Mitsubishi V5A51 Manual

Automatic transmision

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Page 1 23. 2-4WD SHIFT RAIL AND H-L SHIFT RAIL ......23E-23-1 Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I...
Page 2 23E-0-2 NOTES Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I Added...
Page 3: General Information
23E-0-3 V5A51 - General Information GENERAL INFORMATION This transmission is the newly developed 5-speed automatic transmission that merges advanced electronic technology and mechanical technology. (1) A hydraulic balance mechanism is incorporated for the transmission clutch, allowing speed changes at ultra-high speeds to be handled.
Page 4 23E-0-4 V5A51 - General Information SECTIONAL VIEW <TRANSFER> 1. Transfer input gear 7. Viscous coupling 2. H-L clutch 8. Center differential planetary carrier 3. Low speed gear 9. Transfer drive shaft 4. 2-4WD clutch sleeve 10. Rear output shaft 5. Drive sprocket 11.
Page 5 23E-0-5 V5A51 - General Information HYDRAULIC CONTROL SYSTEM 1. Reverse clutch 17. Low-reverse brake solenoid valve 2. Low/reverse brake 18. Second brake solenoid valve 3. Second brake 19. Underdrive clutch solenoid valve 4. Underdrive clutch 20. Overdrive clutch solenoid valve 5.
Page 6: Specifications
23E-1-1 V5A51 - Specifications 1. SPECIFICATIONS TRANSMISSION MODEL TABLE - MODEL 2001 Transmission models Vehicle model Engine model V5A51-7-ACA V65W, V75W 6G74 V5A51-7-SDA V68W, V78W 4M41 V5A51-7-CCA1 V75W 6G74 V5A51-7-CCA2 V65W, V75W 6G74 V5A51-7-SDA1 V78W 4M41 Mitsubishi Motors Corporation Mar. 2000...
Page 7: General Specifications
23E-1-2 V5A51 - Specifications GENERAL SPECIFICATIONS Item V5A51 Torque converter Type 3-element, with torque converter clutch Transmission Type 5-speed, fully automatic Gear ratio 3.789 2.057 1.421 1.000 0.731 Reverse 3.865 Transfer Type 2-speed constant mesh Gear ratio High 1.000 1.900 Mitsubishi Motors Corporation Mar.
Page 8: Service Specifications
23E-1-3 V5A51 - Specifications SERVICE SPECIFICATIONS TRANSMISSION Item Standard value Direct planetary carrier mm 0.25 - 0.55 Underdrive clutch end play mm 1.6 - 1.8 Input shaft end play mm 0.25 - 0.81 Direct clutch end play mm 1.0 - 1.2 Overdrive clutch end play mm 2.0 - 2.2...
Page 9: Valve Body Spring Identification
23E-1-4 V5A51 - Specifications VALVE BODY SPRING IDENTIFICATION Item Wire Outside Free Number of diameter diameter height loops Orifice check ball spring 15.4 Torque converter clutch control valve spring 28.1 Damping valve spring 35.8 Torque converter pressure control valve spring 11.2...
Page 10: Torque Specifications
23E-1-5 V5A51 - Specifications TORQUE SPECIFICATIONS TRANSMISSION Item Torque Nm Output shaft support mounting bolt 23 ± 3 Upper valve body mounting bolt 11 ± 1 Park/neutral position switch mounting bolt 11 ± 1 Anchor plug 98 ± 15 Oil pan mounting bolt 11 ±...
Page 11 23E-1-6 V5A51 - Specifications TRANSFER Item Torque Nm Dynamic damper 35 ± 6 Transfer case cover tightening bolt 19 ± 2 Input gear bearing retainer mounting bolt 20 ± 2 Transfer case to chain cover tightening bolt 35 ± 6 Rear bearing retainer mounting bolt 20 ±...
Page 12 23E-1-7 V5A51 - Specifications SNAP RING, THRUST RACE, SPACER AND PRESSURE PLATE FOR ADJUSTMENT TRANSMISSION Thrust race (for adjustment of direct planetary carrier end play) Thickness mm Identification symbol Part number None MR276705 None MR276706 None MR276707 None MR276708 None...
