Overhaul - Except Evolution: Overhaul Mitsubishi Lancer IX

DISASSEMBLY

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1. Remove the torque converter.
2. Remove each bracket.
3. Remove the dipstick.
4. Remove the eye bolt gauge, gaskets and the oil cooler feed tube.
5. Remove the 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.
6. Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.
7. Remove the Sealing cap and O-ring.
8. Remove the valve body cover.
9. Remove the manual control shaft detent.
10. Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors. CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See 8 .
11. Remove the valve body mounting bolts (27 pieces). CAUTION: Do not lose the two steel balls.
12. Remove the valve body, gasket, and the two steel balls.
13. Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.
14. Remove the strainer and the second brake retainer oil seal.
15. Remove each accumulator piston and spring.
16. Remove the manual control lever shaft roller.
17. Remove the manual control lever shaft and the parking pawl rod.
18. Remove the torque converter housing mounting bolts (18 bolts), and then remove the torque converter housing.
19. Remove the differential bearing outer race and spacer from the torque converter housing.
20. Remove the O-rings (two pieces).
21. Remove the differential.
22. Remove the differential bearing outer race from the transaxle case.
23. Remove the oil filter.
24. Remove the oil pump mounting bolts (six bolts).
25. Install special tool MD998333 in hole "A."
26. Turn special tools MD998333 to remove the oil pump.
27. Remove the oil pump gasket.
28. Remove thrust washer number 1.
29. Holding the input shaft, remove the underdrive clutch and input shaft.
30. Remove thrust bearing number 2.
31. Remove the underdrive clutch hub.
32. Remove the rear cover and input shaft rear bearing.
33. Remove thrust race number 8.
34. Remove the seal rings (four pieces).
35. Remove the O-rings (three pieces).
36. Remove the reverse and overdrive clutch and thrust bearing number 7.
37. Remove overdrive clutch hub and thrust bearing number 6.
38. Remove thrust bearing number 5.
39. Remove the planetary reverse sun gear.
40. Remove the snap ring.
41. Remove the second brake piston and the return spring.
42. Remove the pressure plate, brake discs and brake plate. Number of brake discs and plates
43. Remove the planetary carrier assembly.
44. Remove the snap ring.
45. Remove the reaction plate and the brake disc.
46. Remove the snap ring.
47. Remove the brake plates (four pieces), brake discs (five pieces) and pressure plate.
48. Remove the wave spring.
49. Remove the parking pawl shaft, and then remove the spacer and spring.
50. Remove the two parking roller support shafts, and then remove the parking roller support.
51. Remove the one-way clutch inner race and low-reverse brake piston as follows: Using special tools MD998903 and MD998924, compress the one-way clutch inner race. Remove the snap ring. Remove the special tools. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
52. Remove the four or three transfer drive gear bearing mounting bolts. Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.
53. Remove the transfer drive gear.
54. Remove the cap by jabbing a screw driver in to the center of the cap and prying it up.
55. Using a chisel, straighten the staked portions from the output shaft nut. CAUTION: The jam nut is reverse threaded.
56. Use special tools MB991625 and MB990607 to remove the output shaft jam nut.
57. Remove the bearing retainer mounting bolt.
58. Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.
59. Tap out the outer race and the spacer.
60. Remove the snap ring.

