GROUP 4 DISASSEMBLY AND ASSEMBLY

1. TRANSMISSION
1) DISASSEMBLY
(1) Disassemble torque converter assembly
Drain the transmission fluid and disconn-
ect the torque converter assembly from the
engine and the transmission.

(2) Disassemble input side of torque converter

Remove the input plate bolts and the input
plate, input guide, and O-rings.
Tool(s) required : 12mm wrench.

L15C3TC01

L15C3TC02

(3) Extract torque converter

① Remove the turbine shaft snap ring.
Tool(s) required : Snap ring pliers

L15C3TC03
 ② Ease the torque converter out of the
housing so as not to damage the pump oil
seal.

L15C3TC04

(4) Extract pump

Remove the inner turbine shaft snap ring
and all bolts holding the pump.
Tool(s) required : 12mm socket wrench

L15C3TC05

(5) Extract turbine shaft

① Remove the two snap rings.
Tool(s) required : Snap ring pliers

L15C3TC06

② Extract the turbine shaft.

L15C3TC07
(6) Extract valves
① Remove the two plugs.
Tool(s) required : 24mm wrench.

L15C3TC08

② Remove the springs and pistons.

Level the two sets-the springs especially-
so that they do not get confused.
Tool(s) required : 24mm wrench.

L15C3TC09

(7) Disassemble oil pump

Remove the O-ring and philips screws
and disassemble the pump.
※ Limit disassembly to the minimum
amount required.

L15C3TC10
2) ASSEMBLY
The assembly procedure is the reverse of
the disassembly procedure above, but
requires additional care as noted below.
(1) Assembly oil pump
Return the gears and stator support to
their positions before disassembly.
Check the gear action. If the gears do not
rotate smoothly, disassemble the pump
and start over.
·Bolt tightening torque : 0.1kgf·m(0.72lbf·ft)

L15C3TC10

(2) Install valves

The valve assemblies are different, so make sure that they go back into the proper holes.
·Plug tightening torque : 5.0kgf·m(36.2lbf·ft)

(3) Install turbine shaft

Make sure that the sealing material is seal completely inside before inserting the shaft.
·Bolt tightening torque : 2.1kgf·m(5.2lbf·ft)

(4) Install pump

Lightly grease the pump casing with lithium grease (Shell albania Z or equivalent) to avoid
breaking or twisting O-ring when you insert it.
(5) Install torque convert
Fill the oil seal lip cavity one-half full with lithium grease or coat the surface with clean hydraulic
fluid to avoid damaging the oil seal and bushing when you insert the torque converter.
(6) Install input side of torque converter
Coat the O-ring with lithium grease before installing.
·Bolt tightening torque : 2.1kgf·m(15.2lbf·ft)

(7) Install torque converter assembly

Connect the torque converter assembly to the engine and the transmission.
※ After each step, check your work against the maintenance standards which appear after the
procedure.
※ Apply semidrying liquid gasket to the circumference of oil seals, but do not allow it to get on
the lips or the shaft’s sliding surface.
3) TORQUE CONVERTER ASSEMBLY DRAWING

D255TC12

L15C3TC13
4) CHECK AND INSPECTION

Turbine

Impeller Torque
converter

Input Stator
plate

C1

B
Gear pump

G
H, I

Turbine
shaft

Housing
Engine side

Transmission side

L15C3TC14

A3
A1

A1
E1

A2

E2

F
L15C3TC15
 Unit : mm(in), kg(lb)
Criteria
No. Check item Remedy
Standard size Repair limit
Clearance between piston 0.015-0.025 0.065 Replace
A1 and housing hole (0.0006-0.001) (0.0025) piston
Free 89.9 87.3
length (3.54) (3.43)
Torque converter Installed 63 63
Torque A2 inlet relief valve length (2.48) (2.48)
spring
converter Installed 7.70 6.94
A load (16.98) (15.3)
input output
Free 122 120.4
valve length (4.80) (4.74)
Torque converter
output pressure Installed 103.5 103.5
A3 adjusting valve length (4.07) (4.07)
spring Installed 3.45 3.11
load (7.61) (2.36)
60
B Oil seal O.D - (2.36)
Torque converter Oil seal mating 59.952-60.000 59.852 Replace
C impeller valve C1 face outer dia (2.360-2.362) (2.356)
Clearance of abutment 0.1-0.3 1.0
E1 when housing is inserted (0.004-0.012) (0.04)
E Seal spring
2.47-2.49 2.27
E2 Ring with (0.097-0.098) (0.089)
2.56-2.60 2.7
F Turbine shaft(Seal ring groove width) (0.100-0.102) (0.106)
48.0-48.025 48.12
G Housing(Seal ring portion inner dia) (1.889-1.890) (1.894)
47.951-47.970 Clearance
H Impeller hub O.D (1.887-1.888) between hub
47.975-48.000 and bushing
I Pump bushing (1.889-1.890) 0.1(0.0039)
Corrected
15 14.85 by hard
J Pilot(Tip outer dia) MITSUBISHI engine chrome
(0.59) (0.38)
plating
5) MAINTENANCE STANDARDS
(1) Hydraulic pressure

No Location Pressure (kgf/cm2) Cracking pressure (kgf/cm2)

1 Torque converter input 5~7 5
2 Torque converter output 2.2 ~ 4 2.2
※ Cracking pressure means the pressure at which the valve begins to open.