Page 13 23E-1-8 V5A51 - Specifications Pressure plate (for adjustment of second brake end play) Thickness mm Identification symbol Part number MR336390 MR336391 MR336392 MR336393 MR336394 MR336395 MR336396 MR336397 Snap ring (for adjustment of center support and brake reaction plate end play)
Page 14 23E-1-9 V5A51 - Specifications Snap ring (for adjustment of low/reverse brake end play) Thickness mm Identification symbol Part number MD759425 MD759426 MD759427 MD759428 MD759429 MD759430 MD759431 TRANSFER Spacer (for adjustment of input gear bearing end play) Thickness mm Identification symbol Part number 2.30...
Page 15 23E-1-10 V5A51 - Specifications Snap ring (for adjustment of differential lock hub end play) Thickness mm Identification symbol Part number 2.56 None MD738386 2.63 MD738387 2.70 White MD738388 2.77 Blue MD738389 2.84 Yellow MD738390 2.91 Green MD738391 2.98 Brown MD738392...
Page 16 23E-1-11 V5A51 - Specifications Snap ring (for adjustment of rear output shaft preload) Thickness mm Identification symbol Part number 1.57 None MR486340 1.63 None MR486341 1.69 None MR486342 1.75 None MR486343 1.81 None MR486344 1.87 None MR486345 1.93 None MR486346 1.99...
Page 17 23E-1-12 V5A51 - Specifications SEALANTS TRANSMISSION Item Specified sealant Oil pan MITSUBISHI genuine sealant part No. MR166584 or equivalent Transfer case adapter (transmission side) MITSUBISHI genuine sealant part No. MR166584 or equivalent TRANSFER Item Specified sealant Bearing retainer mounting bolt MITSUBISHI genuine sealant part No.
Page 18 FIPG. LUBRICANTS TRANSFER Item Specified lubricant Lip of transfer case oil seal MITSUBISHI genuine grease part No. 0101011 or equivalent Lip of transfer case plate oil seal Lip of rear cover oil seal Mitsubishi Motors Corporation Mar. 2000...
Page 19: Special Tools
23E-2-1 V5A51 - Special Tools 2. SPECIAL TOOLS TRANSMISSION Tool Number Name MB990929 Installer adapter Installation of transfer case adapter oil seal MB990938 Handle Use with installer adapter MD998727 Oil pan remover Removal of oil pan MD998333 Oil pump remover...
Page 20 23E-2-2 V5A51 - Special Tools Tool Number Name MB991632 Clearance dummy Measurement of brake reaction plate, second plate brake and low/reverse brake end plays MD998913 Dial gauge exten- Measurement of brake reaction plate, second sion brake and low/reverse brake end plays...
Page 21 23E-2-3 V5A51 - Special Tools Tool Number Name MD998907 Spring compressor Removal and installation of underdrive clutch spring retainer snap ring Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I Added...
Page 22 23E-2-4 V5A51 - Special Tools TRANSFER Tool Number Name MB990932 Installer adapter Installation of oil seal MB990938 Handle Use with installer adapter MB990936 Installer adapter Installation of oil seal MD998801 Bearing remover Removal and installation of bearing MD998812 Installer cap...
Page 23 23E-2-5 V5A51 - Special Tools Tool Number Name MD998824 Installer adapter Installation of rear output shaft bearing (50) MD998813 Installer-100 Use with installer cap and installer adapter MD998830 Installer adapter Installation of transfer drive shaft bearing (66) MD998192 Bearing puller...
Page 24: Transmission And Transfer
3 mm the transmission case. diameter Specified sealant: MITSUBISHI genuine sealant part No. MR166584 or equivalent Caution Evenly squeeze out and apply the sealant so that it is not excessive and does not ooze out.
Page 25 23E-4-1 V5A51 - Transfer Case Adapter 4. TRANSFER CASE ADAPTER DISASSEMBLY AND ASSEMBLY Disassembly steps 1. Parking sprag shaft "CA 2. Parking sprag spring 3. Parking sprag "BA 4. Sealing cap 5. Parking roller support shaft 6. Parking roller support "AA 7.
Page 26 23E-4-2 V5A51 - Transfer Case Adapter "BA SEALING CAP INSTALLATION 1. Press the sealing caps into the dimensions shown in Sealing cap the illustration so that they are not slanted. 2. Apply sealant as shown in the illustration. Specified sealant: AAD part No.
