ATSG F4A41.pdf

Technic al Service Informat ion TRANSAXLE DISASSEMBLY INTERNAL COMPONENTS(CONT'D) 73. Rotate the transaxle so the front side is facing up, as shown in Figure 56, and remove allen head socket. 74. Remove the two shafts retaining the parking roller support, as shown in Figure 57. Note: The park in g pawl pi vot pin and park roll er support shafts are soft an d wil l bend or bu r r easily, so use care when removin g. 75. Remove the two shafts and the parking rod roller support, as shown in Figure 58.

Remove these two shaf ts fi r st.

PARKING ROLLER SUPPORT

Continued on P age 38

Copyr ight © 2005 ATSG

Figure 57 RETAINING SHAFTS

F 4A41 & F 4A42 = 3/4" (19 mm) Al len Head Socket F 4A51 = 15/16" (24 mm) All en H ead Socket


T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

1 E5B K2 51 F4A


Figure 56


Figure 58

AUTOMATIC TRANSMISSION SERVICE GRO UP

37

Technic al Service Informat ion TRANSAXLE DISASSEMBLY INTERNAL COMPONENTS(CONT'D) 76. Unhook the parking pawl return spring and remove the parking pawl pivot shaft, as shown in Figure 59. Note: The park pawl pivot pin and par k roll er support shafts are soft an d wil l bend or bu rr easily, so use care when removin g. 77. Remove the parking pawl, parking pawl spring and bushing, as shown in Figure 59. 78. Remove the four pinion shaft support to case retaining bolts, as shown in Figure 60.

79. Remove the pinion shaft and transfer gear as assembly, as shown in Figure 60, by tapping on the rear of pinion shaft with hammer and punch. 80. Set the complete pinion shaft, support, and transfer driven gear assembly aside for the component rebuild section.


BEARING SUPPORT RETAINING BOLTS (4 REQUIRED)

4

1

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

3

2

9 6 7

PINION SHAFTAND DRIVEN TRANSFER GEAR ASSEMBLY

1 5 A 4

5B1 K2E 51 F4A

1 2 3 4

PARKING PAWL PIVOTPIN. PARKING PAWL. PARKING PAWL RETURN SPRING. PARKING PAWL SPACER.


Figure 59

38


Figure 60

AUTOMATIC TRANSMISSION SERVICE GR OUP

Technic al Service Informat ion TRANSAXLE DISASSEMBLY INTERNAL COMPONENTS(CONT'D) 81. Remove the transfer drive gear by accessing the retaining bolts through the access holes provided, as shown in Figure 61. Note: T he tapered rol ler bear in g models wil l have 7 or 8 retain in g bolts. The ball beari ng models wil l have onl y 4 retain in g bolts. 82. Rotate the transfer gear as necessary so the access holes are over the bolts for removal. Note: Reference mar ks must be placed on case and bearing housin g (See F igur e 61). H ousin g bolts in case in 1 dir ection onl y. 83. Remove the transfer drive gear assembly, as shown in Figure 62. Note: I f beari ng service is not n ecessar y, the tr ansfer drive gear does not need to be removed from the case. 84. Set the complete transfer drive gear assembly aside for the component rebuild section.

SPECI AL NOTE: M itsubishi services the tr ansfer dr ive gear and bearings only as an assembly, on the models equi pped with the tapered r oll er style bear ings. Th e exploded views provided in this manual of the tr ansfer dri ve gear and beari ngs are for r eference only. I f beari ng ser vice is necessar y you must pur chase the complete assembly f r om M itsubishi.

RETAINING BOLTS FOUR, SEVEN, OR EIGHT, (MODEL DEPENDENT)

C ENTER PUNC H OR PERM AN ENT M ARKER O N C ASE AND BEARING HO USING TRANSFER DRIVE GEAR ASSEMBLY

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

B1 2E5 51K F4A

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

5 F4A

9 6 7

9 6 7

B1 E5 1K2


Figure 61

Figure 62


39

Technic al Service Informat ion COMPONENT REBUILD SECTION

BALL BEARING STYLE TORQUENUT TO 191NM(141FT.LB.)

TRANSFER DRIVE GEAR ASSEMBLY 1. If you are servicing ball bearing style, install the ball bearings and torque the lock nut to 191 N·m (141 ft.lb.), as shown in Figure 63. 2. Set the completed transfer drive gear assembly aside for the final assembly process. M itsubishi services the tr ansfer dri ve gear and bearings only as an assembly, on the models equi pped with the tapered roll er style bear ings.

Figure 63 TRANSFERDRIVEGEAR "WITHOUT" LOWSPRAG

TRANSFERDRIVEGEAR "WITH" LOWSPRAG 5

5 2

3 2

I ll ustration F or Reference Only Ser viced Onl y As Assembly F rom M itsubishi

4

4

3 2 2 1 1

1 2 4 5

TRANSFERDRIVE GEARBEARING NUT (1STDESIGN). TRANSFERDRIVE GEAR"BALL" BEARING (2 REQUIRED). TRANSFERDRIVE GEARBEARING HOUSING. TRANSFERDRIVEGEAR.

1 2 3 4 5

TRANSFERDRIVE GEARBEARING NUT (2ND DESIGN). TRANSFERDRIVEGEAR"TAPERED ROLLER" BEARING (2 REQ.). TRANSFERDRIVE GEARBEARING CUP(2 REQUIRED). TRANSFERDRIVE GEARBEARING HOUSING. TRANSFERDRIVEGEAR.


Figure 64

40


Technic al Service Informat ion COMPONENT REBUILD SECTION TRANSFER DRIVEN GEAR ASSEMBLY 1. Disassemble the transfer driven gear and the pinion shaft assembly using Figure 65 as a guide. Note: Pi ni on shaft must be pressed out of the tr ansfer dri ven gear, using hydrau li c press. 2. Clean all parts with cleaning solution and dry with compressed air. 3. Inspect all pinion shaft parts thoroughly for any wear and/or damage, and replace as necessary. Continued on P age 42 TRANSFER DRIVEN GEAR AND PINION SHAFT EXPLODED VIEW 4 2

1

® N E K

M I T

6

5

3

7

0 NP 8 8 9 9 6 P 9 0 7 U S A

8

9

10

11

INSTALLED FROM REAR COVER SIDE OF THE CASE

1 2 3 4 5 6

PINION SHAFTASSEMBLY. PINION SHAFTLARGETAPERED ROLLERBEARING. PINION SHAFTLARGE ROLLERBEARING CUP. PINION SHAFTBEARING SUPPORT. TRANSFERDRIVEN GEARASSEMBLY. BEARING COLLAR.

7 8 9 10 11

SNAP RING FOR CASEBORE. BEARING SHIM (SELEC TIVE). PINION SHAFTSMALL ROLLER BEARING C UP. PINION SHAFTSMALL TAPERED ROLLER BEARING. PINION SHAFTRETAINING NUT (LEFT HAND THREAD ).


