ring, oil seal. Always

replace with a new one when assembling.
Do not use grease other than petroleum jelly
(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.
When replacing a bushing, replace the assembly
which it belongs to.
Do not use cloth gloves or shop towels during
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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. 58: Installing Special Tool MD998412

2. Tighten the eight mounting bolts of the transfer drive gear bearing to the
specified torque.
Tightening torque: 34 +/- 2 N.m (25 +/- 1 ft-lb)
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Fig. 59: Transfer Drive Gear Bearing Mounting Bolts

3. Install the low-reverse brake piston, return spring, and spring retainer into the
transaxle case.
4. Fit a new O-ring into the groove of one-way clutch inner race.
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.
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Fig. 60: Identifying Transaxle Case

6. Put the snap ring on the inner race.
7. Set special tools MD998338 and MD998924 as shown, and then compress the
one-way clutch inner race and install the snap ring.
Fig. 61: Installing Snap Ring With Special Tools

8. Install the wave spring onto the low-reverse brake piston.
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Fig. 62: Installing Wave Spring

CAUTION: If necessary, take the measurements in steps 9 to
18 after replacing the pressure plate, brake plate
and brake disc.
9. Install the six brake discs, five brake plates and snap ring as shown in the
illustration.
NOTE:
Do not install the pressure plate at this time.
10. Install special tool MB991632 on the brake disc.

11. Install the reaction plate and the used snap ring.
12. Move special tool MB991632 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)
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Fig. 63: Installing Reaction Plate

13. Install the brake discs and brake plates as shown in the illustration.
14. Place special tool MB991632 on top of the brake disc in place of the pressure
plate.
15. Install the return spring, second brake piston and snap ring.
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Fig. 64: Installing Brake Discs And Brake Plates

16. Move special tool MB991632 and measure its movement.
Standard value of end play (Reference): 1.09 - 1.55 mm (0.0429 - 0.0610
inch)
17. Select a pressure plate whose thickness corresponds to the measured amount of
movement from the following table.
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Fig. 65: Measuring Movement With Special Tool

PRESSURE PLATE
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Fig. 66: Measuring Movement Amount Of Pressure Plate

THICKNESS CHART
MOVEMENT
AMOUNT mm
THICKNESS mm
(in)
(in)
1.1 - 1.3 (0.043 1.8 (0.071)
0.051)
1.3 - 1.5 (0.051 2.0 (0.079)
0.059)
1.5 - 1.7 (0.059 2.2 (0.087)
0.067)
1.7 - 1.9 (0.067 2.4 (0.094)
0.075)
1.9 - 2.1 (0.075 2.6 (0.102)
ID SYMBOL
E
D
C
B
A
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0.083)
2.1 - 2.3 (0.083 0.091)
2.8 (0.110)
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
MB991632 and measure its movement.
Standard value of end play (Reference): 1.65 - 2.11 mm (0.050 - 0.0831
inch)
Fig. 67: Measuring Movement With Special Tool And Dial Gauge
19. Select a pressure plate whose thickness corresponds to the measured amount of
movement from the table below.
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PRESSURE PLATE
Fig. 68: Measuring Movement Amount Of Pressure Plate

THICKNESS CHART
MOVEMENT
AMOUNT mm
THICKNESS mm
(in)
(in)
1.0 - 1.2 (0.039 1.6 (0.063)
0.047)
1.2 - 1.4 (0.047 1.8 (0.071)
0.055)
1.4 - 1.6 (0.055 2.0 (0.079)
0.063)
1.6 - 1.8 (0.063 2.2 (0.087)
ID SYMBOL
F
E
D
C
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0.071)
1.8 - 2.0 (0.071 0.079)
2.0 - 2.2 (0.079 0.087)
2.2 - 2.4 (0.087 0.094)
2.4 - 2.6 (0.094 0.102)
2.4 (0.094)
2.6 (0.102)
2.8 (0.110)
3.0 (0.118)
20. Remove all parts and special tools that were installed to take the measurements
in steps 8 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. Install the thinnest output shaft preload adjustment spacer [thickness 1.88 mm
(0.0740 in); part number MD756579].
23. Use special tools MB990930 and MB990938 to tap the output shaft bearing
outer race in the transaxle case.
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Fig. 69: Taping Output Shaft Bearing Outer Race In Transaxle Case
CAUTION: Do not reuse the bolt, as it has had sealant
applied.
24. Tighten the mounting bolts of the output shaft to the specified torque.
Tightening torque:
54 +/- 5 N.m(40 +/- 4 ft-lb)
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Fig. 70: Tightening Mounting Bolts

25. Use special tool MD998350 to install the collar and taper roller bearing on the
output shaft.
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Fig. 71: Installing Collar And Taper Roller Bearing On Output Shaft
26. 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.
NOTE:
The jam nut is reverse threaded.
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Fig. 72: Tightening Jam Nut

27. Move the output shaft to measure the end play and record the measurement
value.
Standard value of output shaft end play (reference): 0.01 - 0.09 mm
(0.0004 - 0.0035 inch)
28. Remove the parts that were installed in steps 21 to 25.
29. Add 1.88 mm (0.074 inch)* and 0.01 to 0.09 mm (0.0004 to 0.0035 inch)** to
the measured value in step 26 and select a spacer of the same thickness.
Adjustment spacer sizes are all listed on ADJUSTING PLATE, SNAP RING
AND SPACERS . Select the most suitable one from among those listed.
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Fig. 73: Measuring End Play

NOTE:
* is the thickness of the spacer installed in step 21. ** is

the preload of the output shaft.
30. Repeat steps 22 to 25 again, installing each part and using the appropriate
adjustment spacer determined in step 27.
31. Stake the jam nut with a punch (two places).
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Fig. 74: Staking Jam Nut

32. Use special tools MB990931 and MB990938 to install the cap as shown in the
illustration.
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Fig. 75: Installing Cap With Special Tools MB990931 And MB990938
33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
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Fig. 76: Installing Parking Pawl Shaft

34. Install the parking roller support, and then insert the two parking roller support
shafts.
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Fig. 77: Installing Parking Roller Support Shafts

IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND
THRUST WASHERS mm (in)
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Fig. 78: Identifying Thrust Bearing, Thrust Races, And Thrust Washers
Location
THICKNESS CHART
OD
ID
OD
ID
THICKNESS
THICKNESS
SYMBOL mm mm
SYMBOL mm mm
mm (in)
mm (in)
(in)
(in)
(in)
(in)
59
47
48.9 37
1.8 (0.071)
1.6 (0.063)
(2.32) (1.85)
(1.925) (1.46)
59
47
48.9 37
2.0 (0.079)
1.7 (0.067)
(2.32) (1.85)
(1.925) (1.46)
59
47
48.9 37
No. 1
2.2 (0.087)
1.8 (0.071)
(2.32) (1.85)
(1.925) (1.46)
59
47
48.9 37
2.4 (0.094)
1.9 (0.075)
(2.32) (1.85)
(1.925) (1.46)
59
47
48.9 37
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No. 2
No. 3
No. 4
No. 5
No. 6
No. 7
(2.32) (1.85) 2.6 (0.102)

