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TRANSMISSION
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23-2
AUTOMATIC TRANSMISSION
General Information/
Service Specifications
GENERAL INFORMATION
23100010141
Items
Transmission model
R4AW2-6
V4AW2-6
Type
1st
2.826
2.826
2nd
1.493
1.493
3rd
1.000
1.000
4th
0.730
0.688
Reverse
2.703
2.703
2-speed
High
1.000
Low
1.925
22/6
25/8
Gear ratio
Transfer type
Gear ratio
SERVICE SPECIFICATIONS
23100030130
Items
Standard value
Distance between inner cable stopper and end of outer cable <4G63> mm
01
Distance between inner cable stopper and end of outer cable <4D56> mm
34 35
Approx. 13
Stall speed
r/min
At idle speed
At stall speed
4G63
2,100 2,400
4D56
2,300 2,600
1,000 r/min
137 166
2,000 r/min
245 284
3,200 r/min
402 460
D range
480 558
R range
735 852
D range
1,019 1,195
R range
1,519 1,911
On (continuity)
50 3
43
2.4 3.6
LUBRICANTS
23-3
23100040119
Items
Specified lubricants
Quantity
Transmission fluid
DEXRON-II or equivalent
Transfer oil
2.3
DEXRON-II or equivalent
As required
Items
Specified sealant
Remarks
Semi-drying sealant
Semi-drying sealant
Drying sealant
SEALANTS
SPECIAL TOOLS
Tool
23100060139
Number
Name
Use
MD998330
(includes
MD998331)
MD998920
Adapter
MD999563
(includes
MD998331)
23-4
TROUBLESHOOTING
23100760152
ROAD TEST
23100780158
Prior to performing road test, be sure to make basic checks including check and adjustment of fluid
level and condition and adjustment of the throttle cable. For road test, the transfer must be placed in
the 2H (2WD-high) position. In road test, various changes such as slips in transmission and shifting
conditions are checked and the transmission operation at each shift position must have been checked.
23-5
D RANGE TEST
TEST 1
OK
Start with throttle valve opened (50 % and full), and check upshift
from 1-speed ! 2-speed, 2-speed ! 3-speed and 3-speed !
4-speed. Check that shifting points match shift pattern.
TEST 2
NG
No
Does the upshift from 1-speed to 2-speed occur?
Yes
No
Does the upshift from 2-speed to 3-speed occur?
Yes
No
Does the upshift from 3-speed to 4-speed occur? (with throttle
valve opening under 85%)
Yes
Incorrect
Check the shifting points.
Correct
TEST 2
OK
TEST 3
NG
No
Does the downshift occur?
Yes
Incorrect
Check the shifting point.
Correct
D
D
D
D
D
TEST 3
OK
TEST 4
NG
No
Does the downshift from 2-speed to 1-speed occur?
Yes
Incorrect
Check the Shifting point.
Correct
Carry out TEST 3 again.
23-6
TEST 4
Yes
TEST 5
No
No
Does the engine brake function in 2 range?
Yes
No
Does the engine brake function in L range?
Yes
Carry out TEST 4 again.
TEST 5
No
TEST 6
Yes
D High line pressure
D Accumulator malfunction
D Check ball malfunction
TEST 6
No
TEST 7
Yes
D
D
D
D
NOTE
Abnormal noises and vibrations are often caused by an unbalanced propeller shaft, differential, tyre,
torque converter, engine, etc. Extremely thorough inspection is therefore required.
TEST 7
Yes
Check that lock up ON, OFF. Does the shifting points conform
with shift pattern?
No
No
Does the moment when lock up turns ON or OFF conform with
the shift pattern?
D Governor malfunction
D Line pressure malfunction
Yes
No
Does lock up go on, off?
Yes
NOTE
(1) Determine the moment when lock up turns ON by decreased engine r/min or by a slight shock back
and forth.
(2) Determine the moment when lock up turns OFF by increased engine r/min.
(3) Check lock up condition by pumping the accelerator slightly. If engine r/min rises in accordance with
throttle valve opening size, determine that the lock up is OFF, if not, determine it ON.
(When lock up is OFF, drive power is transferred through the fluid in the torque converter and therefore,
when the accelerator pedal is depressed, slipping occurs inside the torque converter with a resulting
large increase in engine r/min.)
TEST 2
No
No
Does the upshift from 1-speed to 2-speed occur?
Yes
Incorrect
Check the shifting point.
Correct
OK
NG
No
Does the downshift occur and is the shifting point correct?
Yes
Carry out TEST 2 again.