Page 27 23E-5-1 V5A51 - Transmission 5. TRANSMISSION DISASSEMBLY AND ASSEMBLY 11 ± 1 Nm 11 ± 1 Nm 11 ± 1 Nm 22 ± 3 Nm 11 ± 1 Nm 11 ± 1 Nm 11 ± 1 Nm 6 ± 1 Nm 6 ±...
Page 28 23E-5-2 V5A51 - Transmission 31 32 Apply automatic transmission fluid to all moving parts before installation. 16. Oil seal 30. Outer spring 17. Oil seal 31. Snap ring 18. Oil strainer 32. Accumulator cover 19. Seal ring 33. O-ring 20. Accumulator piston 34.
Page 29 23E-5-3 V5A51 - Transmission 23 ± 3 Nm 48 ± 6 Nm Apply automatic transmission fluid to all moving parts before installation. 45. Converter housing 52. Overdrive clutch hub 46. Oil pump 53. Thrust bearing No.4 47. Oil pump gasket 54.
Page 30 23E-5-4 V5A51 - Transmission Apply automatic transmission fluid to all moving parts before installation. 58. Pressure plate 64. Reaction plate 59. Brake plate 65. Snap ring 60. Brake disc 66. Brake plate 61. Low/reverse annulus gear 67. Brake disc 62. Thrust bearing No.7 68.
Page 31 23E-5-5 V5A51 - Transmission Apply automatic transmission fluid to all moving parts before installation. 98 ± 15 Nm 23 ± 3 Nm 19 ± 3 Nm 70. Snap ring 83. Reduction brake piston nut 71. Center support 84. Reduction brake piston 72.
Page 32 23E-5-6 V5A51 - Transmission DISASSEMBLY Caution Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not to scratch or damage these parts during disassembly and reassembly. During the work, always use bare hands or vinyl gloves.
Page 33 23E-5-7 V5A51 - Transmission 4. Remove the snap ring, and remove the parking gear using a puller (corresponding load approximately 9,800 Snap ring NOTE The parking gear may be removed without using a puller. Parking gear 5. Remove the twenty oil pan mounting bolts and then remove the oil pan using the special tool.
Page 34 23E-5-8 V5A51 - Transmission 9. Remove the twenty valve body mounting bolts and then remove the valve body, three O-rings and oil temperature sensor. NOTE The twenty valve body mounting bolts are plated bolts. Oil temperature sensor NOTE The O-rings are mounted on the transmission case side as shown in the illustration.
Page 35 23E-5-9 V5A51 - Transmission NOTE To make assembly easier, attach an identification tag on the removed accumulator piston. 13. Remove the detent lever spring pin. Spring pin 14. Remove the pin, and then remove the manual control shaft, two O-rings, detent lever and parking roller rod.
Page 36 23E-5-10 V5A51 - Transmission 18. While screwing in the special tool evenly, remove the oil pump. 19. Remove the oil pump gasket. MD998333 20. Remove the reverse and overdrive clutch, thrust race Thrust No.1 and thrust bearing No.2. bearing Thrust race No.2...
Page 37 23E-5-11 V5A51 - Transmission 24. Remove the snap ring. 25. Remove the second brake and return spring. 26. Remove the pressure plate, brake plates and brake discs. 27. Remove the low/reverse annulus gear. 28. Remove the thrust bearing No.7. Thrust...
Page 38 23E-5-12 V5A51 - Transmission 29. Remove the snap ring. 30. Remove the reaction plate and one brake disc. 31. Remove the snap ring. 32. Remove the brake plates, brake discs, and pressure plate. 33. Remove the wave spring. Mitsubishi Motors Corporation Mar.
Page 39 23E-5-13 V5A51 - Transmission 34. Remove the snap ring and center support. Snap ring Center support 35. Remove the thrust race No.8 and thrust bearing No.9. Thrust bearing No.9 NOTE The thrust race No.8 may be attached to the center support.
Page 40 23E-5-14 V5A51 - Transmission 39. Remove the snap ring and then the reduction brake piston Snap ring Reduction brake cover and O-ring. piston cover 40. Remove the snap ring and then the nut, reduction brake piston, seal ring, adjusting rod and spring.