59
47
2.8 (0.110)
(2.32) (1.85)
49
34
3.6 (0.142)
(1.93) (1.34)
49
34
3.6 (0.142)
(1.93) (1.34)
45.3 31
3.3 (0.130)
(1.783) (1.22)
49
34
3.6 (0.142)
(1.93) (1.34)
49
34
3.6 (0.142)
(1.93) (1.34)
59
37
2.8 (0.110)
(2.32) (1.46)
No. 8
(1.925) (1.46) 2.0 (0.079)

48.9 37
2.1 (0.083)
(1.925) (1.46)
48.9 37
2.2 (0.087)
(1.925) (1.46)
48.9 37
2.3 (0.091)
(1.925) (1.46)
48.9 37
2.4 (0.094)
(1.925) (1.46)
48.9 37
2.5 (0.098)
(1.925) (1.46)
48.9 37
2.6 (0.102)
(1.925) (1.46)
35. Install the planetary carrier assembly.
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Fig. 79: Installing Planetary Carrier Assembly

36. Install the planetary reverse sun gear.
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Fig. 80: Installing Planetary Reverse Sun Gear

37. Install the wave spring on the low-reverse brake piston.
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Fig. 81: Installing Wave Spring

38. Install the pressure plate that was selected in step 18. Next, install six brake
discs and five brake plates, one on top of the other.
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Fig. 82: Installing Pressure Plate

39. Install the snap ring.
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Fig. 83: Installing Snap Ring

40. Install the reaction plate.
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Fig. 84: Installing Reaction Plate

41. Install the snap ring that was selected in step 12.
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42. Install four brake discs and three brake plates, one on top of the other. Next,
install the pressure plate that was selected in step 16.
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Fig. 86: Installing Pressure Plate

43. Install the return spring and second brake piston.
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Fig. 87: Installing Return Spring

44. Install the snap ring.
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CAUTION: Be sure to install the thrust bearing in the correct
direction as shown.
45. Check the installation direction of the thrust bearing number 5, and install it on
the hub of the planetary reverse sun gear.
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Fig. 89: Installing Thrust Bearing Number 5

CAUTION: Use care to install the thrust bearing in the
proper direction.
46. 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.
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47. Install the reverse and overdrive clutch.
direction as shown.
48. Check the installation direction of thrust bearing number 7, and install it on the
reverse clutch retainer.
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49. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
50. Install the four seal rings in the grooves of the rear cover.
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Fig. 92: Taping Input Shaft Rear Bearing In Rear Cover

51. 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.
3. Turn over the transaxle case so that the installation surface of the torque
converter housing is facing up.
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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 measurements in steps (1) to (4), take out the installed
parts.
52. Install the three O-rings.
53. 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.
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Fig. 94: Installing O-rings

THICKNESS CHART
MEASUREMENT VALUE mm (in) THICKNESS mm (in)
0.3 - 0.4 (0.012 - 0.016)
1.6 (0.063)
0.4 - 0.5 (0.016 - 0.020)
1.7 (0.067)
0.5 - 0.6 (0.020 - 0.024)
1.8 (0.071)
0.6 - 0.7 (0.024 - 0.028)
1.9 (0.075)
0.7 - 0.8 (0.028 - 0.031)
2.0 (0.079)
0.8 - 0.9 (0.031 - 0.035)
2.1 (0.083)
0.9 - 1.0 (0.035 - 0.039)
2.2 (0.087)
1.0 - 1.1 (0.039 - 0.043)
2.3 (0.091)
1.1 - 1.2 (0.043 - 0.047)
2.4 (0.094)
1.2 - 1.3 (0.047 - 0.051)
2.5 (0.098)
1.3 - 1.4 (0.051 - 0.055)
2.6 (0.102)
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54. 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).
Fig. 95: Applying Sealant

55. Install the rear cover, and tighten its mounting bolts to the specified torque.
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Page 105

NOTE:
After installation, keep the sealed area away from the oil
for approximately one hour.

56. Install the underdrive clutch hub to the underdrive sun gear.
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Fig. 97: Installing Underdrive Clutch Hub To Underdrive Sun Gear

direction as shown.
57. Check the installation direction of thrust bearing number 2, and install it on the
underdrive clutch hub.
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Fig. 98: Installing Thrust Bearing

58. Hold the input shaft, and install the underdrive clutch.
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Fig. 99: Holding Input Shaft

59. Adjustment of input shaft end play and select the thrust washer number 1.
(Refer to THRUST WASHER SELECTION FOR ADJUSTMENT OF
INPUT SHAFT END PLAY ).
60. Install thrust washer number 1 that was selected in step (69) on the underdrive
clutch retainer.
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Fig. 100: Installing Thrust Washer

61. Install special tool MD998412 as shown.
62. Install the oil pump to the transaxle case.
NOTE:
Do not install the oil pump gasket at this time.
63. Tighten the oil pump mounting bolts (six pieces) to the specified torque.
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Fig. 101: Installing Special Tool MD998412

64. Make sure that the input shaft end play meets the standard value.
Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch)
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65. Install the oil filter.
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Fig. 103: Installing Oil Filter

66. Use special tools MB990936 and MB990938 to tap the differential bearing
outer race in the transaxle case.
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Fig. 104: Taping Differential Bearing Outer Race In Transaxle Case

67. Install the differential.
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Fig. 105: Installing Differential

68. Adjustment of differential case preload and select the spacer. (Refer to
SPACER SELECTION FOR ADJUSTMENT OF DIFFERENTIAL
CASE PRELOAD ).
69. Install the selected spacer to the torque converter housing.
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Fig. 106: Installing Selected Spacer To Torque Converter Housing

70. Use special tools MB990936 and MB990938 to press in the differential bearing
outer race into the torque converter housing.
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Fig. 107: Pressing Differential Bearing Outer Race Into Torque Converter
Housing With Special Tools
Part number MD974421 or equivalent) to the torque converter housing in the
area shown.
NOTE:

wet (with 15 minutes).
NOTE:
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72. Install the two O-rings.
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Fig. 109: Installing O-Rings