(2) Tightening torques

Tightening torque in
No Location Thread specifications kgf·m(lbf·ft)
Target Maximum
1 Input plate Small hex bolt M8×1.25×20 2.1(15.2) 2.7(19.5)
2 Pump Small hex bolt M8×1.25×40 2.1(15.2) 2.7(19.5)
3 Valves Plug M16×1.5 ×10 5.0(36) 6.5(47)
4 Cover Small hex bolt M8×1.25×12 0.98(7) 1.3(9)
Torque converter fluid
5 outlets Hex plug with hole PT 1/4 3.5(25.3) 4.4(31.8)

6 Pump assembly Small flathead screw M5×0.8×16 0.1(0.72) 0.3(2.2)

7 Blind plug Hex plug with hole PT3/4 5.8(42) 7.2(52.1)
2. TRANSMISSION
※ Keep all parts in order as disassembly
progresses. Take care to properly
identify each part and its order of
removal.
If necessary, keep notes and put
markings on parts using a non-
destructive marker such as a felt-tipped
pen.

1) DISASSEMBLY
(1) Differential, torque converter, control
valve
① Detach the differential from the torque
converter. Loctite
#271
3 1

2
L15C3DF01

② Remove the control valve.

D255TM01

(2) Cage
① Remove the cage.
(With holder at the pinion end).

D255TM02
(3) Pinion shaft
① Remove pinion shaft bolt(1).
② Fit a dolly block(copper rod) and tap the
pinion shaft with a hammer to remove.

D255TM03

(4) Seal ring cap

4
① Remove bolt(2) and fit the bolt to the 3
tapped hole.
Remove the seal ring cap.
※ Pull out the cap straight without
2
twisting it.
② Remove seal ring(3).
③ Remove snap ring(4).
D255TM04

(5) Clutch pack assembly

Remove front and rear clutch pack
assembly.

D255TM05

(6) Idler shaft assembly

① Remove bolt(9) and slide the shaft
assembly as shown in the drawing. Bearing
puller
② Remove the bearing and the shaft
assembly using a bearing puller.
9

D255TM06
(7) Disassembly of components of clutch pack assembly
※ The number shows the sequence of disassembly.

9
29

36
35
34
33
7 10 32
19
31
8 27 30
13 25
24
12 23
11
6 28
5
17
4
2 3
1
26

22
21
20
18

16
15
14
L15C3CL01

1 Sealing 13 Spring 25 Snap ring

2 Spring 14 Piston 26 Disc
3 Spacer 15 Sealing 27 Plate
4 Washer 16 Sealing 28 Ring
5 Gear 17 Needle bearing 29 Ball
6 Spacer 18 Shaft assembly 30 Washer
7 Ball 19 Needle bearing 31 Gear
8 Ring 20 Sealing 32 Washer
9 Plate 21 Sealing 33 Spacer
10 Disc 22 Piston 34 Spacer
11 Snap ring 23 Spring 35 Spring
12 Washer 24 Washer 36 Spacer

※ Spring under heavy compression. Carefully remove with press.

2) ASSEMBLY
※ Cleanliness is of extreme importance in the repair and overhaul of this assembly. Perform all
disassembly work in a clean area. Overhaul the transaxle only in a clean, dust-free location,
using clean tools and equipment. Dirt or grit will damage the highly-machined sufaces and
result in premature failure of components. Cleanliness of interior surfaces, orifices, etc. is
extremely important to the proper operation of the hydraulic circuit. The exterior surface of
the unit must be thoroughly cleaned of all dirt and foreign substances to prevent
contamination of the parts during overhaul. Protect all components from dust and dirt while
repairs are being made. Be sure the work area is kept clean.

(1) Assembly of components of the clutch

pack assembly.
Assembly is in the reverse order to
disassembly but pay attention to the
following.
① Piston ring Ball
Fit the piston ring.
② Ball, Spacer, Spring
Coat the ball with oil and then fix it to the
hole of the shaft match the notch of the Notch

spacer with the ball and insert.