Figure 65


41

Technica l Service Informat ion COMPONENT REBUILD SECTION TRANSFER DRIVEN GEAR ASSEMBLY(CONT'D) 3

4

3 PINION SHAFTLARGE ROLLERBEARING CUP. 4 PINION SHAFTBEARING SUPPORT.


Figure 66

INSTALLATION TOOLSREQUIRED

F4A42 = MD998823 F4A51 = MD998827

MD998814

MD998812

4. Press new pinion shaft large roller bearing cup into the bearing support, as shown in Figure 66 using proper adapters and hydraulic press. 5. Install new pinion shaft large roller bearing on pinion shaft, as shown in Figure 67, using the proper adapters and hydraulic press. 6. Install the completed bearing support assembly onto pinion shaft and roller bearing assembly, as shown in Figure 68. 7. Install the driven transfer gear onto the pinion shaft, as shown in Figure 69, and start onto the splines. Note: T he dri ven tr ansfer gear m ust be pressed onto pin ion shaf t with hydrau li c pr ess, un til ful ly seated. 8. Install the bearing collar over pinion shaft and onto installed driven transfer gear, as shown in Figure 69, and retain with a liberal amount of Trans-Jel®. 9. Set the completed pinion shaft assembly aside for the final assembly process (See Figure 70). Continued on P age 43 BEARING SUPPORT ASSEMBLY

2

1 PINION SHAFT AND BEARING ASSEMBLY

1 PINION SHAFTASSEMBLY. 2 PINION SHAFTLARGE TAPERED ROLLER BEARING.


Figure 67

42


Figure 68


Technic al Service Informat ion COMPONENT REBUIL ILD SECTIO ION

INSTALL DRIV IVEN TRANSFER GEAR WITH HYDRAULIC IC PRESS

TRANSAXLE CASE ASSEMBLY

BEARING COLLAR

DRIVEN TRANSFER GEAR

1. Clean Clean transaxle transaxle case thoroughly with with solution and dry with compressed air. 2. Inspect the transaxle transaxle case thoroughly for any wear and/or damage. 3. Install Install new differential bearing cup into case, as shown in Figure 71, using the proper driver. driver. Note: We We wil l cover cover pr e-load -l oad for dif ferenti al dur in g the fi nal ass assembly procedur procedur e. Continued on P age 44

BEARING CUP CUP


Figure 69

COMPLE LETED ED PIN INIO ION SHAFT ASSEMBLY Retain Retain Bearin g Collar With L iberal iberal Amount Of Tr ans-Jel® ans-Jel®

1 E5B K2 51 F4A

C op yr igh t © 2005 AT SG

Figure 70

C op yr igh t © 2005 AT SG

Figure 71

AUTOMATIC AUTOMATIC TRANSMISSION SERVICE GRO UP

43

Technic al Service Informat ion COMPONENT REBU BUIL ILD SECTIO ION TRANSAXLE CASE ASSEMB MBLY (C (CONT'D 'D) 4. If case snap ring was removed, re-install re-install the snap ring into case, as shown in Figure 72. 5. If bearing service was necessary, necessary, install new small bearing cup into the case, as shown in Figure 72, using the original selective spacer. Note: We wil l cover cover t he pr pr e-load -l oad f or pi ni on shaf t dur in g the f in al ass assembly procedur procedur e. 6. Set the completed case assembly aside for the final assembly process.

COMPONENT REBUIL ILD SECTIO ION REA EARCOVERASSEMBLY Before proceeding with the rear cover component rebuild section, it is imperative that the journal and seal ring area of the rear cover be inspected very closely for any wear and/or damage, as shown in Figure 73. Ensure that sealing ring groove clearance is within specification using feeler gage. M itsubishi itsubishi r ecomme commends nds thorough fl ushi ushi ng of the tr ansaxle ansaxle cooler cooler on all r ebui lds.


9 8 7

M AXIM AXIM UM SEALING ALING RING RING C LEARANC ARANC E IS APPRO XIM ATEL ATELY Y .004"-.005" OVERDRIVE SEALI NG RINGS

USE FEELE FEELER R G AG E BETWEEN BETWEEN SEALING SEALIN G RING AND RING LAND

7 SNAP RING FOR C ASEBORE. BORE. 8 BEARING SHIM (SELE (SELEC C TIVE). 9 PINIO PINION SHAFTSMALL ROLLERBEARING C UP.

Copyr ight © 2005 ATSG ATSG

Figure 72


Figure 73

44


Technic al Service Informat ion COMPONENT REBU BUIL ILD SECTIO ION REA EAR COVER ASSEMB MBLY 1. Remove and discard the overdrive clutch seal rings and the reverse clutch seal rings. 2. Inspect Inspect the end cover journal and sealing ring area for any wear and/or damage and check seal ring groove clearance with a feeler gage, as described in Figure 73. 3. Clean the end cover thoroughly and dry with compressed compre ssed air. 4. Install new reverse clutch sealing rings into into the grooves, as shown in Figure 74, and ensure that they are properly hooked and seated. 5. Install Install new overdrive clutch sealing rings into grooves, as shown in Figure 74, and ensure that they are properly hooked and seated. 6. Install Install the selective number 8 thrust plate, as shown in Figure 74, and retain with a small amount of Trans-Jel®. Trans-Jel®. 7. Set the completed rear cover assembly aside for the final assembly process (See Figure 75).

NUMBER 8 THRUST PLATE SELE SELEC C TIVE

SPECI PECI AL NOTE: All Friction Plates Should Be Soaked In The Recommended ATF For One Hour Before I nstallati on. L ets Start Now.

COMPONENT REBUILD SECTION Continued on P age 47

COMPL PLET ETED ED REAR COVER ASSEMB MBLY

OVERDRIVE C LUTC H SEAL RINGS Ensure That Seal Seal Rin gs Are Properly H ooked ooked As Shown

REVERSE C LUTC H SEAL RINGS

NUMBER 8 THRUST PLATE SELE SELEC C TIVE

Copyr ight © 2005 ATSG ATSG

Figure 74


Figure 75


45

Technica l Service Informat ion REVERSE/OVERDRIVECLUTCHHOUSINGEXPLODEDVIEW 7

3

1

2

5

6

9

B W

4

8

16 11

14

12

15

17

13 10

1 5 A 5 F

20

18

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

REVERSECLUTCH BACKING PLATESNAP RING (SELEC TIVE). REVERSECLUTCH BACKING PLATE(.160" THICK). REVERSECLUTCH FRICTION PLATES. REVERSECLUTCH STEEL PLATES(.073" THIC K). OVERDRIVECLUTCH BACKING PLATESNAP RING (SELECTIVE). OVERDRIVECLUTCH BACKING PLATE(.240" THICK). OVERDRIVECLUTCH FRICTION PLATES. OVERDRIVECLUTCH STEEL PLATES(.099" THICK). OVERDRIVECLUTCH APPLYPLATE(.160" THICK). OVERDRIVEBALANCEPISTON RETAINING SNAP RING. OVERDRIVECLUTCH BALANCEPISTON. OVERDRIVECLUTCH BALANCEPISTON "D" RING SEAL. OVERDRIVECLUTCH APPLYPISTON RETURN SPRING. OVERDRIVECLUTCH APPLYPISTON. OVERDRIVECLUTCH APPLY PISTON "D" RING SEAL. REVERSECLUTCH APPLYPISTON. REVERSECLUTCH APPLYPISTON "D" RING SEAL. OVERDRIVECLUTCH PISTON INNER"D" RING SEAL. REVERSECLUTCH APPLYPISTON INNER"D" RING SEAL. REVERSE CLUTCH RETAINER ASSEMBLY.


Figure 76

46


Technic al Service Informat ion COMPONENT REBUILD SECTION OVERDRIVE/REVERSE HOUSINGASSEMBLY 1. Disassemble overdrive/reverse clutch housing using Figure 76 as a guide. 2. Clean all overdrive/reverse parts thoroughly with a good cleaning solution and dry with compressed air. 3. Inspect all overdrive/reverse parts thoroughly for any wear and/or damage. 4. Install new inner piston "D" ring seals into the grooves in reverse clutch retainer assembly, as shown in Figure 77, and lube with a small amount of Trans-Jel®. 5. Install new outer "D" ring seal onto reverse clutch apply piston, as shown in Figure 78, and lube with small amount of Trans-Jel®. 6. Install new outer "D" ring seal onto overdrive clutch apply piston, as shown in Figure 79, and lube with small amount of Trans-Jel®.

16

17

Continued on P age 48 16 REVERSE CLUTCH APPLY PISTON. 17 REVERSECLUTCH APPLYPISTON "D" RING SEAL.


Figure 78

18

19

15 20

14

18 OVERDRIVECLUTCH PISTON INNER"D" RING SEAL. 19 REVERSECLUTCH APPLYPISTON INNER"D" RING SEAL. 20 REVERSE CLUTCH RETAINER ASSEMBLY.