Page 41 23E-5-15 V5A51 - Transmission 44. Remove the anchor plug and the O-ring. 45. Remove the eight output shaft support mounting bolts, and then remove the output shaft support and gasket. Output shaft support Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I Added...
Page 42 23E-5-16 V5A51 - Transmission ASSEMBLY Caution Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling. Never use grease other than blue petrolatum jelly and white Vaseline. Apply ATF to friction components, rotating parts, and sliding parts before installation.
Page 43 23E-5-17 V5A51 - Transmission Identification of thrust bearings and thrust races No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13 Symbol OD mm ID mm Thickness mm Part No. No.1 48.9 MD723063 MD707267 MD723064 MD707268 MD723065...
Page 44 23E-5-18 V5A51 - Transmission Symbol OD mm ID mm Thickness mm Part No. No.8 MR276705 MR276706 MR276707 MR276708 MR276709 No.9 71.4 2.78 MR276587 No.10 71.9 MR263281 No.11 54.1 3.83 MR276588 No.12 38.5 4.62 MR222936 No.13 37.5 MD758555 3. Install a new O-ring on the anchor plug and tighten the anchor plug to the specified torque.
Page 45 23E-5-19 V5A51 - Transmission 5. Install the thrust bearing No.13 onto the direct clutch Thrust bearing No.13 retainer. Caution Take care not to mistake the thrust bearing No.13 mounting direction. Direct clutch retainer Thrust bearing No.13 6. Install the direct clutch.
Page 46 23E-5-20 V5A51 - Transmission 10. Press the reduction brake piston into the transmission case, and then install the snap ring. Snap ring NOTE Set the open of the snap ring at indicated location. Reduction brake piston 11. Tighten the reduction brake piston adjusting rod manually to the full.
Page 47 23E-5-21 V5A51 - Transmission (4) Tighten the reduction brake piston nut to the specified MB991633 torque of 19 ± 3 Nm using the special tool (Wrench) (Socket) while fixing the special tool (Socket) so as not to rotate. MB991633 (Wrench) 13.
Page 48 23E-5-22 V5A51 - Transmission 17. Install the direct annulus gear. Caution Confirm that the thrust bearing No.10 in the direct annulus gear is still at the specified location. 18. Apply Vaseline or petrolatum jelly to the thrust bearing No.9, and then install on the direct annulus gear.
Page 49 23E-5-23 V5A51 - Transmission 21. Using the transfer case adapter bolt, install special tool MB991603. Caution Install the cable end bracket together with the special tool. MB991603 Cable end bracket 22. Select the thrust race No.8 with the following procedure: Direct planetary (1) Fix a dial gauge to the special tool.
Page 50 23E-5-24 V5A51 - Transmission (2) Alternately push in the direct planetary carrier and Center support Direct planetary center support, and measure the end play of the carrier center support. NOTE Be sure to push the direct planetary carrier in fully until the center support contacts the snap ring.
Page 51 23E-5-25 V5A51 - Transmission (7) Next, install the special tool instead of the pressure plate for the second brake. Install the four brake discs Second brake Snap ring and three brake plates. Caution Return spring Take care to the shape and assembly direction of the brake plates installed at section “A”...
Page 52 23E-5-26 V5A51 - Transmission Moving amount mm Pressure plate Thickness mm ID symbol Part No. 1.5 or more - less than 1.7 MD759425 1.7 or more - less than 1.9 MD759426 1.9 or more - less than 2.1 MD759427 2.1 or more - less than 2.3 MD759428 2.3 or more - less than 2.5...
Page 53 23E-5-27 V5A51 - Transmission 27. Install the reverse sun gear. 28. Install the wave spring onto the low/reverse brake piston. 29. Install the pressure plate selected in step 24 (12), brake discs and brake plates. 30. Install the snap ring.
Page 54 23E-5-28 V5A51 - Transmission 32. Install the snap ring selected in step 24 (5). 33. Install the brake discs, brake plates and pressure plate selected in step 24 (9). Pressure plate Brake plate Caution Take care not to mistake the brake plate (reaction plate side) installation direction.