L15C3TM07

③ Spacer, Spring
Spacer Spacer
Spacer consists of two halves. Ball Piston spring Ball
Fix the spacer with a spring.

Spacer
Ball Spacer
Spring Spring
D255TM08
(2) Idler shaft assembly
① Prefit gear(1) in the case.
② Fit bearing(2) on the idler shaft and install
in the case. 2 3

③ Fix bearing(3) fix it with plate(4) and bolt

(5).
45
·Tightening torque : 2.8 ~ 3.5kgf·m
(20 ~25lbf·ft) 1

D255TM09

(3) Clutch pack assembly 2

① Fit bearing(1) in the case. 3 1
② Fit F-R clutch pack assembly.
4
③ Fit snap ring(2).
④ Fit seal ring(3).
⑤ Fit seal ring cap fix with bolt(5). 5
·Tightening torque : 10 ~ 12.5kgf·m
(72 ~90lbf·ft)

D255TM10

(4) Pinion shaft assembly

① Install pinion shaft assembly in the case.
② Fix with plate(1) and bolt(2).
③ Fix cage(3).
Cage(3)

1 2

D255TM11

(5) Differential, control valve

① Fit the differential to the case with cap(1) 5
and bolt(2). 6
3
※ Refer to adjustment of backlash after 4
attaching the differention.
2 1
② Fit control valve(3) and gasket(4) with
bolt(5).
·Tightening torque : 2.8 ~ 3.5kgf·m
(20 ~25lbf·ft)
D255TM12
3) TORQUEFLOW TRANSMISSION ASSEMBLY DRAWING

Loctite #271(Screw hold side)

Loctite #271(Screw hold side)

G2-L1(Lip portion)
(Loctite #271 : Screw hole side)
35 ~ 43.5 kgf . m(253 ~ 315 lbf . ft) Match the stamps on the
inner and outer rings

D255TM13
4) CHECK AND INSPECTION

D G B E F A C

D
H

J1

A2 A1
E2, H2
B1

B2 E1, H1

C2
G1

I1
C1 F1

D2

D255TM14
 Unit : mm(in)
Criteria
No Check item Remedy
Standard size Repair limit
3.13-3.27 2.9
A1 Thickness of drive plate (0.123-0.129) (0.114)
A Plate 2.6(0.102) Replace
A2 Thickness of driven plate 2.90-3.05 (Oil groove depth
(0.114-0.120) Min0.2)(0.008)
Clearance of abutment when 0.36-0.56
B1 piston is inserted (0.014-0.002) -
0.15-0.35 Replace
B Sealing B2 Depth of the side face oil groove (0.006-0.014) To be grooved at each
disassembly
2.60-2.65 2.8
(D1) Width of groove for insertion (0.102-0.104) (0.110)
40.025-40.050 40.2
C1 Sealing matching face I.D (1.576-1.577) (1.583)
C Piston Width of groove when sealing is 3.1-3.2 3.4
C2 inserted. (0.122-0.126) (0.134)
Width of the groove for inserting 2.60-2.65 2.8
D1 sealing. (0.102-0.104) (0.110)
D Drive shaft Width of the groove of inserting 2.60-2.65 2.8
D2 sealing. (0.102-0.104) (0.110)
Clearance of abutment when 0.2-0.4 1.0
E1 clutch case is inserted (0.008-0.157) (0.039)
2.97-2.99 2.77
E Sealing E2 Width (0.117-0.118) (0.109)
3.1-3.2 3.4
(C2) Width of groove for insertions (0.122-0.126) (0.109)
100-100.054 100.3
F Clutch case F1 Sealing matching face I.D (3.937-3.939) (3.949)
2.9-3.1 2.5 Replace
G Thrust G1 Thickness (0.114-0.122) (0.098)
Clearance of abutment when cap 0.05-0.25 0.65
H1 is inserted (0.002-0.010) (0.026)
2.47-2.49 2.25
H Sealing H2 Width (0.097-0.098) (0.089)
2.60-2.65 2.8
(D1) Width of groove for insertions (0.102-0.104) (0.110)
35.000-35.021 35.2
I Cap I1 Sealing matching face I.D (1.378-1.379) (2.552)
64.926-65.000 64.83
J Retainer J1 Oil seal maching face O.D (2.556-2.559) (1.386)
0.08-0.28
- Backlash (0.003-0.011) -
- Each gear 0.3-0.7
- Clearance of thrust (0.012-0.028) -
Replace with
a new part
- Gasket, O-ring, seals - - when
disassembly
and assembly
 3. DIFFERENTIAL
1) STRUCTURE

TRANSMISSION

Loctite #271

12
11

6
5
7
35~43.5 kgf . m
(253~315 lbf . ft) 3 4
2 6
5
13 5~7.5 kgf . m 8 7
(36~54 lbf . ft) 8
Loctite #271(Hole side)
5 5
6
6

(Run out : Max, 0.1 with

dial guage reading) 9

10
16~20 kgf . m
(116~145 lbf . ft) 14
13
Loctite #271(Hole side)
11
Starting torque : 3.1~5.7 kgf . m 12
(22~41 lbf . ft)
Adjust with screw gear(12)

D255DF04

※ Ring gear and pinion must be replaced as one unit.