D
D
D
D
D
L RANGE TEST
TEST 1
Yes
R RANGE TEST
TEST 1
No
D
D
D
D
P RANGE TEST
TEST 1
No
23-7
23-8
SHIFT PATTERN
<4G63 engine>
Throttle opening
(%)
100
80
60
1
2
2
3
40
20
Lock-up ON
Lock-up OFF
1000
0
10
2000
20
30
4000
3000
Output shaft speed r/min
40
50
60
70
Vehicle speed km/h
80
5000
90
100
110
<4D56 engine>
Throttle opening
(%)
100
80
3
2
3
2
60
40
Lock-up ON
20
Lock-up OFF
0
1000
2000
3000
4000
10
20
30
40
50
60
70
80
90
100
110
120
130
120
23-9
23101130013
Inspection
terminal
Inspection item
Check requirement
Overdrive
switch
Ignition switch: ON
Ignition switch
Detection switch
Overdrive
solenoid valve
Standard value
Overdrive switch: OFF
System voltage
Overdrive switch: ON
0V
0V
Ignition switch: ON
System voltage
System voltage
0V
0V
11 V or more
Earth
Always
Engine coolant
temperature
tem
erature
switch
Ignition switch: ON
Vehicle speed
sensor
Ignition switch: ON
Move the vehicle slowly forward
0V
30_C or lower
System voltage
60_C or higher
0V
0V5V
(Changes repeatedly)
23-10
ON-VEHICLE SERVICE
23100090121
HOT
upper limit
HOT
lower limit
COLD
upper limit
COLD
lower limit
COLD
upper limit
COLD
lower limit
23-11
Caution
If ATF change is required due to damage to the
transmission, be sure to clean the cooler system.
(1) Raise the vehicle on hoist. Place a drain container with
large opening under the drain plug (located in bottom
of the oil pan).
(2) Remove the drain plug to let ATF drain.
(3) Install the drain plug and new gasket and tighten to 20
Nm.
(4) Refill ATF through the oil level gauge hole until its level
reached at COLD lower limit of the level gauge.
(5) Start the engine and allow to idle for at least two minutes.
Then, with the parking brake and service brake applied,
move the selector lever through all positions and finally
place in the N or P position.
(6) After the transmission is warmed up to the normal
operating temperature, recheck the fluid level, which must
be between the HOT upper limit and HOT lower limit
marks.
(7) Insert the dipstick fully to prevent dirt from entering the
transmission.
Oil level
23100110063
23-12
23100120066
Quantity: 2.3
5. Tighten the oil filler plug to the specified torque.
Specified torque: 33 Nm
23101110017
Terminal No.
1
2H
4H
Terminal No.
1
4H
4L
4H 4L
0 1 mm
Dust cover
23-13
23100280047
<4G63>
(1) Check the throttle lever and the bracket for deformation.
(2) Measure the distance between the inner cable stopper
and the end of the dust cover when the throttle lever
is fully opened.
Standard value: 0 1 mm
(3) If the distance is not within the standard value, turn the
adjusting nut.
<4D56>
(1) Check throttle lever for defective or bent and the throttle
cable bracket for deformation.
(2) Remove the outer cable side of the boot to expose the
inner cable stopper.
(3) Pull the throttle lever fully open and measure the distance
between the inner cable stopper and the end of the outer
cable.
Standard value: 34 35 mm
(4) If the distance is not within the standard value, turn the
adjusting nut.
23-14
Push button
23100130038
Positi
tion
Terminal No.
1
10
P
R
N
D
2
L
59 Nm
N position
reference
line
Mounting
bolt
Groove
Inhibitor switch
23-15
23100350038
Thermometer
A
OFF
ON
B
Oil
Oil temp.
Temperature
Continuity
(temperature at point A)
143 151 _C
No continuity
(temperature at point B)
125 _C or less
23-16
23100860128
Name
Symbol
Name
Symbol
Detection switch
Overdrive switch
Inhibitor switch
C
E
23-17
23100140222
23101120010
OVERDRIVE SOLENOID VALVE CHECK
1. Disconnect the overdrive solenoid valve connector.
Overdrive
solenoid
valve
Overdrive
solenoid
valve
Detection switch
Continuity
No continuity
(Infinite resistance)
Pressure applied
Continuity (0 )
23-18
Engine coolant
temperature
switch
Engine coolant
temperature
switch
Standard value:
Item
Temperature
On (continuity)
50 3_C
43_C
23100460137
23100380143
23100540138
Caution
Do not stand in front or at rear of the vehicle
during this test.
(1) Check the transmission fluid level. The fluid
temperature should be at the level after normal
operation (70 80_C). The engine coolant
temperature should also be at the level after
normal operation (80 90_C).
(2) Apply chocks to the rear wheels (right and left).
(3) Mount an engine tachometer.
(4) Apply fully the parking and service brakes.
23-19
NOTE
When doing so, do not keep the engine running
with throttle full open for more than 5 seconds.
If two or more stall tests are needed, place
the selector lever in the N position and run
the engine at about 1,000 r/min to allow the
transmission fluid to cool before another stall
test.