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 seven mounting bolts 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. 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.
6. Put the snap ring on the inner race.
7. Set special tools MD998703 and MD998924 as shown, 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, brake plates and snap ring as shown in the figure. NOTE: Do not install the pressure plate at this time.
10. Install special tool MB991631 on the brake disc.
11. Install the brake discs, 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 and brake plates as shown in the figure. Number of brake discs and plates
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 from the following table.
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): 1.35 - 1.81 mm (0.0531 - 0.0713 inch)
19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below. 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. 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. CAUTION: Do not reuse the bolt, as it has had sealant applied.
24. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque. Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)
25. Use special tool MD998350 to install the collar and taper roller bearing on the 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. Tightening torque: 167 +/- 10 N.m (123 +/- 7 ft-lb) NOTE: The jam nut is reverse threaded.
27. Move the output shaft to measure the end play and record the measurement value. Standard value of end play: 0.01 - 0.09 mm (0.0004 - 0.0035 inch)
28. Remove the parts that were installed in steps 21 to 25 .
29. Select a spacer whose thickness corresponds to the measured amount of movement from the table below.
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).
32. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
34. Install the parking roller support, and then insert the two parking roller support shafts.
35. Install the planetary carrier assembly.
36. Install the planetary reverse sun gear.
37. Install the wave spring on the low-reverse brake piston.
38. Install the pressure plate that was selected in step 19 . Next, install five brake discs and four brake plates, one on top of the other.
39. Install the snap ring.
40. Install the reaction plate.
41. Install the snap ring that was selected in step 12 .
42. Install three brake discs and two brake plates, one on top of the other. Next, install the pressure plate that was selected in step 17 .
43. Install the return spring and second brake piston.
44. Install the snap ring. 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. 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.
47. Install the reverse and overdrive clutch. CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
48. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
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.
51. 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 under drive clutch hub on the under drive 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 step (5), take out the installed parts in steps (1) through (4).
52. Install the three O-rings.
53. Select a number 8 thrust race whose thickness corresponds to the measured values taken in step 51 from the table below. Install it on thrust bearing number 7.
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) or leaks will occur if the rear cover is installed after the sealant dries.
55. Install the rear cover, and tighten its mounting bolts to the specified torque. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
56. Install the underdrive clutch hub to the underdrive sun gear. CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
57. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
58. Hold the input shaft, and install the underdrive clutch.
59. Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14 inch) in diameter] on the underdrive clutch retainer as shown in the illustration.
60. Install special tool MD998412 in the illustrated place.
61. Install the oil pump to the transaxle case. NOTE: Do not install the oil pump gasket at this time.
62. Tighten the oil pump mounting bolts (six pieces) to the specified torque. Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)
63. Remove the oil pump mounting bolts.
64. Using special tools MD998333, remove the oil pump and the crushed solders.
65. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
66. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.
67. Install thrust washer number 1 that was selected in step 66 on the underdrive clutch retainer.
68. Install special tool MD998412 in the illustrated place.
69. Install the new oil pump gasket on the transaxle case.
70. Install the oil pump and tighten the mounting bolts (six pieces) to the specified torque. Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)
71. Make sure that the input shaft end play meets the standard value. Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch)
72. Install the oil filter.
73. Use special tools MB990935 and MB990938 to tap the differential bearing outer race in the transaxle case.
74. Install the differential.
75. Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter] on the torque converter housing as shown in the illustration.
76. Use special tools MB990935 and MB990938 to press in the differential bearing outer race into the torque converter housing.
77. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque. Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
78. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
79. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to the measured value and select a spacer with the corresponding thickness. Adjustment spacer sizes are all listed on page «VALVE BODY SPRING IDENTIFICATION TABLE»(ref-183630-S01304693292005081800000) . Select the most suitable one from among those listed. NOTE: * is the thickness for the differential case preload.
80. Install the spacer selected in step 79 to the torque converter housing.
81. Use special tools MB990935 and MB990938 to press the outer race into housing.
82. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the torque converter housing in the area shown. NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries. NOTE: After installation, keep the sealed area away from the ATF for approximately on hour.
83. Install the two O-rings.
84. Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque. Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
85. Insert the two O-rings into the grooves of the manual control lever shaft.
86. Install the manual control lever shaft and parking pawl rod.
87. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".
88. Insert the new seal rings in the grooves of the accumulator pistons. NOTE: The piston and seal ring are common parts.
89. 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.
90. Install the strainer and second brake retainer oil seal.
91. Insert a new O-ring to the groove of the solenoid valve harness connector.
92. 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.
93. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
94. 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.
95. Install the 27 valve body mounting bolts, and tighten to the specified torque. Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
96. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
97. Install the manual control shaft detent and tighten the bolt to the specified torque. Tightening torque: 6 +/- 1 N.m (52 +/- 9 in-lb)
98. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown. NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries. NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
99. Install the valve body cover, and then tighten its mounting bolts to the specified torque. Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
100. Install the Sealing cap and tighten the bolt to the specified torque. Tightening torque: 5 +/- 1 N.m (43 +/- 9 in-lb)
101. Install the park/neutral position switch and tighten the bolt to specified torque. Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
102. Install the manual control lever and tighten the nut to specified torque. Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb)
103. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque. Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
104. Install the oil cooler feed tube together with new gaskets and tighten the eye bolts to the specified torque. Tightening torque: 30 +/- 3 N.m (22 +/- 2 ft-lb)
105. Tighten the oil cooler feed pipe clamp bolt. Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
106. Install the oil dipstick.
107. Install the cable support bracket. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
108. Install the roll stopper brackets. Tightening torque: 69 +/- 10 N.m (51 +/- 7 ft-lb) CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.
109. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value. Reference value: Approximately 12.2 mm (0.48 inch)

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Required Special Tool

1. MD998334: Oil Seal Installer