14 OVERDRIVECLUTCH APPLYPISTON. 15 OVERDRIVECLUTCH APPLYPISTON "D" RING SEAL.


Figure 77


Figure 79


47

Technic al Service Informat ion COMPONENT REBUILD SECTION

10

OVERDRIVE/REVERSE HOUSINGASSEMBLY(CONT'D) 7. Install new "D" ring seal onto overdrive clutch balance piston, as shown in Figure 80, and lube with a small amount of Trans-Jel®. 8. Install the completed reverse apply piston into the retainer, aligning the lube holes, as shown in Figure 81, and ensure that it is fully seated. 9. Install the completed overdrive apply piston into the reverse apply piston, as shown in Figure 81, and ensure that it is fully seated. 10. Install the overdrive clutch piston return spring as shown in Figure 81. Note: En sur e ali gnment h oles ar e seated over the dowels on piston (See F igur e 81). 11. Install the overdrive clutch balance piston over return spring assembly, as shown in Figure 81, and lay snap ring on top of piston. 12. Compress the return spring assembly with a spring compressor, install the snap ring into groove with snap ring pliers, and remove the spring compressor.

11

ALIGN HOLE AND DOWEL

13

14

16


12

20

ALIGN LUBE HOLES

11

11 OVERDRIVECLUTCH BALANCEPISTON. 12 OVERDRIVECLUTCH BALANCEPISTON "D" RING SEAL.

10 11 13 14 16 20

OVERDRIVEBALANCEPISTON RETAINING SNAPRING. OVERDRIVECLUTCH BALANC EPISTON. OVERDRIVECLUTCH APPLYPISTON RETURN SPRING. OVERDRIVE CLUTCH APPLYPISTON AND SEAL ASSEMBLY REVERSECLUTCH APPLYPISTON AND SEAL ASSEMBLY REVERSE CLUTCH RETAINERASSEMBLY.


Figure 80

48


Figure 81


Technic al Service Informat ion

5

6 B

7

8

OVERDRIVE/REVERSEHOUSINGASSEMBLY(CONT'D) 13. Install the overdrive clutch plates beginning with a normal steel plate or a thicker apply plate depending on the model. Note: Th e F 4A51 uni t has an apply plate that is .160" th ick and has a r ounded edge that goes towar d li ned plate (See F igur e 83). 14. Install the apply plate so that the places with no teeth are aligned with the lube holes in the retainer, as shown in Figure 83. 15. Alternate with friction and normal steel plates, as shown in Figure 82, until you have installed 4 frictions and three steel plates. Note: Al ign the steel pl ates so that the places with no teeth are ali gned with the lu be hol es in the retain er (See F igur e 83). Fr iction plates shoul d be soaked in ATF for 1 hour . 16. Install the overdrive clutch backing plate, as shown in Figure 82, with the rounded edge toward friction plate. Note: A li gn the backing plate with th e lube hol es in retainer as you did the steel plates. 17. Install the selective backing plate snap ring, as shown in Figure 82 Continued on P age 50

9

LUBE HOLE

LUBE HOLE 20

SPAC E BETWEEN TEETH ON STEEL PLATE

F5 A51

ROUNDED EDGE TOWARDS FRICTION

BACKING PLATE

F4A42 UNIT

ROUNDED EDGE TOWARDS FRICTION 5 6 7 8 9 20

OVERDRIVECLUTCH BACKING PLATESNAPRING (SELECTIVE). OVERDRIVECLUTCH BACKING PLATE(.240" THICK). OVERDRIVECLUTCH FRICTION PLATES. OVERDRIVECLUTCH STEEL PLATES(.099" THICK). OVERDRIVECLUTCH APPLYPLATE(.160" THICK). REVERSE CLUTCH RETAINER ASSEMBLY.

F4A51 UNIT


Figure 82

BACKING PLATE


Figure 83


49

Technica l Service Informati on UNDERDRIVE AND OVERDRIVE SELECTIVE SNAP RING CHART 40 SERIES Thickness 1.6 mm (.063" ) 1.7 mm (.067" ) 1.8 mm (.071" ) 1.9 mm (.075" ) 2.0 mm (.079" )

I .D. Color None Blue Br own None Blue

2.1 mm (.083" ) 2.2 mm (.087" ) 2.3 mm (.091" ) 2.4 mm (.094" ) 2.5 mm (.098" ) 2.6 mm (.102" ) 2.7 mm (.106" ) 2.8 mm (.110" ) 2.9 mm (.114" ) 3.0 mm (.118" )

Br own None Blue Br own None Blue Brown None Blue Brown

50 SERIES Part N umber MD759666 M D759667 M D759668 M D752124 M D752125 M D752126 M D752127 M D752128 M D752129 M D752130 M D752131 M D752132 M D752133 M D752134 M D754680

Thickness 1.6 mm (.063" )

I .D. Color Brown

1.7 mm (.067" ) 1.8 mm (.071" ) 1.9 mm (.075" ) 2.0 mm (.079" )

None Blue Brown None

2.1 mm (.083" ) 2.2 mm (.087" ) 2.3 mm (.091" ) 2.4 mm (.094" ) 2.5 mm (.098" ) 2.6 mm (.102" ) 2.7 mm (.106" ) 2.8 mm (.110" ) 2.9 mm (.114" ) 3.0 mm (.118" )

Blue Brown None Blue Brown None

Part N umber MD759960

Blue Brown None Blue

M D759961 M D759962 M D759963 M D750841

M D750842 M D750843 M D750844 M D750845 M D750846 M D750847 M D750848 M D750849 M D750850 M D750851

Figure 84

COMPONENT REBUILD SECTION OVERDRIVE/REVERSE HOUSINGASSEMBLY(CONT'D) 18. Install the clutch compressing tools as shown in Figure 85 and 86. Note: T he over dri ve li ned plates are " Waved" and must be compr essed as shown to achi eve the proper clut ch clearance reading. 19. Compress the plates and measure with feeler gage between snap ring and backing plate, as shown in Figure 86. 20. With the plates compressed clutch clearance should be 1.6-1.8 mm (.063"-.071").

21. Change the selective snap ring as necessary using the chart in Figure 84, to obtain proper overdrive clutch clearance. Continued on P age 51

OVERDRIVECLUTCHCLEARANCE 1.6-1.8 MM (.063"-.071")

F5 A51

B

F4A42 = MB991628 F4A51 = MB991629

MD998924


Figure 85

50


Figure 86


Technic al Service Informat ion COMPONENT REBUILD SECTION OVERDRIVE/REVERSEHOUSINGASSEMBLY(CONT'D) 22. Install the reverse clutch plates beginning with a steel plate and alternating with friction plates until you have installed two of each, as shown in Figure 87. Note: F r icti on pl ates shoul d be soaked in ATF for 1 hour, pri or to install ation. 23. Install the reverse clutch backing plate with the rounded edge towards friction plate, as shown in Figure 87 and 88. 24. Install the reverse clutch backing plate snap ring, as shown in Figure 87.

1

2

Continued on P age 52 W

3 4

20


F5 A51

BACKING PLATE

B

1 2 3 4 20

REVERSECLUTCH BACKING PLATESNAP RING (SELEC TIVE). REVERSECLUTCH BACKING PLATE(.160" THICK). REVERSECLUTCH FRICTION PLATES. REVERSECLUTCH STEEL PLATES(.073" THIC K). REVERSE CLUTCH RETAINER ASSEMBLY.