73. Install the torque converter housing and then tighten its 18 mounting bolts to
the specified torque.
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74. Insert the two O-rings into the grooves of the manual control lever shaft.
75. Install the manual control lever shaft and parking pawl rod.
76. Align hole "A" with the groove in the manual control lever shaft. Insert the
manual control lever shaft roller into hole "A".
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Fig. 111: Installing Manual Control Lever Shaft

77. Insert the new seal rings in the grooves of the accumulator pistons.
NOTE:
The piston and seal ring are common parts.
78. 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.
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Fig. 112: Identifying Accumulator Spring

ACCUMULATOR NUMBER CHART
NO. NAME
IDENTIFICATION "BLUE-ING"
1 For low-reverse brake None
2 For underdrive clutch Half
3 For second brake
Whole surface
4 For overdrive clutch None
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Fig. 113: Identifying Accumulator Spring Location

79. Install the strainer and second brake retainer oil seal.
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Fig. 114: Installing Strainer

80. Insert a new O-ring to the groove of the solenoid valve harness connector.
81. 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.
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82. Install a steel ball into each of the two holes in the top face of the valve body
(outside valve body).
83. 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.
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Fig. 116: Installing Transaxle Case

84. Install the 27 valve body mounting bolts, and tighten to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
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Fig. 117: Installing Mounting Bolts

85. Attach the solenoid valve harness to the valve body by connecting the fluid
temperature sensor and all the connectors.
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Fig. 118: Installing Connectors

VALVE REFERENCE CHART
SOLENOID VALVE
HARNESS
CONNECTOR
PARTS TO BE
CABLE
HOUSING
NO. CONNECTED
COLOR
COLOR
1
Underdrive solenoid
White, red, red Black
valve
2
Overdrive solenoid
Orange, red
Black
valve
3
Low-reverse solenoid Brown, yellow Milky white
valve
4
Second solenoid valve Blue, red, red Milky white
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Torque converter
Blue, yellow,
clutch control solenoid yellow
valve
Black
86. Install the manual control shaft detent and tighten the bolt to the specified
torque.
Tightening torque: 6.0 +/- 1.0 N.m (52 +/- 9 in-lb)
Fig. 119: Tightening Bolt

Part number MD974421 or equivalent) to the valve body cover in the area
shown.
NOTE:

wet (with 15 minutes).
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Page 129

NOTE:

88. Install the valve body cover, and then tighten its mounting bolts to the
specified torque.
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89. Install the Sealing cap and tighten the bolt to the specified torque. < Type with
sealing cap >
Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 9 in-lb)
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Fig. 122: Installing Sealing Cap

90. Install the park/neutral position switch and tighten the bolt to specified torque.
91. Install the manual control lever and tighten the nut to specified torque.
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Fig. 123: Installing Manual Control Lever

92. Install the input shaft speed sensor and output shaft speed sensor and tighten
the bolt to the specified torque.
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Fig. 124: Installing Input Shaft Speed Sensor

93. Press Face "A" of the air breather to be even with Face "B" of the transmission
case as shown in the illustration.
94. Apply ATF on the both sides of the new gasket and threads of the eye bolts,
and then tighten to the specified torque.
95. Tighten the oil cooler feed pipe clamp bolt to the specified torque.
96. Install the oil dipstick.
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Fig. 125: Identifying Air Breather Face (A) And Transmission Case Face
(B)
97. Install the control cable support bracket.
98. Install the roll stopper brackets.
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.
99. Install the torque converter, and secure it so that the shown dimension "A"
meets the reference value.
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Page 135

Reference value:
Approximately 9.4 mm (0.37 inch)
100. Install the transfer together with new o-ring and tighten the bolts to the
specified torque < W4A5A >
Fig. 126: Checking Dimension A

ADJUSTMENT OF TRANSAXLE
THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY
< Measurement using a Solder >
CAUTION:
If solder is not available, select the thrust washer
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Page 136

in accordance with Plastigage method.

If the thrust washer appropriate for the standard
value cannot be selected using solder, select the
thrust washer in accordance with Plastigage
method.
1. Put solders (1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long) in
the illustrated positions of the underdrive clutch retainer.
2. Install the adjusting thrust washer having minimum thickness.
Fig. 127: Identifying Underdrive Clutch Retainer Location

CAUTION: Never use a gasket that has been tightened.
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Page 137

3. Use the special tool Guide (MD998412) to install a new oil pump gasket and
the oil pump. Tighten the oil pump mounting bolts to the specified torque of 29
+/- 2 N.m (21 +/- 2 ft-lb).
4. Remove the oil pump mounting bolts.
Fig. 128: Identifying Special Tool Guide MD998412

5. Using special tools MD998333, remove the oil pump and then take out crushed
solders.
6. If the solders have not crushed, use thicker thrust washer and repeat steps 3 to
5.
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Page 138

Fig. 129: Removing Oil Pump

7. Use a micrometer to measure the thickness of the crushed solder beads and
record the measured value.
8. Select the thrust washer, calculated by the following formula, in the table.
T = T1 + T2
T: Clearance mm
T1: The crushed solder thickness mm
T2: The thrust washer thickness used for measurement mm
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Fig. 130: Measuring Thickness Of Crushed Solder Beads

Available thrust washer
THICKNESS CHART
MEASUREMENT THICKNESS mm
VALUE mm (in)
(in)
2.25 - 2.45(0.089 1.8 (0.071)
0.096)
2.45 - 2.65(0.096 2.0 (0.079)
0.104)
ID SYMBOL
18
20
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2.65 - 2.85(0.104 0.112)

2.85 - 3.05(0.112 0.120)
3.05 - 3.25(0.120 0.128)
3.25 - 3.45(0.128 0.136)
2.2 (0.087)
22
2.4 (0.094)
24
2.6 (0.102)
26
2.8 (0.110)
28
< Measurement using Plastigage >
1. Put plastigage (about 10 mm (0.039 inch) long) in the illustrated positions of

the underdrive clutch retainer.
Fig. 131: Installing/Positioning Plastigage

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Page 141

2. Install the adjusting thrust washer having the minimum thickness.

CAUTION: Never use a gasket that has been tightened.
3. Use the special tool Guide (MD998412) to install a new oil pump gasket and
the oil pump. Tighten the oil pump mounting bolts to the specified torque.
4. Remove the oil pump mounting bolts.
Fig. 132: Identifying Special Tool Guide MD998412

5. Using special tools MD998333, remove the oil pump and then take out crushed
Plastigages.
6. If the plastigage have not crushed, use thicker adjusting thrust washer and
repeat steps 3 to 5.
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Fig. 133: Removing Oil Pump Using Special Tool