Page 55 23E-5-29 V5A51 - Transmission 36. Apply Vaseline or petrolatum jelly on the thrust bearing Thrust bearing No.4, and then install on the reverse sun gear. No.4 Caution Take care not to mistake the thrust bearing No.4 installation direction. Thrust bearing No.4...
Page 56 23E-5-30 V5A51 - Transmission Caution Take care not to mistake the thrust bearing No.2 mounting direction. Thrust bearing No.2 41. Apply Vaseline or petrolatum jelly on the thrust race No.1, Thrust race and then install on the oil pump. No.1 42.
Page 57 23E-5-31 V5A51 - Transmission 48. Install the parking roller rod to the detent lever. Parking roller rod Detent lever 49. Install two new O-rings to the manual control shaft, and assemble onto the transmission case together with the detent lever and parking roller rod.
Page 58 23E-5-32 V5A51 - Transmission 52. Install a new seal ring onto each accumulator piston. 53. Install each accumulator piston and spring, then install Outer springs accumulator cover with O-ring and snap ring. NOTE (1) Install the accumulator pistons to the original positions following the identification tags attached when they were removed.
Page 59 23E-5-33 V5A51 - Transmission 55. Install the solenoid valve harness, and then secure the Snap ring snap ring to connector groove. NOTE Install the harness so that it is oriented as shown in the illustration. 56. Install new three O-rings onto the transmission case at the positions shown in the illustration.
Page 60 Oil filter O-ring 64. Apply sealant on the oil pan. 3 mm diameter Specified sealant: MITSUBISHI genuine sealant part No. MR166584 or equivalent Caution Evenly squeeze out the sealant so that it is not insufficient or excessive. 65. Install the oil pan.
Page 61 23E-5-35 V5A51 - Transmission 67. Install the parking gear and snap ring. Snap ring Parking gear Caution Install the parking gear so that the side without the spline cut faces the transmission side. Heat the parking gear to 160 - 180_C, and shrink Transmission fit up to the stepped section of the output shaft.
Page 62 23E-6-1 V5A51 - Reverse and Overdrive Clutch 6. REVERSE AND OVERDRIVE CLUTCH DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. Disassembly steps 1. Seal ring AA" "DA 12. Snap ring 2. Snap ring 13. Spring retainer 3.
Page 63 23E-6-2 V5A51 - Reverse and Overdrive Clutch DISASSEMBLY SERVICE POINT MD998924 MD999590 AA" SNAP RING REMOVAL 1. Set the special tools as shown in the illustration. 2. Compress the return spring, and remove the snap ring. Snap ring ASSEMBLY SERVICE POINTS "AA D-RING INSTALLATION...
Page 64 23E-6-3 V5A51 - Reverse and Overdrive Clutch "EA CLUTCH PLATE / CLUTCH DISC / REACTION PLATE INSTALLATION Clutch plates Rounded edge Reaction 1. Alternately assemble the clutch discs and clutch plates plate in the reverse clutch piston. 2. Install the reaction plate so that it is oriented as shown in the illustration.
Page 65 23E-6-4 V5A51 - Reverse and Overdrive Clutch "HA SNAP RING INSTALLATION MD998924 MB991789 1. Install the snap ring in the reverse clutch retainer groove. End play 2. Set the special tools as shown in the illustration, and compress the clutch element.
Page 66: Second Brake
23E-7-1 V5A51 - Second Brake 7. SECOND BRAKE DISASSEMBLY AND ASSEMBLY Disassembly steps 1. Second brake retainer 2. Second brake piston "AA 3. D-ring "AA 4. D-ring ASSEMBLY SERVICE POINT "AA D-RING INSTALLATION 1. Apply ATF to the D-ring. 2. Install the D-ring in the groove on the outer and inner periphery of the piston.
Page 67: Low/Reverse Annulus Gear
23E-8-1 V5A51 - Low/reverse Annulus Gear 8. LOW/REVERSE ANNULUS GEAR DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. Disassembly steps 1. Snap ring 2. Overdrive planetary carrier "DA 3. Thrust bearing No.5 4. Underdrive sun gear "CA 5.