Figure 87


Figure 88


51

Technic al Service Informat ion REVERSE CLUTCH SELECTIVE SNAP RING CHART 40 SERIES

50 SERIES Part N umber MD761085 M D761086 M D761087 M D752137 M D752138


I .D. Color None Blue Br own None Blue

Part N umber MD761088 M D761089 M D761090 M D758947 M D756690

Thickness 1.6 mm (.063" ) 1.7 mm (.067" ) 1.8 mm (.071" ) 1.9 mm (.075" ) 2.0 mm (.079" )

I .D. Color None Blue Brown None Blue

2.1 mm (.083" ) 2.2 mm (.087" ) 2.3 mm (.091" )

Brown None Blue

M D752139 M D752140 M D752141

2.1 mm (.083" ) 2.2 mm (.087" ) 2.3 mm (.091" )

Br own None Blue

2.4 mm (.094" ) 2.5 mm (.098" ) 2.6 mm (.102" ) 2.7 mm (.106" ) 2.8 mm (.110" )

Brown None Blue Brown None

M D752142 M D752143 M D752144 M D752145 M D752146

2.4 mm (.094" ) 2.5 mm (.098" ) 2.6 mm (.102" ) 2.7 mm (.106" ) 2.8 mm (.110" )

Br own None Blue Br own None

1.7 mm (.067" ) 1.8 mm (.071" ) 1.9 mm (.075" ) 2.0 mm (.079" )

M D756691 M D756692 M D756693

M D756694 M D756695 M D756696 M D756697 M D756698

Figure 89

COMPONENT REBUILD SECTION OVERDRIVE/REVERSE HOUSINGASSEMBLY(CONT'D) 25. Install the clutch compressing tools that are shown in Figure 91. Note: Th e r everse li ned plates ar e " Waved" and must be compr essed as shown to achi eve the proper clut ch clearance r eading.

REVERSE CLUTCHCLEARANCE 1.5-1.7 MM(.059"-.067")

26. Compress the plates and measure with feeler gage between snap ring and backing plate, as shown in Figure 90. Note: Pr oper compression can at ti mes be achieved by hand, as shown in Fi gur e 90, as there are onl y 2 fr icti on plates. 27. With the plates compressed clutch clearance should be 1.5-1.7 mm (.059"-.067"). 28. Change the selective snap ring as necessary using the chart in Figure 89, to obtain proper reverse clutch clearance. Continued on P age 53 REVERSE CLUTCHCOMPRESSION TOOL

F5 A51

B

F4A42 = MB991790 F4A51 = MB991789

MD998924


Figure 90

52


Figure 91


Technic al Service Informat ion COMPONENT REBUILDSECTION OVERDRIVE/REVERSE HOUSINGASSEMBLY(CONT'D) 29. Turn the overdrive/reverse clutch housing over as shown in Figure 92. 30. Install the number 7 thrust bearing in direction shown in Figure 92, and retain with a small of Trans-Jel®. 31. Set the completed overdrive/reverse clutch housing aside for the final assembly process.

COMPONENT REBUILDSECTION OVERDRIVE CLUTCHHUB 1. Clean the overdrive clutch hub thoroughly in cleaning solution and dry with compressed air. 2. Inspect the overdrive clutch hub thoroughly for any wear and/or damage. 3. Install the number 6 thrust bearing in direction shown in Figure 93, and retain with a small amount of Trans-Jel®. 4. Set the completed overdrive clutch hub aside for the final assembly process (See Figure 94).

NUMBER 7 THRUSTBEARING

COMPLETEDOVERDRIVECLUTCHHUB

Copyr ight © 2005 ATSG Copyr ight © 2005 ATSG

Figure 94

Figure 92



OVERDRIVE CLUTCH HUB


Figure 93


53

Technica l Service Informat ion GEAR TRAIN EXPLODED VIEW 3

7 5 4

2

1

6

9

8

13 10

11

12

14

1 2 3 4 5 6 7 8 9 10 11 12 13 14

THRUSTBEARING RACENUMBER8 (SELECTIVE). THRUSTBEARING NUMBER7. REVERSEAND OVERDRIVECLUTCH HOUSINGS. THRUSTBEARING NUMBER6. OVERDRIVECLUTCH HUB. THRUSTBEARING NUMBER5. REVERSESUN GEAR AND SHELLASSEMBLY. PLANETARYRETAINING SNAP RING. OVERDRIVEPLANETARYCARRIER. THRUSTBEARING NUMBER4. UNDERDRIVE SUN GEAR. THRUSTBEARING NUMBER3. OUTPUTPLANETARYCARRIERASSEMBLY. OUTPUTINTERNAL RING GEAR.


Figure 95

54


Technic al Service Informat ion LOWSPRAGASSEMBLY(SOME MODELS) EXPLODED VIEW 15 18

16

15 OUTPUTINTERNAL RING GEAR. 16 LOW SPRAG END BEARINGS(2 REQUIRED).

17

16

17 LOW SPRAG ASSEMBLY. 18 LOW SPRAG ASSEMBLY RETAINER.


Figure 96

COMPONENT REBUILD SECTION

18

16

17

16

15

PLANETARY GEAR TRAIN ASSEMBLY 1. Disassemble the planetary gear train by first removing the snap ring, and using Figure 95 and 96 as a guide. 2. Clean all of the planetary gear train parts using a suitable cleaning solution and dry with compressed air. 3. Inspect all planetary gear train parts for any wear and/or damage, replace as necessary. Note: F 4A40 Series and F 4A50 Series have diff erent planetary gear r atios and wil l not in ter change. I nspect any replacement parts ver y careful ly. 4. Place output internal ring gear on a flat work surface, as shown in Figure 97. 5. Install one low sprag end bearing in direction shown in Figure 97, until fully seated. 6. Install the low sprag assembly into the ring gear so that the arrows are pointing down, as shown in Figure 97. 7. Install the second low sprag end bearing in the direction shown in Figure 97, until fully seated. 8. Install the low sprag assembly retainer by snapping it over the lip on the ring gear, as shown in Figure 97. Special N ote: L ow Sprag Assembly is not used on all models. Refer to Page 117 for specif ic details.

15 OUTPUTINTERNAL RING GEAR. 16 LOW SPRAG END BEARINGS(2 REQUIRED). 17 LOW SPRAG ASSEMBLY.



Figure 97


55

Technic al Service Informat ion COMPONENT REBUILD SECTION PLANETARYGEAR TRAIN ASSEMBLY(CONT'D) 9. Ensure that low sprag retainer is fully seated, as shown in Figure 98, and check it the full 360 degrees. 10. Turn the ring gear assembly over and set on device to raise it off of the work surface, as shown in Figure 99. 11. Install the output planetary carrier into output ring gear, as shown in Figure 99, and rotate to engage planetary gears. 12. Install the number 4 thrust bearing onto the overdrive carrier, as shown in Figure 100, and retain with Trans-Jel®. ENSURE THAT RETAINER IS FULLY SEATED

Continued on P age 57 Copyr ight © 2005 ATSG

Figure 98

OUTPUT PLANETARY CARRIER


OVERDRIVE PLANETARY CARRIER OUTPUT RING GEAR ASSEMBLY


BLOCKS


Figure 99

56


Figure 100


Technic al Service Informat ion COMPONENT REBUILD SECTION 8

9

10

11

12

OUTPUTCARRIER AND RING GEAR ASSEMBLY

8 9 10 11 12

PLANETARYGEAR TRAIN ASSEMBLY(CONT'D) 13. Install the number 3 thrust bearing into the output planetary carrier in the direction shown in Figure 101. 14. Install the underdrive sun gear into the output planetary carrier in the direction shown in Figure 101, and rotate into position to engage into planetary gears. 15. Ensure the number 4 thrust bearing (10) is still in place in the overdrive carrier (9). Refer to Figure 101. 16. Install the overdrive carrier and the number 4 thrust bearing as an assembly, by rotating into position, as shown in Figure 101. 17. Install the overdrive carrier retaining snap ring, as shown in Figure 101, and ensure that it is fully seated. 18. Set completed planetary gear train assembly aside for the final assembly process, as shown in Figure 102.


COMPLETED PLANETARY GEAR TRAIN ASSEMBLY

PLANETARYRETAINING SNAP RING. OVERDRIVEPLANETARYCARRIER. THRUSTBEARING NUMBER 4. UNDERDRIVE SUN GEAR. THRUSTBEARING NUMBER 3.


Figure 101


Figure 102


57

Technica l Service Informat ion COMPONENT REBUILD SECTION SUNGEARDRUMASSEMBLY 1. Install the number 5 thrust bearing onto the sun gear and shell assembly in the direction shown in Figure 103, and retain with a small amount of Trans-Jel®. 2. Set the completed sun gear and shell assembly aside for the final assembly process, as shown in Figure 104.