7. Measure the width of the crushed plastigage at its widest part using a scale
printed on the plastigage package.
8. Select the thrust washer, calculated by the following formula, in the table.
T = T3 + T2
T: Clearance mm
T3: The crushed plastigage thickness mm
T2: The thrust washer thickness used for measurement mm
Available thrust washer
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Fig. 134: Measuring Thickness Using Plastigage

THICKNESS CHART
MEASUREMENT THICKNESS mm
VALUE mm (in)
(in)
2.25 - 2.45(0.089 1.8 (0.071)
0.096)
2.45 - 2.65(0.096 2.0 (0.079)
0.104)
2.65 - 2.85(0.104 2.2 (0.087)
0.112)
2.85 - 3.05(0.112 2.4 (0.094)
0.120)
ID SYMBOL
18
20
22
24
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3.05 - 3.25(0.120 0.128)

3.25 - 3.45(0.128 0.136)
2.6 (0.102)
26
2.8 (0.110)
28
SPACER SELECTION FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD

< Measurement using a Solder >
CAUTION:
If solder is not available, select the spacer in

accordance with Plastigage method.
If the spacer appropriate for the standard value
cannot be selected using solder, select the
spacer in accordance with Plastigage method.
1. Put solders (1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long) in
the illustrated positions of the converter housing.
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Fig. 135: Putting Solders In Illustrated Positions Of Converter Housing

2. Use the special tools MB990935 and MB990938 to drive the outer race into
position.
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Page 146

Housing
3. Install the converter housing on the transaxle case without applying FIPG.
Tighten the mounting bolts to the specified torque.
4. Remove the bolts and converter housing, and take out the solder pieces.
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Fig. 137: Installing Torque Converter Housing To Transaxle Case

5. If the solders have not crushed, use thicker solders (1.6 mm (0.063 inch)
diameter, about 10 mm (0.39 inch) long) and repeat steps 2 to 4.
6. Measure the thickness of the crushed solder with a micrometer, and then select
a spacer that will provide the standard value.
Spacer thickness: (T1 - 0.045 mm (0.0018 inch) to (T1 - 0.105mm (0.0041
inch)
T1: The crushed solder thickness mm (inch)
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Fig. 138: Measuring Thickness Of Crushed Solder Beads

< Measurement using Plastigage >
1. Put plastigage (about 10 mm (0.39 inch) long) in the illustrated positions of the
converter housing.
2. Install the adjusting spacer having the minimum thickness.
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Page 149

Fig. 139: Putting Plastigage In Illustrated Positions Of Converter Housing

3. Use the special tools MB990935 and MB990938 to drive the outer race into
position.
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Page 150

Housing
4. Install the converter housing on the transaxle case without applying FIPG.
Tighten the mounting bolts to the specified torque.
5. Remove the bolts and converter housing, and take out the solder pieces.
6. If the solders have not crushed, use thicker solders (1.6 mm (0.063 inch)
diameter, about 10 mm (0.39 inch) long) and repeat steps 3 to 5.
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Fig. 141: Installing Torque Converter Housing To Transaxle Case

7. Measure the width of the crushed plastigage at its widest part using a scale
printed on the plastigage package, and then select a spacer that will provide the
standard value.
Spacer thickness: (T1 - 0.045 mm (0.0018 inch) to (T1 - 0.105 mm (0.0041
inch)
T1: The crushed solder thickness mm (inch)
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Fig. 142: Measuring Width Of Crushed Plastigage

OIL PUMP
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Fig. 143: Disassembling/Assembling Oil Pump

Required Special Tool:
MD998334: Oil Seal Installer
ASSEMBLY SERVICE POINTS

>> A << OIL SEAL INSTALLATION
1. Apply a small amount of ATF to the oil seal lip.

2. Use special tool MD998334 to tap the oil seal in the oil pump body.
>> B << O-RING INSTALLATION
Install a new O-ring to the outer groove of the oil pump, and apply ATF or
petroleum jelly (Vaseline) to the O-ring.
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Fig. 144: Installing Oil Seal Lip With Special Tool

UNDERDRIVE CLUTCH AND INPUT SHAFT
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Fig. 145: Disassembling/Assembling Underdrive Clutch And Input Shaft


MB991629: Spring Compressor

MD998907: Spring Compressor
DISASSEMBLY SERVICE POINT

<< A >> SNAP RING REMOVAL
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Page 156

1. Set special tools MD998907 and MD998924 as shown in the illustration.

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

>> A << D-RING INSTALLATION
1. Install a D-ring in the groove in the underdrive clutch retainer and piston, and
in the groove in the outside of the spring retainer. Be careful not to twist or
damage the D-rings.
2. Apply ATF or petroleum jelly (Vaseline) to the D-rings.
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Fig. 147: Installing D-ring

>> B << SNAP RING INSTALLATION
1. Place the snap ring on top of the spring retainer, and then set special tool
MD998907 as shown in the illustration.
2. Compress the return spring and install the snap ring.
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>> C << CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION
CAUTION: Immerse the clutch disc in ATF before assembling it.

IF the clutch disc is new, soak it in ATF for at least
two hours.
1. Assemble the four clutch plates and four clutch discs one on top of the other
inside the underdrive clutch retainer. All four clutch plates should be
assembled so that the places with no teeth (marked "A") are aligned with the
holes in the retainer (marked "B").
2. Install the clutch reaction plate in the direction shown in stall it the same as the
clutch plates, so that the areas with no teeth (marked "A") are aligned with the
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Page 159

retainer (marked "B").
Fig. 149: Locating Teeth Marked

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Fig. 150: Installing Clutch Reaction Plate

>> D << SNAP RING INSTALLATION
1. Install the snap ring into the groove of clutch retainer.

2. Set special tools MB991629 and MD998924 as shown in the illustration, and
then compress the clutch element.
3. Check that the clearance between the snap ring and the clutch reaction plate is
within the standard value. If not within the standard value, select a snap ring so
that it is.
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REVERSE AND OVERDRIVE CLUTCH
NUMBER OF CLUTCH DISCS AND PLATES

CLUTCH REFERENCE CHART
PRESSURE
PLATE
Over drive
1
clutch
Reverse
clutch
CLUTCH
DISC
CLUTCH
PLATE
CLUTCH
REACTION
PLATE
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Page 162

Fig. 152: Disassembling/Assembling Reverse And Overdrive Clutch



MD999575: Spring Compressor
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Page 163


<< A >> SNAP RING REMOVAL

2. Compress the return spring and remove the snap ring.
Fig. 153: Removing Snap Ring With Special Tools

1. Install D-rings in the grooves on the reverse clutch retainer, piston, overdrive
clutch piston and spring retainer. Be careful not to twist or damage the D-rings.
2. Apply ATF or petroleum jelly (Vaseline) to D-rings.
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Fig. 154: Installing D-rings In Grooves On Reverse Clutch Retainer

>> B << REVERSE CLUTCH PISTON INSTALLATION
Align the outer circumference holes ("A" and "B") of the reverse clutch piston and
the reverse clutch retainer to assemble them.
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Fig. 155: Aligning Reverse Clutch Piston Outer Circumference Holes A & B
>> C << SNAP RING INSTALLATION

2. Tighten the nut on the special tool to press down on the spring retainer and
reverse clutch retainer, and then install the snap ring.
3. Check that the clearance between the snap ring and the return spring retainer is
that it is.
Standard value: 0 - 0.09 mm (0 - 0.0035 inch)
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>> D << PRESSURE PLATE/CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION
1. Install the pressure plate in the direction shown.