Page 68 23E-8-2 V5A51 - Low/reverse Annulus Gear "BA STOPPER PLATE INSTALLATION Stopper plate Install the stopper plate onto the low/reverse annulus gear. Make sure that the stopper plate claws are securely engaged in the annulus gear groove. Claw Groove "CA THRUST BEARING NO.6 INSTALLATION Apply Vaseline or petrolatum jelly on the thrust bearing No.6,...
Page 69 23E-9-1 V5A51 - Center Support 9. CENTER SUPPORT DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. Disassembly steps AA" "CA 1. Snap ring 6. Return spring 2. Plate 7. Low/reverse brake piston 3. One-way clutch inner race "AA 8.
Page 70 23E-9-2 V5A51 - Center Support DISASSEMBLY SERVICE POINT MD998924 MB991630 AA" SNAP RING REMOVAL 1. Set the special tools as shown in the illustration so that Snap they are pressed against the inner race of the one-way ring clutch. 2. Screw in the special tool nut, and lightly press against the inner race of the one-way clutch.
Page 71 23E-10-1 V5A51 - Underdrive Clutch 10. UNDERDRIVE CLUTCH DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I Added...
Page 72 23E-10-2 V5A51 - Underdrive Clutch Disassembly steps "EA 1. Snap ring "BA 8. Return spring "DA 2. Reaction plate 9. Underdrive clutch piston "DA 3. Clutch disc "AA 10. D-ring "DA 4. Clutch plate "AA 11. D-ring AA" "CA 5. Snap ring "AA 12.
Page 73 23E-10-3 V5A51 - Underdrive Clutch "DA CLUTCH PLATE / CLUTCH DISC / REACTION PLATE INSTALLATION 1. Alternately assemble the clutch plates and clutch discs in the underdrive clutch retainer. When assembling the four clutch plates, align the seciton having no teeth (A in the illustration) with the underdrive clutch retainer hole (B in the illustration).
Page 74 23E-11-1 V5A51 - Valve Body 11. VALVE BODY DISASSEMBLY AND ASSEMBLY 11 ± 1 Nm 11 ± 1 Nm Apply automatic transmission fluid to all moving parts before installation. 6 ± 1 Nm 11 ± 1 Nm Disassembly steps "GA 1. Manual valve pin 9.
Page 75 23E-11-2 V5A51 - Valve Body 6 ± 1 Nm Apply automatic transmission fluid to all moving parts before installation. Disassembly steps 16. Solenoid support 28. Fail-safe valve A AA" "AA 17. Low/reverse brake solenoid valve 29. Fail-safe valve A spring AA"...
Page 76 23E-11-3 V5A51 - Valve Body Apply automatic transmission fluid to all moving parts before installation. 11 ± 1 Nm 11 ± 1 Nm Disassembly steps 39. Manual valve 57. Underdrive clutch pressure control 40. Roller valve 41. Low/reverse brake pressure control 58.
Page 77 23E-11-4 V5A51 - Valve Body DISASSEMBLY SERVICE POINT AA" SOLENOID VALVE REMOVAL Before removing the solenoid valves, make marks with white paint, etc., so that these valves can be reinstalled in the original positions. ASSEMBLY SERVICE POINTS "AA SOLENOID VALVE INSTALLATION 1.
Page 78 23E-11-5 V5A51 - Valve Body "DA KNOCK BUSHING INSTALLATION Install the knock bushing onto the lower valve body position shown in the illustration. 4.5 mm "EA SPRING / STEEL BALL (LINE RELIEF) INSTALLATION Install the spring (7 mm in diameter, 17.3 mm in length) and Steel ball the steel ball (6.4 mm in diameter) onto the lower valve body...
Page 79 23E-11-6 V5A51 - Valve Body "GA MANUAL VALVE INSTALLATION Fit the manual valve pin into the groove of the manual valve. Manual valve Manual valve pin Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I Added...
Page 80 23E-12-1 V5A51 - Direct Annulus Gear 12. DIRECT ANNULUS GEAR DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. Disassembly steps 1. Snap ring "AA 5. Thrust bearing No.11 2. Output flange 6. Underdrive clutch "BA 3. Thrust bearing No.10 7.
Page 81 23E-12-2 V5A51 - Direct Annulus Gear "BA THRUST BEARING NO.10 INSTALLATION Apply vaseline or petrolatum jelly on the thrust bearing No.10, and then install on the underdrive clutch hub. Thrust bearing No.10 Caution Take care not to mistake the thrust bearing No.10 mounting direction.