Do not replace one without the other.

1 Case 6 Washer 11 Taper bearing

2 Case 7 Differential pinion 12 Screw gear
3 Hexagon bolt 8 Bushing 13 Bolt
4 Spider 9 Bevel gear 14 Plate
5 Differential pinion 10 Bolt
2) DIFFERENTIAL ASSEMBLY DRAWING

Backlash : 0.10-0.18 mm
(0.004-0.007 in)

Runout is Max 0.1

Starting torque (1)

3.1-5.7 kgf . m
(22-41 lbf . ft)

Loctite#271(screw portion) Loctite#271(screw portion)

5-7.5 kgf . m
16-20 kgf . m
(36-54.4 lbf . ft)
(116-145 lbf . ft)

Loctite#271(screw hole side)

35-43.5 kgf . m
(253-315 lbf . ft)

D255DF05
3) CHECK AND INSPECTION

C E

D B
D255DF07

Unit : mm(in)
Criteria
No Check item Remedy
Standard size Repair limit
Differential pinion gear and Scratches on the Replace (Replace bevel
A side gear - teeth gear and pinion)
24.959-24.980 24.75
B O.D of spider (0.983-0.984) (0.974)
25.0-25.1 25.2
C I.D of differential pinion gear (0.984-0.988) (0.992)
1.94-2.06 1.7
D Width of bushing (0.076-0.081) (0.067) Replace
1.52-1.68 1.3
E Width of bushing (0.060-0.066) (0.05)
310.0-310.2 312
- (I.D of brake drum) (12.20-12.21) (12.28)
Gasket Replace with new parts
- O-ring - - when reassembling after
Seals disassembling.
4. DRIVE AXLE
1) DISASSEMBLY AND ASSEMBLY

2
7
6

8
9
26

3 25
29
1 27
5
4 12
17
16
Loctite #1215
6~8 kgf . m All face of flange
(43~58 lbf . ft)
29
28 15 11
18
32.5~43.5 kgf . m
19 (235~315 lbf . ft)
20 Loctite #271
21
13
14
Starting torque
0.6~1.5 kgf . m
(4.3~10.8 lbf . ft)
22 30~50 kgf . m
(217~362 lbf . ft)
10
24
23

10~13 kgf . m
(72~94 lbf . ft)
D255DA01

1 Housing 11 Hub 21 Bolt

2 Cap 12 Brake drum 22 Oil seal
3 Plug 13 Bolt 23 Bolt
4 Plug 14 Nut 24 Spring washer
5 Gasket 15 Nut 25 Brake assy(LH)
6 Dowel pin 16 Bearing 26 Brake assy(RH)
7 Gasket 17 Oil seal 27 Reamer bolt
8 Bolt 18 Bearing 28 Bolt
9 Spring washer 19 Plate 29 Spring washer
10 Shaft 20 Nut
2) ASSEMBLY OF DRIVE AXLE

6-8 kgf . m
(43-58 lbf . ft)

4
14
D
PC

Three Bond #1215

Loctite #271 (All face of flange)
Starting torque :
0.6-1.5 kgf . m
(4.3-10.8 lbf . ft)
10~13 kgf . m
(72-94 lbf . ft)
Loctite #271
30-50 kgf . m G2,L1
(217-362 lbf . ft)

Loctite #271
32.5-43.5 kgf . m
(235-315 lbf . ft)
G2,L1
Grease by 1/2-2/3 of space
capacity(On hub side)

G2,L1

D255DA02
3) INSTALLATION
Perform installation in the reverse order to
removal, paying attention to the following.
(1) Tightening torque converter case
mounting bolt. Mounting
bolt
·Tightening torque : 6.0-7.5kgf·m
(43-54lbf·ft)

D255TIN01

(2) Tightening flexible plate mounting bolt.

Flexible plate
·Tightening torque : 2.8-3.5kgf·m mounting bolt
(20-25lbf·ft)

D255TIN02

(3) Pedal assembly brake piping.

① Inching drawing
Refer to the drawing on the right.
② Adjustment of pedal
Refer to “Adjustment of pedal” T/M control
valve
33mm
Clearance : 0~0.5 mm
(0~0.02 in)
D255TIN03

(4) Mast
Cap mounting bolt.
·Tightening torque : 25-31.5kgf·m
(181-228lbf·ft)