CAUTION: Immerse the clutch disc in ATF before
assembling it. IF the clutch disc is new, soak it in
ATF for more than two hours.
2. Assemble the clutch discs and clutch plates, one on top of the other, inside the
reverse clutch piston.
3. Install the clutch reaction plate in the direction shown.
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>> E << SNAP RING INSTALLATION
1. Install the snap ring into the groove in the reverse clutch piston.
2. Set special tools, MB991629 and MD998924 as shown in the illustration, and
compress the clutch element.
that it is.
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Fig. 158: Checking Clearance Between Snap Ring And Clutch Reaction
Plate
>> F << CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION
CAUTION: Immerse the clutch disc in ATF before assembling it.

If the clutch disc is new, soak it in ATF for at least
two hours.
1. Assemble two clutch discs and two clutch plates, one on top of the other, inside
the reverse clutch retainer. Assemble both clutch plates so that the places with
no teeth (marked "A") are aligned with the holes in the retainer (marked "B").
2. Install the clutch reaction plate in the direction shown. Install it the same as the
clutch plate, so that the places with no teeth (marked "A") are aligned with the
holes in the retainer (marked "B").
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Fig. 159: Identifying Clutch Plate Teeth Marked

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Page 170


>> G << SNAP RING INSTALLATION
1. Install the snap ring into the groove of reverse clutch retainer.
2. Set special tools MB991789 and MD998924 as shown in the illustration, and
compress the clutch element.
that it is.
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Fig. 161: Installing Snap Ring Into Groove Of Reverse Clutch Retainer
PLANETARY GEAR
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Fig. 162: Disassembling/Assembling Planetary Gear

>> A << THRUST BEARING NUMBER 4 AND THRUST BEARING NUMBER 3 INSTALLATION
CAUTION: Use care to install the thrust bearings in the correct

direction.
Check the installation direction of thrust bearings number 3 and 4, and install them
as shown.
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Fig. 163: Checking Installation Direction Of Thrust Bearings Number 3 And 4

>> B << ONE-WAY CLUTCH INSTALLATION
Insert the one-way clutch into the overdrive annulus gear so that the arrow points
towards the output planetary carrier.
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Fig. 164: Installing One-Way Clutch

LOW-REVERSE BRAKE
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Fig. 165: Disassembling/Assembling Low-Reverse Brake

ASSEMBLY SERVICE POINT
Apply ATF or petroleum jelly (Vaseline) to the D-ring, and install carefully.
SECOND BRAKE
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Fig. 166: Disassembling/Assembling Second Brake

Apply ATF or petroleum jelly (Vaseline) to the D-ring, and install carefully.
OUTPUT SHAFT
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Fig. 167: Disassembling/Assembling Output Shaft



MB990938: Handle
MD998801: Bearing Remover
MD998812: Installer Cap
MD998813: Installer-100
MD998814: Installer-200
MD998824: Installer Adapter (50)
MD998917: Bearing remover
DISASSEMBLY SERVICE POINTS

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<< A >> TRANSFER DRIVEN GEAR REMOVAL
1. Support the transfer driven gear with the special tool MD998917, and then set
them on the press.
2. Push down on the output shaft with the press to remove the transfer driven
gear.
Fig. 168: Supporting Transfer Driven Gear With Special Tool

<< B >> TAPER ROLLER BEARING REMOVAL
1. Support the taper roller bearing with the special tool MD998801, and then set
them on the press.
2. Push down on the output shaft with the press to remove the tapper roller
bearing.
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Fig. 169: Supporting Taper Roller Bearing With Special Tool

>> A << TAPER ROLLER BEARING INSTALLATION
1. Set the output shaft on the press support stand.

2. Using special tools MD998825, MD998812 and MD998814, press install the
taper roller bearing.
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Fig. 170: Installing Taper Roller Bearing

>> B << OUTER RACE INSTALLATION
Use the special tools, MB990937 and MB990938 to tap the outer race in the bearing
retainer.
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Fig. 171: Taping Outer Race In Bearing Retainer

>> C << TRANSFER DRIVEN GEAR INSTALLATION
1. Set the output shaft on the press support stand.

2. Using special tools MD998824, MD998812 and MD998813, press in the
transfer driven gear.
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Fig. 172: Installing Transfer Driven Gear

DIFFERENTIAL
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Fig. 173: Disassembling/Assembling Differential (With Torque Specifications)




<< A >> TAPER ROLLER BEARING REMOVAL
1. Support the taper roller bearing with special tool MD998801, and then set them
on the press.
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Page 184

2. Push down on the differential case with the press to remove the bearing.
Fig. 174: Supporting Taper Roller Bearing With Special Tool

>> A << SPACER, SIDE GEAR, WASHER, PINION AND PINION SHAFT INSTALLATION
1. Mount a spacer on the back surface of the side gear, and then install the side
gear in the differential case.
NOTE:
When a new side gear is to be installed, mount a

medium thickness spacer [0.93 to 1.00 mm (0.0366 to
0.0395 inch)].
2. Set the washer on the back of each pinion, and put both pinions simultaneously
in mesh with the side gears. While rotating them, install them into position.
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Fig. 175: Installing Side Gear In Differential Case

3. Insert the pinion shaft.
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Fig. 176: Installing Pinion Shaft

4. Measure the backlash between the side gear and pinion.
5. If the backlash is out of the standard value, select a spacer and re-measure the
backlash.
NOTE:
Adjust until the backlashes on both sides are equal.
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Fig. 177: Measuring Backlash Between Side Gear And Pinion

>> B << LOCK PIN INSTALLATION
Install the lock pin so that it will be oriented in the direction shown.
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Fig. 178: Installing Lock Pin