COMPONENT REBUILD SECTION 2ND CLUTCH PISTON ANDRETAINER ASSEMBLY 1. Disassemble the 2nd clutch retainer assembly using Figure 105 as a guide. 2. Remove and discard inner and outer "D" ring seal from the piston, as shown in Figure 105. 3. Clean the retainer and piston thoroughly with cleaning solution and dry with compressed air. 4. Inspect the retainer and piston thoroughly for any wear and/or damage. Replace as necessary. Continued on P age 59


2NDCLUTCHRETAINER EXPLODED VIEW SUN GEAR AND SHELL ASSEMBLY 51

52


Figure 103 53

COMPLETED SUN GEAR AND SHELL ASSEMBLY

54

51 2ND CLUTCH RETAINER. 52 2ND C LUTCH PISTON INNER"D" RING SEAL. 53 2ND C LUTCH PISTON OUTER"D" RING SEAL.


Figure 104

58


Figure 105


Technic al Service Informat ion COMPONENT REBUILD SECTION 2NDCLUTCHPISTON AND RETAINER (CONT'D) 5. Install new inner and outer "D" ring seals onto the 2nd clutch piston, as shown in Figure 106, and lube with a small amount of Trans-Jel®. 6. Lube the inside seal surfaces of the retainer with a small amount of Trans-Jel® and install the piston assembly into the retainer, as shown in Figure 107. 7. Use care so as not to cut the "D" ring seals during installation. 8. Set completed 2nd clutch piston and retainer assembly aside for the final assembly process, as shown in Figure 108.

52

53

54

COMPLETED 2NDCLUTCH PISTON ANDRETAINER ASSEMBLY

52 2ND CLUTCH PISTON INNER"D" RING SEAL. 53 2ND CLUTCH PISTON OUTER"D" RING SEAL. 54 2ND CLUTCH PISTON.


Figure 106


Figure 108 51

COMPONENT REBUILD SECTION Continued on P age 61 54

51 2ND CLUTCH RETAINER. 54 2ND C LUTCH PISTON AND SEALSASSEMBLY.


Figure 107


59

Technic al Service Informat ion UNDERDRIVE CLUTCHHOUSING EXPLODED VIEW 14 16

15

18 17

13

10

11

8

7

9 6

12

5

4

3 2

1. 2 . 3. 4. 5. 6. 7. 8. 9.

TURBINE SHAFTSEALING RINGS. TURBINE SHAFT. UNDERDRIVECLUTCH HOUSING TO PUMP THRUSTWASHER. UNDERDRIVECLUTCH HOUSING. TURBINE SHAFTRETAINING SNAP RING. UNDERDRIVECLUTCH HOUSING INNER"D" RING SEAL. UNDERDRIVE CLUTCH PISTON OUTER"D" RING SEAL. UNDERDRIVECLUTCH APPLYPISTON. UNDERDRIVECLUTCH PISTON RETURN SPRING ASSEMBLY.

10. 11. 12. 13. 14 . 15. 16. 17. 18.

1

UNDERDRIVE CLUTCH BALANC EPISTON "D" RING SEAL. UNDERDRIVE CLUTCH BALANC EPISTON. UNDERDRIVE CLUTCH BALANC EPISTON SNAP RING. UNDERDRIVE CLUTCH STEEL PLATES. UNDERDRIVE CLUTCH FRICTION PLATES. UNDERDRIVE CLUTCH BACKING PLATE. UNDERDRIVE CLUTCH BACKING PLATESNAP RING. UNDERDRIVE CLUTCH HUBTO DRUM THRUSTBEARING. UNDERDRIVE CLUTCH HUB.


Figure 109

60


Technic al Service Informat ion COMPONENT REBUILD SECTION UNDERDRIVE CLUTCHHOUSING 1. Disassemble the underdrive clutch housing using Figure 109 as a guide. 2. Clean all underdrive clutch housing parts with cleaning solution and dry with compressed air. 3. Inspect all underdrive clutch housing parts for any wear and/or damage. Replace as necessary. 4. Install new underdrive clutch inner "D" ring seal in underdrive clutch housing, as shown in Figure 110, and lube with a small amount of Trans-Jel®. 5. Install new underdrive clutch outer "D" ring seal onto underdrive clutch apply piston, as shown in Figure 111, and lube with a small amount of Trans-Jel®. 6. Install new "D" ring seal onto the underdrive clutch balance piston, as shown in Figure 112, and lube with a small amount of Trans-Jel®.

8

7

7. UNDERDRIVECLUTCH PISTON OUTER"D" RING SEAL. 8. UNDERDRIVECLUTCH APPLYPISTON.


Figure 111


6 11 4

10

4. UNDERDRIVECLUTCH HOUSING. 6. UNDERDRIVECLUTCH HOUSING INNER"D" RING SEAL.

10. UNDERDRIVE CLUTCH BALANC EPISTON "D" RING SEAL. 11. UNDERDRIVE CLUTCH BALANC EPISTON.


Figure 110


Figure 112


61

Technica l Service Informati on COMPONENT REBUILD SECTION UNDERDRIVE CLUTCHHOUSING(CONT'D) 7. Install the underdrive clutch piston assembly into the underdrive housing with a twisting motion, as shown in Figure 113. 8. Install the return spring assembly in direction shown in Figure 113, and ensure that holes in retainer are engaged over dowels on piston. 9. Install the underdrive clutch balance piston over the return spring assembly, as shown in Figure 113. 10. Compress the balance piston and return spring using the proper adapters and compressor. 11. Install the snap ring, as shown in Figure 113, and slowly remove the compression tool.

12

11

9


ALIGN HOLE AND DOWEL

8

4

4. 8. 9. 11. 12.

UNDERDRIVECLUTCH HOUSING. UNDERDRIVECLUTCH APPLYPISTON. UNDERDRIVECLUTCH PISTON RETURN SPRING ASSEMBLY. UNDERDRIVECLUTCH BALANCEPISTON ASSEMBLY. UNDERDRIVE CLUTCH BALANC EPISTON SNAP RING.


Figure 113

62


Technic al Service Informat ion COMPONENT REBUILD SECTION UNDERDRIVE CLUTCHHOUSING (CONT'D) 12. Install the underdrive clutch plates beginning with a steel plate and alternating with friction plates, as shown in Figure 115, until you have installed four of each. Note: Wh en in stall in g the steel plates, ali gn them so that the places with no teeth wil l be ali gned with the lu be hol es in the housing, as shown in F igur e 114. Note: F ricti on plates shoul d be soaked in ATF for 1 hour befor e install ation. 13. Install the underdrive clutch backing plate, as shown in Figure 114 and 115, with the rounded edge towards the friction. 14. Install the underdrive backing plate selective snap ring, as shown in Figure 115.

16

15


14 13

LUBE HOLE

LUBE HOLE

4 SPAC E BETWEEN TEETH ON STEEL PLATE


BACKING PLATE

ALL MODELS 4. 13. 14 . 15. 16.

UNDERDRIVECLUTCH HOUSING ASSEMBLY. UNDERDRIVE CLUTCH STEEL PLATES. UNDERDRIVE CLUTCH FRICTION PLATES. UNDERDRIVE CLUTCH BACKING PLATE. UNDERDRIVE CLUTCH BACKING PLATESNAP RING.