Page 82 23E-13-1 V5A51 - Direct Clutch 13. DIRECT CLUTCH DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. 10 11 Disassembly steps "DA 1. Snap ring "CA 2. Reaction plate "CA 3. Clutch disc "CA 4. Clutch plate AA"...
Page 83 23E-13-2 V5A51 - Direct Clutch DISASSEMBLY SERVICE POINT MB991630 MD998924 AA" SNAP RING REMOVAL 1. Set the special tools as shown in the illustration. 2. Compress the return spring, and remove the snap ring. Snap ring ASSEMBLY SERVICE POINTS "AA D-RING INSTALLATION 1.
Page 84 23E-13-3 V5A51 - Direct Clutch "DA SNAP RING INSTALLATION Snap ring 1. Install the snap ring in the direct clutch retainer groove. 2. Press the entire periphery of the reaction plate with a force of 49 N, and confirm that the clearance between...
Page 85: Output Shaft Support
23E-14-1 V5A51 - Output Shaft Support 14. OUTPUT SHAFT SUPPORT DISASSEMBLY AND ASSEMBLY Apply automatic transmission fluid to all moving parts before installation. Disassembly steps 1. Snap ring 3. Seal ring "AA 2. One-way clutch 4. Output shaft support ASSEMBLY SERVICE POINT "AA ONE-WAY CLUTCH INSTALLATION...
Page 86 23E-15-1 V5A51 - Transfer 15. TRANSFER DISASSEMBLY AND ASSEMBLY 35 ± 6 Nm Apply gear oil to all 35 ± 6 Nm moving parts before installation. 35 ± 6 Nm 35 ± 6 Nm 11 ± 1 Nm 19 ± 2 Nm 35 ±...
Page 87 23E-15-2 V5A51 - Transfer Disassembly steps 1. Vacuum hose "VA 17. Transfer case cover "WA 2. 4LLC switch "UA 18. Shift rail drive gear 3. Gasket "UA 19. Shift rail drive gear 4. Steel ball 20. Dust seal guard "WA 5. 2WD switch 21.
Page 88 23E-15-3 V5A51 - Transfer Apply gear oil to all 35 ± 6 Nm moving parts before installation. 35 ± 6 Nm Disassembly steps "SA 32. Rear cover "MA 50. Drive sprocket "RA 33. Oil seal 51. Bearing 34. Snap ring "LA 52.
Page 89 23E-15-4 V5A51 - Transfer Apply gear oil to all moving parts before installation. 20 ± 2 Nm 35 ± 6 Nm 35 ± 6 Nm Disassembly steps "GA 67. Transfer case plate 76. Bearing 68. Bearing "CA 77. Rear bearing retainer 69.
Page 90 1. Use the special tools to install the oil seal on the transfer MB990932 case. 2. Apply grease to the lip of the oil seal. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent "CA REAR BEARING RETAINER INSTALLATION The bolts used for mounting the rear bearing retainer are pre-coated ones.
Page 91 H-L shift fork and H-L clutch sleeve in combined state in the transfer case. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent "FA SPACER INSTALLATION 1. Put pieces of solder (approx. 10 mm long and 1.6 mm in diameter) at the illustrated positions of the transfer case.
Page 92 (in the direction of the countershaft gear bearing hole). 3. Apply sealant to the illustrated position of the transfer case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze sealant out evenly to make sure that it is not broken or excessively supplied.
Page 93 2-4WD shift fork and 2-4WD clutch sleeve in combined state in the transfer case. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent "KA SNAP RING INSTALLATION Select a proper snap ring so that the end play of the 2-4WD clutch hub will have the standard value, and install it on the sun gear.
Page 94 "NA REAR OUTPUT SHAFT INSTALLATION Apply grease to the O-ring at the illustrated position and install the rear output shaft. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent "OA CHAIN COVER INSTALLATION 1. Apply grease to the indicated 2-4WD shift rail inserting portion.
Page 95 1. Use the special tools to install the oil seal in the rear MB990932 cover. 2. Apply grease to the lip of the oil seal. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent "SA REAR COVER INSTALLATION Apply sealant to the illustrated position of the chain cover. Specified sealant: MITSUBISHI genuine sealant part No.