>> C << TAPER ROLLER BEARING INSTALLATION
Using special tools MD998812 and MD998820, press in the taper roller bearing
with the press.
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>> D << DIFFERENTIAL DRIVE GEAR INSTALLATION
Apply ATF to the bolts, and then tighten the bolts to the specified torque in the
shown sequence.
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Fig. 180: Differential Drive Gear Bolt Tightening Sequence

CENTER DIFFERENTIAL
< W4A5A >
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Fig. 181: Disassembling/Assembling Center Differential (With Torque

Specifications)


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DISASSEMBLY SERVICE POINTS

<< A >> TAPER ROLLER BEARING REMOVAL
1. Support the taper roller bearing with special tool MD998917, and then set them
on the press.
Fig. 182: Removing Taper Roller Bearing Using Special Tool

<< B >> TAPER ROLLER BEARING REMOVAL
1. Support the taper roller bearing with special tools MD998917 and MB990930,
and then set them on the press.
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Fig. 183: Removing Taper Roller Bearing

>> A << TAPER ROLLER BEARING INSTALLATION
Using special tool MB990937, press in the taper roller bearing.
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Fig. 184: Pressing Taper Roller Bearing

>> B << TAPER ROLLER BEARING INSTALLATION
Using special tools MD998812 and MD998824, press in the taper roller bearing.
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Page 195


>> C << SPACER, SIDE GEAR, WASHER, PINION AND PINION SHAFT, PINION SHAFT HOLDER, LOCK PIN, FRONT
OUTPUT SHAFT, SNAP RING, CENTER DIFFERENTIAL FLANGE, INSTALLATION
1. Mount a spacer on the back surface of the side gear, and then install the side
NOTE:
When a new side gear is to be installed, use a medium

thickness spacer [0.93 to 1.00 mm (0.0366 to 0.0395
inch)].
2. Place the washers on the back of the pinions, and simultaneously mesh the four
pieces with the side gears. Place them into position while rotating them. Then,
install the pinion shaft holder.
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Page 196

Fig. 186: Installing Side Gear In Differential Case

3.
4.
5.
6.
Insert the pinion shaft.

Install the lock pin so that it will be oriented in the direction shown.
Install the front output shaft on the side gear, and install the snap ring.
Mount a spacer on the back surface of the side gear, and then install the side
NOTE:
When a new side gear is to be installed, use a medium

thickness spacer [0.93 to 1.00 mm (0.0366 to 0.0395
inch)].
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Page 197

Fig. 187: Installing Pinion Shaft

7. Install the center differential flange by aligning the matching marks, and
temporarily tighten the four machine screws.
8. Measure the backlash between the side gear and pinion.
9. If the backlash is out of the standard value, select a spacer and re-measure the
backlash.
NOTE:
Adjust until the backlash on both sides are equal.
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Page 198

Fig. 188: Measuring Backlash Between Side Gear And Pinion

>> D << CENTER DIFFERENTIAL DRIVE GEAR INSTALLATION
Apply ATF to the bolts, and then tighten the bolts to the specified torque in the
sequence shown.
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Fig. 189: Center Differential Drive Gear Bolt Tightening Sequence

VALVE BODY
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Fig. 190: Disassembling/Assembling Valve Body (1 Of 3) (With Torque

Specifications)
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Fig. 191: Disassembling/Assembling Valve Body (2 Of 3)

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Fig. 192: Disassembling/Assembling Valve Body (3 Of 3)

<< A >> SOLENOID VALVES REMOVAL
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Page 203

Mark the solenoid valves with white paint to make assembly easier.
>> A << SPRING, STEEL BALL, DAMPING VALVE AND DAMPING VALVE SPRING INSTALLATION
1. Install the two steel balls and two springs to the inside valve body as shown.
2. Install the damping valve and spring to the inside valve body as shown.
Fig. 193: Identifying Steel Balls And Springs

>> B << SPRING AND STEEL BALL INSTALLATION
Install the three steel balls and two springs to the inside valve body as shown.
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Fig. 194: Installing Steel Balls And Springs

>> C << SOLENOID VALVES INSTALLATION
1. Apply ATF or petroleum jelly (Vaseline) to the O-ring and install carefully.
2. Install the solenoid valves by referring to the marks applied during
disassembly.
VALVE REFERENCE CHART
NO. NAME
1 Underdrive solenoid valve
2 Second solenoid valve
3 Torque converter clutch control solenoid valve
4 Overdrive solenoid valve
5 Low-reverse solenoid valve
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Fig. 195: Identifying Solenoid Valves

DRIVE SHAFT OIL SEAL
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Fig. 196: Disassembling/Assembling Drive Shaft Oil Seal

Required Special Tool:

>> A << OIL SEAL INSTALLATION
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Page 207

Use special tool MD998800 to tap the oil seal into the torque converter housing.
Fig. 197: Taping Oil Seal Into Torque Converter Housing

>> B << OIL SEAL INSTALLATION
Use special tool MD998800 to tap the oil seal in the transaxle case.
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Fig. 198: Taping Oil Seal In Transaxle Case

TRANSFER
< W4A5A >
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Fig. 199: Disassembling/Assembling Transfer (With Torque Specifications)



MB990938: Handle
MB990887: Ring
MB990891: Bushing Remover Installer Base
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Page 210


>> A << O-RING INSTALLATION
Install a O-ring to the transfer, and apply ATF or petroleum jelly (Vaseline) to the
O-ring.
>> B << OIL SEAL INSTALLATION
Use special tool MD998800, to tap the oil seal into the transfer cover.
Fig. 200: Installing Oil Seal Into Transfer Cover

>> C << OIL SEAL INSTALLATION
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Page 211

Use special tools MB990937 and MB990938, to tap the oil seal into the transfer
cover.
Fig. 201: Taping Oil Seal Into Transfer Cover

>> D << OIL SEAL INSTALLATION
CAUTION: Apply ATF to the oil seal lip before installing the
transfer.
Use special tools MB990887 and MB990891, to tap the oil seal into the transfer.
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Page 212

Fig. 202: Taping Oil Seal Into Transfer

>> E << OIL SEAL INSTALLATION
CAUTION: Apply ATF to the gear oil before installing the

transfer.
Use special tool MB990936, to tap the oil seal into the transfer.
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Page 213

Fig. 203: Installing Transfer Oil Seal

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

ITEM
SPECIFICATIONS
Transaxle
Control cable support bracket 23 +/- 3 N.m (17 +/- 2 ft-lb)
Eye bolt
24 +/- 3 N.m (18 +/- 2 ft-lb)
Oil cooler feed pipe clamp
11 +/- 1 N.m (95 +/- 9 in-lb)
Fluid temperature sensor
11 +/- 1 N.m (95 +/- 9 in-lb)
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Page 214