Figure 114


Figure 115


63

Technic al Service Informat ion UNDERDRIVE AND OVERDRIVE SELECTIVE SNAP RING CHART 40 SERIES Thickness 1.6 mm (.063" ) 1.7 mm (.067" ) 1.8 mm (.071" ) 1.9 mm (.075" ) 2.0 mm (.079" )

I .D. Color None Blue Brown None Blue

2.1 mm (.083" ) 2.2 mm (.087" ) 2.3 mm (.091" )

Brown None Blue

2.4 mm (.094" ) 2.5 mm (.098" ) 2.6 mm (.102" ) 2.7 mm (.106" ) 2.8 mm (.110" ) 2.9 mm (.114" ) 3.0 mm (.118" )

Brown None Blue Brown None Blue Brown

50 SERIES Part N umber MD759666 M D759667 M D759668 M D752124 M D752125

Thickness 1.6 mm (.063" ) 1.7 mm (.067" ) 1.8 mm (.071" ) 1.9 mm (.075" ) 2.0 mm (.079" )

I .D. Color Brown

None Blue Brown None

M D752126 M D752127 M D752128

2.1 mm (.083" ) 2.2 mm (.087" ) 2.3 mm (.091" )

M D752129 M D752130 M D752131 M D752132 M D752133 M D752134 M D754680

2.4 mm (.094" ) 2.5 mm (.098" ) 2.6 mm (.102" ) 2.7 mm (.106" ) 2.8 mm (.110" ) 2.9 mm (.114" ) 3.0 mm (.118" )

Part N umber MD759960

M D759961 M D759962 M D759963 M D750841

Blue Brown None

M D750842 M D750843 M D750844

Blue Brown None

M D750845 M D750846 M D750847 M D750848 M D750849 M D750850 M D750851

Blue Brown None Blue

Figure 116

COMPONENT REBUILD SECTION UNDERDRIVE CLUTCHHOUSING (CONT'D) 15. Install the clutch compressing tools, as shown in Figure 117 and 118. Note: U nderdr ive li ned plates are " Waved" on all models and must be compr essed as shown in F igu r e 118 to achieve the proper clut ch clearance r eading. The un der dri ve fr icti on plates wer e changed in M ay, 2000 to a fr iction with a l ess per ceptable wave, but must still be compressed. 16. Compress the plates and measure with feeler gage between snap ring and backing plate, as shown in Figure 118.

17. With the plates compressed clutch clearance should be 1.6-1.8 mm (.063"-.071"). 18. Change the selective snap ring as necessary, using the chart in Figure 116, to obtain proper underdrive clutch clearance. Continued on P age 65

UNDERDRIVECLUTCHCOMPRESSIONTOOL

F4A42 = MB991628 F4A51 = MB991629

MD998924

Figure 117

64


Figure 118


Technic al Service Informat ion COMPONENT REBUILD SECTION UNDERDRIVE CLUTCHHOUSING (CONT'D) 19. Install the turbine shaft through the underdrive clutch housing, as shown in Figure 119, install snap ring and ensure that it is fully seated. 20. Install the number 1 thrust washer, as shown in Figure 120, and retain with Trans-Jel®. 21. Install two new turbine shaft sealing rings, as shown in Figure 120, and ensure rotation. 22. Set the completed underdrive clutch housing aside for the final assembly process.

1

3

COMPONENT REBUILD SECTION Continued on P age 66 2

4

I nstall Snap Ring And Ensure F ull y Seated

1. 2. 3. 4.

TURBINE SHAFTSEALING RINGS. TURBINESHAFT. UNDERDRIVECLUTCH HOUSING TO PUMP THRUSTWASHER. UNDERDRIVECLUTCH HOUSING.


Figure 119


Figure 120


65

Technic al Service Informat ion COMPONENT REBUILDSECTION UNDERDRIVE CLUTCHHUB 1. Clean and inspect the underdrive clutch hub thoroughly. 2. Install the number 2 thrust bearing onto the underdrive clutch hub, in the direction shown in Figure 121, and retain with a small amount of Trans-Jel®. 3. Set the completed underdrive clutch hub aside for the final assembly process, as shown in Figure 122.

COMPONENT REBUILD SECTION DIFFERENTIAL ASSEMBLY 1. Disassemble the differential assembly using Figure 124 as a guide. 2. Clean and inspect all of the differential parts thoroughly. Replace as necessary. 3. If bearing service is required, the tools shown in Figure 123, or their equivalant will be necessary. Continued on P age 68 DIFFERENTIALREQUIREDSPECIAL TOOLS FOR BEARING SERVICE

17

18

MD998917 MD998812 17. UNDERDRIVE CLUTCH HUBTO DRUM THRUSTBEARING. 18. UNDERDRIVE CLUTCH HUB.

MD998820


Figure 121

COMPLETED UNDERDRIVE CLUTCH HUB

MD998814


Figure 122 MD998823


Figure 123

66


Technic al Service Informat ion DIFFERENTIALEXPLODEDVIEW 12

1

2

7

8

9

6

11

5 10

10 11

9

4 8

3

2

1 2 3 4 5 6 7 8 9 10 11 12

DIFFERENTIAL BEARING CUP(2 REQUIRED). DIFFERENTIAL TAPERED ROLLERBEARING (2 REQUIRED). DIFFERENTIAL RING GEARTO CARRIERBOLTS(8 REQUIRED). DIFFERENTIAL RING GEAR. DIFFERENTIAL CROSSSHAFT. DIFFERENTIAL CARRIERASSEMBLY. DIFFERENTIAL CROSSSHAFTRETAINING PIN. DIFFERENTIAL SIDEGEARWASHER. DIFFERENTIAL SIDEGEAR. DIFFERENTIAL PINION GEAR. DIFFERENTIAL PINION GEARWASHER. SELECTIVESHIM TO SETPRE-LOAD (C ONV HOUSING SIDE)

1


Figure 124


67

Technica l Service Informati on COMPONENT REBUILD SECTION DIFFERENTIALASSEMBLY 4. Remove the bearings using the split puller and the appropriate size general service gear puller as shown in Figure 125. 5. Install the tapered roller bearings using the special tools, shown in Figure 126 and using a suitable press. 6. Assemble the differential side gears and pinion gears, as shown in Figure 124.

MD998812 MD998820 TAPERED ROLLER BEARING


MD998812 MD998820 BEARING REMOVER

TAPERED ROLLER BEARING


Figure 125

68


Figure 126


Technic al Service Informat ion COMPONENT REBUILD SECTION DIFFERENTIALASSEMBLY(CONT'D) 7. Measure the backlash between the side gears and pinion gears, as shown in Figure 127. 8. If backlash is out of specification, as shown in Figure 127, select a spacer from the chart and re-measure the backlash. Note: Adj ust unti l th e backl ash i s equal at both side gears. 9. If gear service was necessary, torque the ring gear bolts to 135 N·m (100 ft.lb.), as shown in Figure 128, using a criss-cross pattern. 10. Set the differential assembly aside for the final assembly process (See Figure 129).

TORQUE TO 135 NM (100 FT.LB.)


DI FF ERENTIAL SI DE GEAR WASH ERS Thickness

Part No.

.75-.82 mm (.029" -.032" )

MD722986

.83-.92 mm (.033" -.036" )

MD722985

.93-1.00 mm (.037" -.040" )

MD722984

1.01-1.08 mm (.040" -.043" )

MD722982

1.09-1.16 mm (.043" -.046" )

MD722983

SIDE GEAR BACKLASH .025-.150 MM (.001"-.006")


Figure 128 COMPLETED DIFFERENTIALASSEMBLY

10

0

10

20

20

30

30

40

40 50

0

50


Figure 127


Figure 129


69


7 8 10

9

4 5 6

2 2 8 2 0 0 5 9 -

3

1

11

1

1 2 3 4 5 6 7 8 9 10 11

OIL PUMP CONVERTERSEAL. OIL PUMPBODY"O" RING SEAL. OIL PUMPBODY BUSHING. OIL PUMPBODY. OIL PUMPBODY OUTERGEAR. OIL PUMPBODY INNERGEAR. OIL PUMP COVER/STATORSHAFTASSEMBLY. PUMPCOVERTO PUMPBODY RETAINING BOLTS (7 REQUIRED). OIL PUMP STEEL SEALING RINGS. OIL PUMP ASSEMBLY TO CASEGASKET. OIL PUMPBODY (FRONTVIEW).


