ASSEMBLY Mitsubishi Eclipse IV рестайлинг

ASSEMBLY

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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.
2. Tighten the mounting bolts (seven pieces) of the transfer drive gear bearing to the specified torque. Tightening torque: 34 +/- 2 N. m (25 +/- 1 ft-lb)
3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
4. Install 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.
6. Put the snap ring on the inner race.
7. Set special tools MD998903 and MD998924 as shown in illustration, and then compress the one-way clutch inner race and install the snap ring.
8. Install the wave spring onto the low-reverse brake piston.
9. Install the brake discs (six pieces), brake plates (five pieces) and snap ring as shown in illustration NOTE: Do not install the pressure plate at this time.
10. Install special tool MB991631 on the brake disc.
11. Install the reaction plate and the used snap ring.
12. Move special tool MB991631 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)
13. Install the brake discs (three pieces) and brake plates (two pieces) as shown in illustration. NOTE: Do not install the pressure plate at this time.
14. Place special tool MB991631 on top of the brake disc in place of the pressure plate.
15. Install the return spring, second brake piston and snap ring.
16. Move special tool MB991631 and measure its movement. Standard value of end play (Reference): 0.79-1.25 mm (0.0311-0.0492 inch)
17. Select a pressure plate whose thickness corresponds to the measured amount of movement, refer to «THICKNESS SPECIFICATION»(ref-308284-S22925110732009020200000) . PRESSURE PLATE FOR SECOND BRAKE THICKNESS SPECIFICATION MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL 0.6-0.8 (0.024-0.031) 1.6 (0.063) L 0.8-1.0 (0.031-0.039) 1.8 (0.071) 1 1.0-1.2 (0.039-0.047) 2.0 (0.079) 0 1.2-1.4 (0.047-0.055) 2.2 (0.087) 2 1.4-1.6 (0.055-0.063) 2.4 (0.094) 4 1.6-1.8 (0.063-0.071) 2.6 (0.102) 6
18. Turn the transaxle over so that the installation surface of the torque converter housing is facing up Install special tool MD998913 in a dial gauge, and then move special tool MB991631 and measure its movement. Standard value of end play (Reference) : 1.65-2.11 mm (0.0649-0.0831 inch)
19. Select a pressure plate whose thickness corresponds to the measured amount of movement, refer to «THICKNESS SPECIFICATION»(ref-308284-S15669934032009020200000) . PRESSURE PLATE FOR LOW-REVERSE BRAKE THICKNESS SPECIFICATION MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL 1.3-1.5 (0.051-0.059) 1.6 (0.063) L 1.5-1.7 (0.059-0.067) 1.8 (0.071) 1 1.7-1.9 (0.067-0.075) 2.0 (0.079) 0 1.9-2.1 (0.075-0.083) 2.2 (0.087) 2 2.1-2.3 (0.083-0.091) 2.4 (0.094) 4 2.3-2.5 (0.091-0.098) 2.6 (0.102) 6 2.5-2.7 (0.098-0.106) 2.8 (0.110) 8 2.7-2.9 (0.106-0.114) 3.0 (0.118) D CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
20. Remove all parts and special tools that were installed to take the measurements in steps 9 to 18 . Remove and separate the pressure plate and snap ring chosen in steps 12 , 16 and 18
21. Install the snap ring into the groove of transaxle case output shaft bore.
22. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case. CAUTION: Do not reuse the bolt, as it has had sealant applied.
23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque. Tightening torque: 29 +/- 2 N. m (21 +/- 1 ft-lb)
24. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
25. Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again. Tightening torque: 170 +/- 10 N. m (125 +/- 7 ft-lb) NOTE: The jam nut is reverse threaded.
26. 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
27. Remove the parts that were installed in steps 22 to 25
28. Select a spacer whose thickness corresponds to the measured amount of movement, refer to «SPACER THICKNESS SPECIFICATION»(ref-308284-S07099556212009020200000) . SPACER FOR OUTPUT SHAFT SPACER THICKNESS SPECIFICATION MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL 1.81-1.85 (0.0713-0.0728) 1.88 (0.0740) 88 1.85-1.89 (0.0728-0.0744) 1.92 (0.0756) 92 1.89-1.93 (0.0744-0.0760) 1.96 (0.0772) 96 1.93-1.97 (0.0760-0.0776) 2.00 (0.0787) 00 1.97-2.01 (0.0776-0.0791) 2.04 (0.0803) 04 2.01-2.05 (0.0791-0.0807) 2.08 (0.0819) 08 2.05-2.09 (0.0807-0.0823) 2.12 (0.0835) 12 2.09-2.13 (0.0823-0.0839) 2.16 (0.0850) 16 2.13-2.17 (0.0839-0.0854) 2.20 (0.0866) 20 2.17-2.21 (0.0854-0.0870) 2.24 (0.0882) 24 2.21-2.25 (0.0870-0.0886) 2.28 (0.0898) 28 2.25-2.29 (0.0886-0.0902) 2.32 (0.0913) 32 2.29-2.33 (0.0902-0.0917) 2.36 (0.0929) 36 2.33-2.37 (0.0917-0.0933) 2.40 (0.0945) 40 2.37-2.41 (0.0933-0.0949) 2.44 (0.0961) 44 2.41-2.45 (0.0949-0.0965) 2.48 (0.0976) 48 2.45-2.49 (0.0965-0.0980) 2.52 (0.0992) 52 2.49-2.53 (0.0980-0.0996) 2.56 (0.1008) 56 2.53-2.57 (0.0996-0.1012) 2.60 (0.1024) 60 2.57-2.61 (0.1012-0.1028) 2.64 (0.1039) 64 2.61-2.65 (0.1028-0.1043) 2.68 (0.1055) 68 2.65-2.69 (0.1043-0.1059) 2.72 (0.1071) 72 2.69-2.73 (0.1059-0.1075) 2.76 (0.1087) 76
29. Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in Step 28 .