Page 96 "TA MAIN SHIFT RAIL / SHIFT ACTUATOR INSTALLATION 1. Apply grease to the O-ring. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent 2. Combine the main shift rail key with actuator key and insert them in the transfer case.
Page 97: Transfer Case Plate
"AA OIL SEAL INSTALLATION MB990936 1. Use the special tool to install the oil seal. 2. Apply grease to the lip of the oil seal. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent Mitsubishi Motors Corporation Mar. 2000 PWEE8920-I...
Page 98 V5A51 - Transfer Case Plate "BA BOLT INSTALLATION Apply sealant to the threads. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent NOTE New bolts are precoated with sealant, so sealant does not need to be applied. Mitsubishi Motors Corporation Mar.
Page 99: Input Gear
23E-17-1 V5A51 - Input Gear 17. INPUT GEAR DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps "BA 1. Snap ring AA" "AA 2. Ball bearing 3. Snap ring (some model) 4. Cone spring (some model) 5.
Page 100 23E-17-2 V5A51 - Input Gear "BA SNAP RING INSTALLATION 1. Install the thickest snap ring that can be fitted in the snap ring groove of the input gear. 2. Make sure that the ball bearing end play meets the standard value.
Page 101 23E-18-1 V5A51 - Countershaft Gear 18. COUNTERSHAFT GEAR DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation. AB" "AA 4. Roller bearing Disassembly steps AB" "AA 5. Inner race AA" "CA 1. Ball bearing 6. Countershaft gear "BA 2.
Page 102 23E-18-2 V5A51 - Countershaft Gear ASSEMBLY SERVICE POINTS "AA INNER RACE / ROLLER BEARING / SPACER INSTALLATION MD998812 1. Using the special tool, install the inner race. MD998818 2. Install the roller bearing and spacer. "BA SNAP RING INSTALLATION Install the thickest snap ring that can be fitted in the snap ring groove of the countershaft gear.
Page 103: Rear Output Shaft
23E-19-1 V5A51 - Rear Output Shaft 19. REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps "CA 1. Snap ring 2. Annulus gear "BA 3. Snap ring AA" "AA 4. Ball bearing 5.
Page 104 23E-19-2 V5A51 - Rear Output Shaft "BA SNAP RING INSTALLATION 1. Install the thickest snap ring that can be fitted in the snap ring groove of the rear output shaft. 2. Make sure that the rear output shaft bearing end play meets the standard value.
Page 105 23E-20-1 V5A51 - Front Output Shaft 20. FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps AA" "BA 1. Ball bearing 2. Sensor rotor AB" "AA 3. Ball bearing 4. Front output shaft DISASSEMBLY SERVICE POINT AA"...
Page 106 23E-20-2 V5A51 - Front Output Shaft ASSEMBLY SERVICE POINTS MD998812 "AA BALL BEARING INSTALLATION 1. Use the special tool to support the front output shaft. MD998818 2. Use the special tools to install the ball bearing. "BA BALL BEARING INSTALLATION 1.
Page 107: Transfer Drive Shaft
23E-21-1 V5A51 - Transfer Drive Shaft 21. TRANSFER DRIVE SHAFT DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps AA" "AA 1. Ball bearing 2. Transfer drive shaft DISASSEMBLY SERVICE POINT AA" BALL BEARING REMOVAL Use the special tool to remove the ball bearing.
Page 108: Shift Rail Drive Gear
23E-22-1 V5A51 - Shift Rail Drive Gear 22. SHIFT RAIL DRIVE GEAR DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps 1. Snap ring 4. Shift rail drive gear shaft "AA 2. Shift rail drive gear 5.
Page 109: Wd Shift Rail And H-L Shift Rail
Apply grease to the outer periphery of the shift fork mounting portion of the shift rail and then assemble the shift fork and shift rail. Specified grease: Mitsubishi genuine grease part No. 0101011 or equivalent "BA SPRING PIN INSTALLATION H-L shift rail...
Page 110 NOTES...

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V5a51-7-aca V5a51-7-sda V5a51-7-cca1 V5a51-7-cca2 V5a51-7-sda1