Figure 130

70


Technic al Service Informat ion COMPONENT REBUILD SECTION INSPECTRING LANDS VERY CAREFULLY

3

4

OILPUMPASSEMBLY 1. Disassemble the oil pump assembly using Figure 130 as a guide. 2. Remove and discard oil pump gasket, "O" ring seal and converter seal (See Figure 130). 3. Clean all oil pump parts thoroughly with good cleaning solution and dry with compressed air. 4. Inspect all oil pump parts thoroughly for any wear and/or damage. Note: I nspect ri ng l ands on th e pump cover ver y careful ly, as shown in F igu r e 131. I t is ver y common to see wear her e. 5. Install new oil pump bushing if necessary, as shown in Figure 131, using the proper bushing driver. 6. Turn oil pump over and install new converter seal, as shown in Figure 132, using the proper seal installer. 7. Turn the oil pump over and install pump gears into the pump pocket, as shown in Figure 133, with the "Dots" facing UP, as shown. Note: L ubr icate pump gears and pocket with li ber al amount of ATF.

2 8 2 0 0 5

9 -


3 OIL PUMPBODY BUSHING. 4 OIL PUMPBODY.

DOTS FACING UP AS SHOW N

6


Figure 131 5

1 4 4 2 8 2 0 0 5

9 -

1 OIL PUMPCONVERTERSEAL. 4 OIL PUMPBODY.

4 OIL PUMPBODY. 5 OIL PUMPBODY OUTERGEAR. 6 OIL PUMPBODY INNERGEAR.


Figure 132


Figure 133


71

Technica l Service Informati on SONNAX® KMPUMP ALIGNMENT TOOL SONNAX

KM PUMP ALIGNMENT TOOL


Figure 134

8

7

COMPONENT REBUILD SECTION OILPUMPASSEMBLY(CONT'D) 8. There is now available from Sonnax®, a new oil pump alignment tool, that is mandatory for proper pump to cover alignment, as shown in Figure 134. 9. Install the pump alignment tool through the bushing, as shown in Figure 135, and set the completed oil pump body assembly on flat surface. 10. Install the oil pump cover through and into the pump alignment tool, as shown in Figure 135. 11. Install the oil pump to pump cover retaining bolts, as shown in Figure 135. 12. Torque oil pump to pump cover retaining bolts to (85 in.lb.), as shown in Figure 136, using a criss-cross pattern. Note: Th e oil pump alignment tool " M ust" remain in place un til the torqu e process is completed.


4

TORQUE COVER TOBODYBOLTSTO (85 IN.LB.) WITHTHE ALIGNMENT TOOL IN PLACE 2 8 2 0 0 5

9 -

Sn a p -O n

SON NAX® KM PUM P ALIGNM ENT TOO L

2 8 2 0 0 5

9 -

4 COMPLETED OIL PUMP BODY ASSEMBLY. 7 OIL PUMP COVER/STATOR SHAFTASSEMBLY. 8 PUMP COVER TO PUMP BODY RETAINING BOLTS (7 REQUIRED).

SON NAX® KM PUM P ALIGNM ENT TOO L


Figure 135

72


Figure 136


Technic al Service Informat ion COMPONENT REBUILD SECTION OILPUMPASSEMBLY(CONT'D) 13. Install the underdrive clutch sealing rings, as shown in Figure 137, and ensure that they are properly hooked and have free rotation. 14. Turn the completed assembly over and remove the pump alignment tool. 15. Install the oil pump to case "O" ring seal, as shown in Figure 138, and lubricate with small amount of Trans-Jel®. 16. Set the completed oil pump assembly aside for the final assembly process (See Figure 139).

PUMP BODY "O" RING


Figure 138


HOOK JOINT SEALING RINGS (2) Ensure That Seal Rin gs Are Properly H ooked As Shown

COMPLETED OIL PUMP ASSEMBLY

2 8 2 0 0 5

9 -


Figure 137


Figure 139


73

Technic al Service Informat ion .375" DIAMETER CHECKBALLS (2 REQUIRED) MAIN VALVE BODY AND SPACER PLATE

SOLENOID VALVE BODY

SOLENOID VALVE BODY COVER SOLENOID BODY TO MAIN VALVE BODY BOLTS (4 REQUIRED)

INTERNAL WIRE HARNESS CLIP SOLENOID VALVE BODY SPACER PLATE


Figure 140

COMPONENT REBUILD SECTION VALVEBODYASSEMBLY 1. Remove the two exhaust check balls from the top of the solenoid body and place in a safe location, as shown in Figure 140. 2. Remove the four solenoid body to main valve body retaining bolts, as shown in Figure 140. 3. Remove the solenoid body cover, the solenoid valve body, and solenoid body spacer plate, as shown in Figure 140. 4. Remove the two check balls and springs, and the check ball from the bath tub location, and place in a safe location. 5. Turn the main valve body over and remove the two main spacer plate retaining bolts, as shown in Figure 141. 6. Remove the two check balls and springs, and the check valve and spring from this side of the valve body and place in a safe location.

SPAC ER PLATE RETAINING BOLTS



Figure 141

74


Technic al Service Informat ion COMPONENT REBUILD SECTION VALVEBODYASSEMBLY(CONT'D) 7. Disassemble main valve body and place valves, springs, retainers in appropriate trays exactly as they were removed (See Figure 142). 8. Clean all valve body parts thoroughly and dry with compressed air.

9. Assemble the main valve body partsexactly, as shown in Figure 142, and lube with ATF as they are installed. Continued on P age 76

MAIN VALVE BODYEXPLODED VIEW 1

23

19 18 17

2 16

22 6 5 21 4 20

3

10

7 9

8

15

11 14 13

29.197

12 1 2 3 4 5 6 7 8 9 10 11 12

MAIN VALVEBODYCASTING. MANUAL VALVE. ROLLPIN. TORQUE CONVERTERCLUTCH CONTROL VALVESLEEVE. TORQUECONVERTERCLUTCH CONTROL VALVE. TORQUECONVERTERCLUTCH CONTROL VALVESPRING. PRESSUREREGULATOR VALVE RETAINER. PRESSUREREGULATOR ADJUSTMENTC ONTROL. PRESSUREREGULATOR VALVESPRING. PRESSUREREGULATOR VALVE. FAIL SAFEVALVE"A" SLEEVERETAINER. FAIL SAFE VALVE "A" SLEEVE.

13 14 15 16 17 18 19 20 21 22 23

FAIL SAFEVALVEA2. FAIL SAFEVALVE"A" SPRING. FAIL SAFEVALVEA1. TORQUE CONVERTERVALVESPRING. TORQUE CONVERTERVALVE. TORQUE CONVERTERVALVEBORE PLUG. BORE PLUG RETAINER. FAIL SAFEVALVE"B". FAIL SAFEVALVE"B" SLEEVE. FAIL SAFE VALVE "B" RETAINER. MAIN VALVEBODYTO C ASESPACERPLATE.


Figure 142


75

Technica l Service Informat ion COMPONENT REBUILD SECTION VALVEBODYASSEMBLY(CONT'D) 10. Disassemble solenoid valve body and place the valves, springs, retainers in appropriate trays exactly as they were removed (See Figure 143). 11. Clean all solenoid valve body parts thoroughly and dry with compressed air.

12. Assemble solenoid valve body parts exactly, as shown in Figure 143, and lube with ATF as they are installed. Continued on P age 77

SOLENOIDVALVEBODYEXPLODEDVIEW 22 13 14 21

15

1 16

17 18 19 2 20 3

4 5 6 7 12 8 9

10 11

1 2 3 4 5 6 7 8 9 10 11

SOLENOID VALVEBODY CASTING. OVERDRIVEPRESSURECONTROL VALVESPRING. OVERDRIVEPRESSURECONTROL VALVE. OVERDRIVEPRESSURECONTROL VALVESLEEVE. OVERDRIVEPRESSURECONTROL VALVESLEEVERETAINER. LOW/REVERSEPRESSURECONTROL VALVESPRING. LOW/REVERSEPRESSURECONTROL VALVE. LOW/REVERSEPRESSURECONTROL VALVESLEEVE. LOW/REVERSEPRESSURECONTROL VALVESLEEVERETAINER. SWITCHING VALVE. SWITCHING VALVEBOREPLUG.