30. Stake the jam nut with a punch (two places).
31. Use special tools MB990931 and MB990938 to install the cap as shown in illustration.
32. Install the planetary carrier assembly.
33. Install the planetary reverse sun gear.
34. Install the wave spring on the low-reverse brake piston.
35. Install the pressure plate that was selected in Step 19 . Next, install brake discs (six pieces) and brake plates (five pieces), one on top of the other.
36. Install the snap ring.
37. Install the reaction plate.
38. Install the snap ring that was selected in Step 12 .
39. Install brake discs (three pieces) and brake plates (two pieces), one on top of the other. Next, install the pressure plate that was selected in Step 17 .
40. Install the return spring and second brake piston.
41. Install the snap ring. IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS THICKNESS SPECIFICATION SYMBOL OD mm (in) ID mm (in) THICKNESS mm (in) No. 1 59 (2.32) 47 (1.85) 1.8 (0.071) 59 (2.32) 47 (1.85) 2.0 (0.079) 59 (2.32) 47 (1.85) 2.2 (0.087) 59 (2.32) 47 (1.85) 2.4 (0.094) 59 (2.32) 47 (1.85) 2.6 (0.102) 59 (2.32) 47 (1.85) 2.8 (0.110) No. 2 49 (1.93) 34 (1.34) 3.6 (0.142) No. 3 49 (1.93) 34 (1.34) 3.6 (0.142) No. 4 46 (1.81) 31 (1.22) 3.3 (0.130) No. 5 49 (1.93) 34 (1.34) 3.6 (0.142) No. 6 49 (1.93) 34 (1.34) 3.6 (0.142) No. 7 59 (2.32) 37 (1.46) 2.8 (0.110) No. 8 48.9 (1.925) 37 (1.46) 1.6 (0.063) 48.9 (1.925) 37 (1.46) 1.7 (0.067) 48.9 (1.925) 37 (1.46) 1.8 (0.071) 48.9 (1.925) 37 (1.46) 1.9 (0.075) 48.9 (1.925) 37 (1.46) 2.0 (0.079) 48.9 (1.925) 37 (1.46) 2.1 (0.083) 48.9 (1.925) 37 (1.46) 2.2 (0.087) 48.9 (1.925) 37 (1.46) 2.3 (0.091 48.9 (1.925) 37 (1.46) 2.4 (0.094 48.9 (1.925) 37 (1.46) 2.5 (0.098) 48.9 (1.925) 37 (1.46) 2.6 (0.102) CAUTION: Be sure to install the thrust bearing in the correct direction as shown in illustration.
42. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear. CAUTION: Use care to install the thrust bearing in the proper direction.
43. 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. CAUTION: Be sure to install the thrust bearing in the correct direction as shown in illustration.
44. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
45. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
46. Install the seal rings (four pieces) in the grooves of the rear cover.
47. Measure the end play of the under drive sun gear by the following procedures. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7. Install the rear cover on the transaxle case and tighten the bolts to the specified torque. Tightening torque: 23 +/- 3 N. m (17 +/- 2 ft-lb) Turn over the transaxle case so that the installation surface of the torque converter housing is facing up. Install the underdrive clutch hub on the underdrive sun gear. 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) After taking the measurement in steps 5 , take out the installed parts in steps 1 ) through 4 .
48. Install the O-rings (three pieces).
49. Select a thrust race number 8 whose thickness corresponds to the measured values taken in Step 47 from the table below. Install it on thrust bearing number 7. THICKNESS SPECIFICATION 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)
50. 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). Leaks will occur if the rear cover is installed after the sealant dries.
51. Install the rear cover, and tighten its mounting bolts to the specified torque. Tightening torque: 23 +/- 3 N. m (17 +/- 2 ft-lb) NOTE: After installation, keep the sealed area away from ATF for approximately one hour.
52. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
53. Install the parking roller support, and then insert the parking roller support shafts (two pieces).
54. Install the underdrive clutch hub to the underdrive sun gear. CAUTION: Be sure to install the thrust bearing in the correct direction as shown in illustration.
55. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
56. Hold the input shaft, and install the underdrive clutch.
57. Adjustment of input shaft end play and select the thrust washer number 1. (Refer to «ADJUSTMENT OF TRANSAXLE THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY»(ref-308284-S03684370582009020200000) ).
58. Install special tool MD998412 as shown.
59. Install the oil pump to the transaxle case. NOTE: Do not install the oil pump gasket at this time.
60. Tighten the six oil pump mounting bolts to the specified torque. Tightening torque: 29 +/- 2 N. m (21 +/- 1 ft-lb)
61. Make sure that the input shaft end play meets the standard value. Standard value : 0.70-1.45 mm (0.028-0.057 inch)
62. Install the oil filter.
63. Use special tools MB990935 and MB990938 to tap the differential bearing outer race in the transaxle case.
64. Install the differential.
65. Adjustment of differential case preload and select the spacer (Refer to «ADJUSTMENT OF TRANSAXLE THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY»(ref-308284-S03684370582009020200000) ).
66. Install the selected spacer to the torque converter housing.
67. Use special tools MB990935 and MB990938 to press the differential bearing outer race into the torque converter housing.
68. Apply a 1.6 mm (0.06 inch) diameter bead of sealant (Mitsubishi Genuine Part number MD974421 or equivalent) to the torque converter housing in the area shown. NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes). Leaks will occur if the rear cover is installed after the sealant dries. NOTE: After installation, keep the sealed area away from ATF for approximately one hour.
69. Install the O-rings (two pieces).
70. Install the torque converter housing and then tighten its mounting bolts (eighteen pieces) to the specified torque. Tightening torque: 48 +/- 6 N. m (36 +/- 4 ft-lb)
71. Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
72. Install the manual control lever shaft and parking pawl rod.
73. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A.
74. Insert the new seal rings in the grooves of the accumulator pistons. NOTE: The piston and seal ring are common parts.
75. 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 illustration. NAME REFERENCE CHART NO. NAME IDENTIFICATION "BLUEING" 1 For low-reverse brake None 2 For underdrive clutch Half 3 For second brake Whole surface 4 For overdrive clutch None
76. Install the strainer and second brake retainer oil seal.
77. Insert a new O-ring to the groove of the solenoid valve harness connector.
78. Insert the solenoid valve harness connector into the hole from the inside of the transaxle case so it is oriented as shown in illustration. Then secure the snap ring to the connector groove.
79. Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
80. 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.
81. Install the valve body mounting bolts (twenty seven pieces), and tighten to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
82. Attach the solenoid valve harness to valve body by connecting the all the connectors. SOLENOID VALVE HARNESS SPECIFICATION NO. PARTS TO BE CONNECTED SOLENOID VALVE HARNESS CABLE COLOR CONNECTOR HOUSING COLOR 1 Underdrive solenoid valve White, red, red Black 2 Overdrive solenoid valve Orange, red Black 3 Low-reverse solenoid valve Brown, yellow Milky white 4 Second solenoid valve Blue, red, red Milky white 5 Torque converter clutch control solenoid valve Blue, yellow, yellow Black
83. Install the fluid temperature sensor to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
84. Install the manual control shaft detent and tighten the bolt to the specified torque. Tightening torque: 6.0 +/- 1.0 N. m (53 +/- 9 in-lb)
85. Apply a 2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown. NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries. NOTE: After installation, keep the sealed area away from ATF for approximately one hour.
86. Install the valve body cover, and then tighten its mounting bolts to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
87. Install the Sealing cap and tighten the bolt to the specified torque. Tightening torque: 5.0 +/- 1.0 N. m (44 +/- 9 in-lb)
88. Install the park/neutral position switch and tighten the bolt to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
89. Install the manual control lever and tighten the nut to the specified torque. Tightening torque: 22 +/- 3 N. m (16 +/- 2 ft-lb)
90. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
91. Press Face "A" of the air breather to be on the same plane as the Face "B" of the transaxle case as shown in illustration.
92. Apply ATF on the both sides of the new gasket and threads of the eye bolts, and then tighten to the specified torque. Tightening torque: 24 +/- 3 N. m (18 +/- 2 ft-lb)
93. Tighten the oil cooler feed pipe clamp bolt to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
94. Install the oil dipstick
95. Install the cable support brackets to the specified torque. Tightening torque: 23 +/- 3 N. m (17 +/- 2 ft-lb)
96. Install the harness bracket to the specified torque. Tightening torque: 11 +/- 1 N. m (97 +/- 9 in-lb)
97. Install the roll stopper brackets. Tightening torque: 90 +/- 10 N. m (66 +/- 7 ft-lb) CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.
98. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value. Reference value: Approximately 12.2 mm (0.48 inch)