Overhaul - Except Evolution: Removal & Installation Mitsubishi Lancer IX

>> A << OIL SEAL INSTALLATION

1. Apply a small amount of ATF to the oil seal lip.
2. Use special tool MB998334 to tap the oil seal in the oil pump body.

Scheme 821

>> 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.

Scheme 822

Required Special Tools

1. MB991628: Spring Compressor
2. MD998907: Spring Compressor
3. MD998924: Spring Compressor Retainer

Scheme 823

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.

Scheme 824

Scheme 825

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.

>> C << CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION

Scheme 826

Scheme 827

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. Install it the same as the clutch plates, so that the areas with no teeth (marked "A") are aligned with the holes in the retainer (marked "B").

>> D << SNAP RING INSTALLATION

1. Install the snap ring into the groove of clutch retainer.
2. Set special tools MB991628 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.

Standard value: 1.6 - 1.8 mm (0.0630 - 0.0709 inch)

Scheme 828

Scheme 829

Scheme 830

Required Special Tools

1. MB991628: Spring Compressor
2. MB991790: Spring Compressor
3. MD998924: Spring Compressor Retainer
4. MD999590: Spring Compressor

Scheme 831

1. Set special tools MD999590 and MD998924 as shown in the illustration.
2. Compress the return spring and remove the snap ring.

Scheme 832

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.

>> 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.

Scheme 833

Scheme 834

1. Set special tools MD999590 and MD998924 as shown in the illustration.
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 within the standard value. If not within the standard value, select a snap ring so that it is. Standard value: 0 - 0.09 mm (0 - 0.0035 inch)

>> D << PRESSURE PLATE/CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION

Scheme 835

Scheme 836

1. Assemble the clutch discs and clutch plates, one on top of the other, inside the reverse clutch piston.
2. Install the clutch reaction plate in the direction shown.

Scheme 837

1. Install the snap ring into the groove in the reverse clutch piston.
2. Set special tools MB991628 and MD998924 as shown in the illustration, and 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. Standard value: 1.6 - 18 mm (0.0630 - 0.0709 inch)

>> F << CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION

Scheme 838

Scheme 839

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").

Scheme 840

1. Install the snap ring into the groove of reverse clutch retainer.
2. Set special tools MB991790 and MD998924 as shown in the illustration, and 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 to adjust. Standard value: 1.5 - 1.7 mm (0.0591 - 0.0669 inch)

Scheme 841

>> A << THRUST BEARING NUMBER 4 AND THRUST BEARING NUMBER 3 INSTALLATION

Check the installation direction of thrust bearings number 3 and 4, and install them as shown.

Scheme 842

>> 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.

Scheme 843

Scheme 844

Apply ATF or petroleum jelly (Vaseline) to the D-ring, and install carefully.

Scheme 845

Apply ATF or petroleum jelly (Vaseline) to the D-ring, and install carefully.

Scheme 846

Required Special Tools

1. MB990936: Installer Adapter
2. MB990938: Handle
3. MD998801: Bearing Remover
4. MD998812: Installer Cap
5. MD998813: Installer-100
6. MD998814: Installer-200
7. MD998823: Installer Adapter (48)
8. MD998917: Bearing Remover

Scheme 847

1. Support the transfer driven gear with 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.

Scheme 848

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 taper roller bearing.

Scheme 849

1. Set the output shaft on the press support stand.
2. Using special tools MD998823, MD998812 and MD998814, press install the taper roller bearing.

>> B << OUTER RACE INSTALLATION

Use the special tools MB990936 and MB990938 to tap the outer race in the bearing retainer.

Scheme 850

Scheme 851

1. Set the output shaft on the press support stand.
2. Using special tools MD998823, MD998812 and MD998813, press install the transfer driven gear.

Scheme 852

Required Special Tools

1. MD998801: Bearing Remover
2. MD998812: Installer Cap
3. MD998820: Installer Adapter (42)

Scheme 853

1. Support the taper roller bearing with special tool MD998801, and then set them on the press.
2. Push down on the differential case with the press to remove the bearing.

Scheme 854

Scheme 855

Scheme 856

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, use 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.
3. Insert the pinion shaft.
4. Measure the backlash between the side gear and pinion. Standard value: 0.025 - 0.150 mm (0.0010 - 0.0059 inch)
5. 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.

>> B << LOCK PIN INSTALLATION

Install the lock pin so that it will be oriented in the direction shown.

Scheme 857

>> C << TAPER ROLLER BEARING INSTALLATION

Using special tools MD998812 and MD998820, press install the taper roller bearing with the press.

Scheme 858

>> D << DIFFERENTIAL DRIVE GEAR INSTALLATION

Apply ATF to the bolt, and then tighten the bolts to the specified torque in the sequence shown.

1. Tightening torque: 132 +/- 5 N.m (98 +/- 4 ft-lb)

Scheme 859

Scheme 860

Scheme 861

Scheme 862

<< A >> SOLENOID VALVES REMOVAL

Mark the solenoid valves with white paint to make assembly easier.

Scheme 863

Scheme 864

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.

>> B << SPRING AND STEEL BALL INSTALLATION

Install the three steel balls and two springs to the inside valve body as shown.

Scheme 865

Scheme 866

Scheme 867

Scheme 868

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.

Scheme 869

Required Special Tool

1. MD998800: Oil Seal Installer

Use special tool MD998800 to tap the oil seal into the torque converter housing.

Scheme 870

>> B << OIL SEAL INSTALLATION

Use special tool MD998800 to tap the oil seal in the transaxle case.

Scheme 871