Input shaft speed sensor

Manual control lever
Manual control shaft detent
Oil pump
Output shaft
Output shaft jam nut
Components
Transfer
Output shaft speed sensor

Park/neutral position switch
(PNP switch)
Rear cover
Roll stopper bracket
Sealing cap < Type with sealing
cap >
Torque converter housing
Transfer drive gear
Valve body cover
Valve body mounting bolt
Transfer mounting bolt
Differential drive gear
11 +/- 1 N.m (95 +/- 9 in-lb)

22 +/- 3 N.m (16 +/- 2 ft-lb)
6.0 +/- 1.0 N.m (52 +/- 9 inlb)
29 +/- 2 N.m (21 +/- 1 ft-lb)
54 +/- 5 N.m (40 +/- 4 ft-lb)
170 +/- 10 N.m (125 +/- 7 ftlb)
11 +/- 1 N.m (95 +/- 9 in-lb)
11 +/- 1 N.m (95 +/- 9 in-lb)
23 +/- 3 N.m (17 +/- 2 ft-lb)

70 +/- 10 N.m (52 +/- 7 ft-lb)
5.0 +/- 1.0 N.m (43 +/- 9 inlb)
48 +/- 6 N.m (35 +/- 4 ft-lb)
34 +/- 2 N.m (25 +/- 1 ft-lb)
11 +/- 1 N.m (95 +/- 9 in-lb)
11 +/- 1 N.m (95 +/- 9 in-lb)
69 +/- 9 N.m (52 +/- 6 ft-lb)
135 +/- 5 N.m (100 +/- 4 ftlb)
Center differential drive gear
135 +/- 5 N.m (100 +/- 4 ftlb)
Center differential flange to
3.9 +/- 1.0N.m (34 +/- 9 indifferential case mounting bolt lb)
Solenoid valve support
6.0 +/- 1.0N.m (52 +/- 9 inlb)
Plate
6.0 +/- 1.0N.m (52 +/- 9 inlb)
Valve body
11 +/- 1 N.m (95 +/- 9 in-lb)
transfer cover
23 +/- 3 N.m (17 +/- 2 ft-lb)
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Page 215

GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEMS
SPECIFICATIONS
Transaxle model
F4A5A
W4A5A
Type
3-element, 1-stage, 2-phase type
Torque converter Lock-up
Provided
Stall torque ratio 1
4 forward speed, 1 reverse speed, fully
Transaxle type
automatic
1st
2.842
2nd
1.529
Transaxle gear ratio 3rd
1.000
4th
0.686
Reverse
2.193
Final reduction ratio (Differential
4.011
4.316
gear ratio)
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
ITEMS
STANDARD VALUE
0.01 - 0.09 (0.0004 0.0035)
0 - 0.16 (0 - 0.0063)
1.65 - 2.11 (0.050 0.0831)
1.09 - 1.55 (0.0429 0.0610)
0.25 - 0.45 (0.0098 0.0177)
0.70 - 1.45 (0.028 - 0.057)
0.045 - 0.105 (0.0018 0.0041)
Output shaft preload mm (in)

Brake reaction plate end play mm (in)
Low-reverse brake end play mm (in)
Second brake end play mm (in)
Underdrive sun gear end play mm (in)
Input shaft end play mm (in)
Differential case preload mm (in)
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Page 216

Underdrive clutch end play mm (in)

Reverse and overdrive clutch return spring retainer
end play mm (in)
Overdrive clutch end play mm (in)
Reverse clutch end play mm (in)
Backlash between differential side gear and pinion
mm (in)
1.6 - 1.8 (0.0630 - 0.0709)

0 - 0.09 (0 - 0.0035)
1.6 - 1.8 (0.0630 - 0.0709)
1.5 - 1.7 (0.0591 - 0.0669)
0.025 - 0.150 (0.0010 0.0059)
VALVE BODY SPRING IDENTIFICATION TABLE
VALVE BODY SPRING IDENTIFICATION TABLE

WIRE
OUTSIDE
FREE
SPRING
DIAMETER DIAMETER
LENGTH
mm (in)
mm (in)
mm (in)
Regulator valve
1.8 (0.071)
15.7 (0.618)
86.7 (3.413)
spring
Underdrive
pressure control 0.7 (0.028)
7.6 (0.299)
37.7 (1.484)
valve spring
Overdrive
7.6 (0.299)
37.7 (1.484)
valve spring
Low-reverse
7.6 (0.299)
37.7 (1.484)
valve spring
Second pressure
control valve
0.7 (0.028)
7.6 (0.299)
37.7 (1.484)
spring
Torque
1.6 (0.063)
11.2 (0.441)
34.4 (1.354)
converter spring
Torque
converter clutch
0.7 (0.028)
5.9 (0.232)
28.1 (1.106)
control valve
spring
NUMBER
OF LOOPS
24
25
25
25
25
12.5
19
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Page 217

Fail-safe valve
spring
Damping valve
spring
Line relief valve
spring
Orifice check
ball spring
0.7 (0.028)
8.9 (0.350)
21.9 (0.862) 9.5
1.0 (0.039)
7.7 (0.303)
35.8 (1.409) 17
1.0 (0.039)
7.0 (0.276)
17.3 (0.681) 10
0.5 (0.020)
4.5 (0.177)
17.2 (0.677) 15
ADJUSTING PLATE, SNAP RING AND SPACERS

Thrust washer (For adjustment of input shaft end play)
THRUST WASHER THICKNESS CHART

THICKNESS IDENTIFICATION THICKNESS
mm (in)
SYMBOL
mm (in)
1.8 (0.071)
18
2.4 (0.094)
2.0 (0.079)
20
2.6 (0.102)
2.2 (0.087)
22
2.8 (0.110)
IDENTIFICATION
SYMBOL
24
26
28
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
SNAP RING THICKNESS CHART