(7) Place the selector lever in the R range and
perform the test as above.
(1)
(2)
(3)
(4)
(5)
(1)
(2)
(3)
(4)
(5)
23-20
23100550131
MD998331
MD998920
MD999563
1,000
137 166
2,000
245 284
3,200
402 460
D
D
D
23-21
MD998920
MD998331
MD998330
Items
At idle
At stall
D range
R range
4G63
480 558
735 852
4D56
441 500
608 686
4G63
1019 1195
1519 1911
4D56
1098 1294
1470 1863
(1)
(2)
(3)
(4)
(5)
(1)
(2)
(3)
(4)
23-22
HYDRAULIC CIRCUIT
23100880100
N (NEUTRAL)
3
5
4
7
6
9
8
1
10
2
11
12
13
14
36
29
15
37
38
30
16
17
28
31
18
39
19
20
32
To oil
pan
25
33
23
34
22
21
24
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
26
Lock-up clutch
Torque converter
Overdrive clutch
Overdrive brake
Forward clutch
Direct clutch
Brake No. 1
Brake No. 2
Brake No. 3
Governor
Lock-up signal valve
Accumulator B2
Accumulator C2
Accumulator C3
Lock-up relay valve
Secondary regulator valve
Cut-back valve
Relief valve
Throttle valve
Check valve
35
40
27
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Oil cooler
Damping check valve
Oil pump
Strainer
Cooler bypass valve
Primary regulator valve
1-2 shift valve
Low-coast shift valve
Manual valve
Low coast modulator valve
Intermediate shift valve
Reverse clutch sequence valve
Intermediate modulator valve
Detent regulator valve
2-3 shift valve
Overdrive solenoid valve
Overdrive switch
D-2 down timing valve
3rd-coast shift valve
3-4 shift valve
23-23
TRANSMISSION CONTROL
23100660162
Caution: SRS
Be careful not to subject the SRS diagnosis unit
to any shocks during removal and installation of
the selector lever assembly.
12
14
15
Sealant:
3M ATD Part No.8661
or equivalent
<4WD>
5 Nm
Sealant:
3M ATD Part No.8661 or equivalent
16
15
11
14
10
12 Nm
13
12
19 Nm
4
3
1
<2WD>
24 Nm
12 Nm
4
3
5
24 Nm
24 Nm
23-24
Front
23100680106
4
3
5
2
2.0 Nm
1.5 Nm
6
7
1
10
17
15
14
13 16
12 Nm
11
12
11
12 Nm
Removal steps
AA"
1. Overdrive switch and indicator lamp
connector
2. Overdrive switch
3. Button
4. Spring
"BA 5. Shift knob
6. Indicator panel assembly
7. Bulb
8. Position indicator socket assembly
23-25
"AA 9.
10.
11.
12.
13.
14.
15.
16.
17.
Sleeve
Lever assembly
Shift bushing
Collar
Pin
Spring
Ball support
Ball
Bracket
23-26
Terminal
Screwdriver
Sleeve
Lever assembly
Detent plate
A
Pin
INSPECTION
1 (W)
23101100014
2 (W)
Terminal No.
Always
Terminal No.
3
3 (W)
4 (R)
5 (Y)
ON
(Overdrive activation)
OFF
(Overdrive non-activation)
23100380129
23-27
23100570168
Post-installation Operation
(1) Propeller Shaft Installation (Refer to GROUP 25.)
(2) Transmission Fluid Filling (Refer to P.23-11.)
(3) Selector Lever Installation (Refer to P.23-23.)
(4) Selector Lever Operation Check (Refer to P.23-14.)
(5) Speedometer Operation Check
45 Nm
13
36 Nm
16 Nm
2 50 Nm
10
25 Nm
26 Nm
4
24 Nm
11
12
10 12 Nm
24 Nm
9 Nm
Removal steps
"BA 1. Throttle cable connection
2. Filler tube assembly
3. O-ring
4. Transmission control cable connection
5. Cable end bracket
6. Speedometer cable connection
7. Earth cable
AA"
8.
9.
10.
11.
12.
13.
23-28
20
25 Nm
15
50 Nm
14
16
20 24 Nm
19
17
18
35 42 Nm
50 Nm
47 Nm
47 Nm
22 Nm
AB"
14.
15.
16.
17.
Breather hose
Throttle cable clamp
Exhaust pipe clamp bracket
Torque converter and drive plate connection bolt
23-29
B
C
Adjusting nut
Dust
cover
Diameter x Length mm
10 x 40
8 x 55
10 x 60
10 x 65
Inner cable
stopper
23-30
23100630033
Post-installation Operation
(1) Front and Rear Propeller Shaft Installation
(Refer to GROUP 25.)
(2) Transfer Oil Filling (Refer to P.23-12.)
(3) Transmission Fluid Filling (Refer to P.23-11.)