THICKNESS IDENTIFICATION
mm (in)
COLOR
1.6 (0.063)
Brown
1.7 (0.067)
None
1.8 (0.071)
Blue
1.9 (0.075)
Brown
2.0 (0.079)
None
2.1 (0.083)
Blue
2.2 (0.087)
Brow
2.3 (0.091)
None
THICKNESS
mm (in)
2.4 (0.094)
2.5 (0.098)
2.6 (0.102)
2.7 (0.106)
2.8 (0.110)
2.9 (0.114)
3.0 (0.118)
IDENTIFICATION
COLOR
Blue
Brown
None
Blue
Brown
None
Blue
Snap ring (For adjustment of low-reverse brake and second brake reaction plates end play)
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Page 218


mm (in)
COLOR
2.2 (0.087)
None
2.3 (0.091)
Blue
THICKNESS
mm (in)
2.4 (0.094)
2.5 (0.098)
IDENTIFICATION
COLOR
Brown
None
Pressure plate (For adjustment of low-reverse brake and second brake end plays)
PRESSURE PLATE THICKNESS CHART

mm (in)
SYMBOL
mm (in)
1.6 (0.063)
F
2.4 (0.094)
1.8 (0.071)
E
2.6 (0.102)
2.0 (0.079)
D
2.8 (0.110)
2.2 (0.087)
C
3.0 (0.118)
IDENTIFICATION
SYMBOL
B
A
0
1
Snap ring (For adjustment of reverse clutch end play)

mm (in)
COLOR
1.6 (0.063)
None
1.7 (0.067)
Blue
1.8 (0.071)
Brown
1.9 (0.075)
None
2.0 (0.079)
Blue
2.1 (0.083)
Brown
2.2 (0.087)
None
THICKNESS
mm (in)
2.3 (0.091)
2.4 (0.094)
2.5 (0.098)
2.6 (0.102)
2.7 (0.106)
2.8 (0.110)
IDENTIFICATION
COLOR
Blue
Brown
None
Blue
Brown
None
Snap ring (For adjustment of reverse clutch and overdrive clutch spring retainer end plays)

THICKNESS IDENTIFICATION THICKNESS IDENTIFICATION
mm (in)
COLOR
mm (in)
COLOR
1.48 (0.0583) Brown
1.58 (0.0622) Blue
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Page 219

1.53 (0.0602)
None
1.63 (0.0642)
Brown
Thrust race (For adjustment of underdrive sun gear end play)
THRUST RACE THICKNESS CHART

mm (in)
SYMBOL
mm (in)
1.6 (0.063)
2.2 (0.087)
1.7 (0.067)
2.3 (0.091)
1.8 (0.071)
2.4 (0.094)
1.9 (0.075)
2.5 (0.098)
2.0 (0.079)
2.6 (0.102)
2.1 (0.083)
-
IDENTIFICATION
SYMBOL
-
Spacer (For adjustment of output shaft preload)
SPACER THICKNESS CHART

mm (in)
SYMBOL
1.88 (0.0740) 88
1.92 (0.0756) 92
1.96 (0.0772) 96
2.00 (0.0787) 00
2.04 (0.0803) 04
2.08 (0.0819) 08
2.12 (0.0835) 12
2.16 (0.0850) 16
2.20 (0.0866) 20
2.24 (0.0882) 24
2.28 (0.0898) 28
2.32 (0.0913) 32
THICKNESS
mm (in)
2.36 (0.0929
2.40 (0.0929)
2.44 (0.0961)
2.48 (0.0976)
2.52 (0.0992)
2.56 (0.1008)
2.60 (0.1024)
2.64 (0.1039)
2.68 (0.1055)
2.72 (0.1071)
2.76 (0.1087)
IDENTIFICATION
SYMBOL
36
40
44
48
52
56
60
64
68
72
76
Spacer (For adjustment of differential case preload)

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Page 220

THICKNESS
mm (in)
0.65 (0.0256)
0.68 (0.0268)
0.71 (0.0280)
0.74 (0.0291)
0.77 (0.0303)
0.80 (0.0315)
0.83 (0.0327)
0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
IDENTIFICATION
SYMBOL
65
68
71
74
77
80
83
86
89
92
95
98
THICKNESS
mm (in)
1.01 (0.0398)
1.04 (0.0409)
1.07 (0.0421)
1.10 (0.0433)
1.13 (0.0445)
1.16 (0.0457)
1.19 (0.0469)
1.22 (0.0480)
1.25 (0.0492)
1.28 (0.0504)
1.31 (0.0516)
1.34 (0.0528)
IDENTIFICATION
SYMBOL
01
04
07
10
13
16
19
22
25
28
31
34
Spacer (For adjustment of backlash between differential side gear and pinion) < F4A5A >

mm (in)
SYMBOL
0.56 - 0.64
(0.0220 0.0252)
0.66 - 0.74
(0.0260 0.0291)
0.76 - 0.84
(0.0299 0.0331)
THICKNESS
mm (in)
0.86 - 0.94
(0.0339 0.0370)
0.96 - 1.04
(0.0378 0.0409)
1.06 - 1.14
(0.0417 0.0449)
IDENTIFICATION
SYMBOL
-
Spacer (For adjustment of backlash between center differential side gear and pinion) < W4A5A >

THICKNESS IDENTIFICATION THICKNESS IDENTIFICATION
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Page 221

mm (in)
0.56 - 0.64
(0.0220 0.0252)
0.66 - 0.74
(0.0260 0.0291)
0.76 - 0.84
(0.0299 0.0331)
SYMBOL
-
mm (in)
0.86 - 0.94
(0.0339 0.0370)
0.96 - 1.04
(0.0378 0.0409)
1.06 - 1.14
(0.0417 0.0449)
SYMBOL
-
SEALANTS
SEALANTS SPECIFICATIONS
ITEMS
Rear cover
Torque converter housing
Valve body cover
SPECIFIED SEALANT
Mitsubishi genuine sealant Part No.
MD974421 or equivalent
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Page 222

2007 Mitsubishi Endeavor Auto Transmission Service Information

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2007 Mitsubishi Endeavor LS

2007 TRANSAXLE/TRANSMISSION Automatic Transaxle Overhaul - Endeavor

This automatic transaxle is made up of the following main parts.

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 1: Automatic Transaxle Sectional View (F4A5A)

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 2: Automatic Transaxle Sectional View (W4A5A)

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 3: Automatic Transaxle Hydraulic Circuit

SPECIAL TOOLS SPECIFICATIONS

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Use with spring

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

reaction plate lowreverse brake and

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Use with installer

General service tool

Use with installer

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

cap and installer

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

DISASSEMBLY AND ASSEMBLY

Fig. 4: Disassembling/Assembling Transaxle (1 Of 2) (With Torque

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 5: Disassembling/Assembling Transaxle (2 Of 2) (With Torque

Fig. 6: Disassembling/Assembling Transaxle (1 Of 2) (With Torque

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 7: Disassembling/Assembling Transaxle (2 Of 2) (With Torque

MB990607: Torque Wrench Socket

Because the automatic transaxle is manufactured

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

normal detergent, but they should be dried

Remove the transfer and O-ring < W4A5A >

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 8: Measuring Input Shaft End Play

Fig. 9: Removing Air Breather

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 11: Removing Manual Control Lever

2005 Mitchell Repair Information Company, LLC.

2007 Mitsubishi Endeavor LS

Fig. 12: Removing Sealing Cap