(4) Transfer Case Protector Installation
(5) Selector Lever and Transfer Control Lever
Installation (Refer to P.23-23.)
(6) Selector Lever Operation Check (Refer to P.23-14.)
(7) Speedometer Operation Check
45 Nm
16 Nm
10
11
26 Nm
13
36 Nm
12
25 Nm
15
2
14
10 12 Nm
24 Nm
22 Nm
24 Nm
9 Nm
Removal steps
"BA 1. Throttle cable connection
2. Filler tube assembly mounting bolt
3. Oil cooler tube connection
4. Transmission control lever connection
5. Cable end bracket
6. Cable bracket
7. Speedometer cable connection
8. Earth cable
12 Nm
AA"
9.
10.
11.
12.
13.
14.
15.
23-31
26
16
50 Nm
17
21
18
45 Nm
24 Nm
25
45 Nm
19
20
22 Nm
22
50 Nm
35 42 Nm
40 Nm
24
23
26 Nm
22 Nm
65 Nm
AB"
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
"AA 26.
23-32
Diameter x Length mm
10 x 40
10 x 55
10 x 65
AUTOMATIC TRANSMISSION
Outer cable
Adjusting nut
23-33
4WD INDICATOR-ECU
REMOVAL AND INSTALLATION
Refer to GROUP 22.
23101090014
23-34
23100700017
<2WD>
8
12
45 Nm
11
<4WD>
10
29 34 Nm
10
12
1
45 Nm
2
5
7
11
8
4
5
35 Nm
Removal steps
1. Eye bolt (for engine oil cooler)
2. Gasket (for engine oil cooler)
3. Engine oil cooler tube assembly
connection
4. Eye bolt (for transmission oil cooler)
5. Gasket
6. Transmission oil cooler tube assembly
connection
7.
8.
9.
10.
11.
12.
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
SERVICE BULLETIN
No.: MSB-99E23-001
Date: 1999-12-15
ADDITION OF DESCRIPTION OF ABS IDLE-UP
SOLENOID VALVE ABOLISHMENT
Group:
Draft No.: 99SY031213
AUTOMATIC
TRANSAXLE
INTERNATIONAL
INFORMATION
Subject:
CAR
ADMINISTRATION
OFFICE
<Model>
(EC,EXP) L200
(K00)
<M/Y>
99-10
1. Description:
In the 99 L200 Workshop Manual, a description of abolishment of the ABS idle-up solenoid valve
has been added.
2. Applicable Manuals:
Manual
99 L200
Workshop Manual chassis
Pub. No.
PWTE96E1-C
PWTS96E1-C
PWTF96E1-C
PWTG96E1-C
3. Interchangeability:
Not interchangeable
4. Effective Date:
From the first production vehicle of 1999 model
Language
Page(s)
(English) 23-3
(Spanish)
(French)
(German)
23-3
Hose clip
Hose
Mark
INSTALLATION
1. Connect the feed hose, return hose (B) and return hose
(A) with the mark upwards
2. Insert the hose up to bulge A on the nipple and tube, as
shown.
3. Attach the hose clip at the position being sure that it is
not on top of bulge B, as shown.
AO9G0209
35B/35C-1
GROUP 35B/35C
ANTI-SKID BRAKING SYSTEM (ABS) <2WD/4WD>
GENERAL
OUTLINE OF CHANGES
16V0202
16V0104
<Added>
23-1
GROUP 23
AUTOMATIC TRANSMISSION
GENERAL
OUTLINE OF CHANGES
With additional vehicle with emission regulation step III compatible 4D5 engine, the service procedure
different from service adjustment procedure of the vehicle with 4D5 engine has been established.
SERVICE SPECIFICATIONS
Items
Standard value
12
Dimension of the throttle cable inner cable stopper and outer cable end mm
0.8 1.5
TROUBLESHOOTING
SHIFT PATTERN
<2WD>
Throttle opening (%)
100
3
80
60
1
40
2
Lock-up ON
20
Lock-up OFF
Output shaft speed
(r/min)
Vehicle speed (km/h)
1,000
0
2,000
50
3,000
4,000
100
5,000
23-2
<4WD>
Throttle opening (%)
100
80
L
1
60
1
2
2
40
20
Lock-up ON
Lock-up OFF
1,000
0
2,000
50
4,000
3,000
5,000
100
ON-VEHICLE SERVICE
ACCELERATOR CABLE AND THROTTLE
CABLE CHECK AND ADJUSTMENT
1. Check the accelerator cable and the throttle cable for
bends.
2. Check that the A/T throttle control cable link assembly
and bracket do not become deformed.
Accelerator cable
(Inner cable)
Lock nut
Adjusting
nut
Throttle cable
(Inner cable)
23-3
Stopper
Boot
Lock nut
Adjusting
nut
Throttle cable
(Outer cable)
NOTES