12 13 14 15 16 17 18 19 20 21 22

SWITCHING VALVEBORE PLUG RETAINER. UNDERDRIVEPRESSURECONTROL VALVE SLEEVERETAINER. UNDERDRIVEPRESSURECONTROL VALVESLEEVE. UNDERDRIVEPRESSURECONTROL VALVE. UNDERDRIVEPRESSURECONTROL VALVESPRING. 2ND CLUTCH PRESSURECONTROL VALVESLEEVE RETAINER. 2ND CLUTCH PRESSURECONTROL VALVESLEEVE. 2ND CLUTCH PRESSURECONTROL VALVE. 2ND CLUTCH PRESSURECONTROL VALVESPRING. SOLENOID BODY TO MAIN VALVEBODY SPACERPLATE. EXHAUSTCHECK BALLS (.375" DIAMETER).


Figure 143

76


Technica l Service Informat ion COMPONENT REBUILD SECTION VALVEBODYASSEMBLY(CONT'D) 13. The overdrive solenoid, low/reverse solenoid, 2nd solenoid, underdrive solenoid and the TCC solenoid are all the same, and will interchange in any of their positions (See Figure 144). 14. The OEM part number for all solenoids is MD758981, and is also available from several aftermarket sources. 15. All solenoids can be air checked using the procedure shown in Figure 144.

16. Install new "O" rings onto the solenoids, as shown in Figure 144, and lubricate with small amount of Trans-Jel®. 17. Install all of the solenoid assemblies into the locations shown in Figure 144. 18. Install both solenoid retainers and bolts, and torque the bolts to 6 N·m (55 in.lb.). Continued on P age 78

SOLENOID IDENTIFICATION AND LOCATIONS SOLENO ID RESISTAN C E SHO ULD BE APPROXIM ATELY 3. 6 O HM S @ 7 2° F

WHENSOLENOIDIS“ENERGIZED” PORT 2 AND PORT 3 ARE CONNECTED WHEN SOLENOID IS“NOT ENERGIZED” PORT1ANDPORT2ARE CONNECTED

3 DIFFERENT SIZE "O" RINGS

MD758981

6604

3 PORT 3 1. 2. 3. 4. 5. 6. 7.

PORT 2

PORT 1

OVERDRIVECLUTCH SOLENOID LOW/REVERSECLUTCH SOLENOID UNDERDRIVE CLUTCH SOLENOID SECOND CLUTCH SOLENOID TCC CONTROL SOLENOID OUTERVALVEBODY COVER OUTERVALVEBODY ASSEMBLY

7

4

5 1

2

6


Figure 144


77

Technic al Service Informat ion VALVE BODY RETAINER LOCATIONS


Figure 145

COMPONENT REBUILD SECTION VALVEBODYASSEMBLY(CONT'D) 19. The main valve body and solenoid valve body retainer locations have been provided for you in Figure 145. 20. Lay the assembled main valve body on a flat work surface, as shown in Figure 146. 21. Install the "C" check ball and spring with the spring going in first, as shown in Figure 146. 22. Install the "D" check ball and spring with the spring going in first, as shown in Figure 146. 23. Install new seal on the damping valve "E" and install assembly with the spring going in first, as shown in Figure 146. Note: Spri ng and check ball dimension s are shown in F igur e 146.

"D"

"C"

"E" SEAL

Continued on P age 79 CHECK BALL AND SPRING DIMENSIONS

SPRING

LENGTH

DIAMETER

"C"

.665"

"D"

.677"

.177" .277"

"E"

1.398"

.300"

ALL CHECK BALLS ARE .250" DIAMETER STEEL


Figure 146

78


Technic al Service Informat ion COMPONENT REBUILD SECTION VALVEBODYASSEMBLY(CONT'D) 24. Install the main valve body spacer plate and bolts, as shown in Figure 147. Torque spacer plate bolts to 6 N·m (55 in.lb.). Note: I nstall the holl ow dowels in valve body to ali gn spacer plate befor e tor quin g. 25. Turn the valve body over with the spacer plate facing down, as shown in Figure 148. 26. Install the "A" check ball and spring with the spring going in first, as shown in Figure 148. 27. Install the "B" check ball and spring with the spring going in first, as shown in Figure 148. 28. Install the last check ball into the bath tub, as shown in Figure 148. Note: Spri ng and check ball dimension s are shown in F igur e 148.

"B" "A"

Continued on P age 80 CHECK BALL AND SPRING DIMENSIONS

Torque two spacer plate bolt s to 6 N· m (55 i n.lb.)

SPRING

LENGTH

DIAMETER

"A"

.665"

.177"

"B"

.665"

.177"

ALL CHECKBALLS ARE .250" DIAMETER STEEL


Figure 148


Figure 147


79

Technica l Service Informati on .375" DIAMETER CHECKBALLS (2 REQUIRED) MAIN VALVE BODY AND SPACER PLATE

SOLENOID VALVE BODY

SOLENOID VALVE BODY COVER SOLENOID BODY TO MAIN VALVE BODY BOLTS (4 REQUIRED)

INTERNAL WIRE HARNESSCLIP SOLENOID VALVE BODY SPACER PLATE


Figure 149

COMPONENT REBUILD SECTION VALVEBODYASSEMBLY(CONT'D) 29. Install the solenoid body spacer plate, solenoid body and the solenoid body cover, as shown in Figure 149. 30. Install the four solenoid body to main valve body bolts in locations shown in Figure 149. Note: H and tigh ten th e bolts as the torque process wil l fol low in fi nal assembly. 31. Set the completed valve body assembly aside for final assembly process (See Figure 150).

COMPLETEDVALVEBODYASSEMBLY

.375" DIAMETER CHECKBALLS (2 REQUIRED)


Figure 150

80


Technic al Service Informat ion FINAL ASSEMBLY INTERNAL COMPONENTS 1. If it was removed for bearing service, pinion shaft and driven transfer gear assemblymust be installed first, as shown in Figure 151. Note: Pin ion shaft and dri ven tr ansfer gear pr e-l oad must be set and checked whi le not engaged with any other gears. 2. Install the completed pinion shaft and driven transfer gear assembly into the case, as shown in Figure 151. Note: Ensure beari ng collar is stil l in place.

BEARING SUPPORT RETAINING BOLTS (4 REQUIRED)

3. Install the four required new retaining bolts, as shown in Figure 151, and torque the bolts to: F4A42 ... 23 N·m (18 ft.lb.) F4A51 ... 54 N·m (40 ft.lb.) Note: New bolts ar e requi red because there is sealer on t he thr eads. 4. Rotate transaxle case so that rear is facing up, as shown in Figure 152, and ensure that small bearing cup and spacer are still in place. 5. Install the small tapered roller bearing onto pinion shaft, as shown in Figure 152. 6. Install a new pinion shaft nut, as shown in Figure 152. Special Note: This nut is " L eft H and" thread. Continued on P age 82

PINION SHAFTAND DRIVEN TRANSFER GEAR ASSEMBLY T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

NOTE: T his nut is " Left Hand" Thread

ENSURE BEARING C O LLAR IS STILL IN PLAC E, AS IT WILL NO T GO IN FROM THE OTHER SIDE

11 10

B1 2E5 51K F4A

10 PINION SHAFTSMALL TAPERED ROLLER BEARING. 11 PINION SHAFTRETAINING NUT (LEFT HAND THREAD ).


Figure 151


Figure 152


81

Technic al Service Informat ion FINAL ASSEMBLY F 4A41 & F 4A42 = 3/4" (19 mm) All en H ead Socket F 4A51 = 15/16" (24 mm) All en H ead Socket

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

1 E5B K2 51 F4A

INTERNAL COMPONENTS(CONT'D) 7. Tighten the new pinion nut to the specified torque, then back off one turn, and tighten to specified torque again, using a 41 mm socket, as shown in Figure 153. Note: Th is nut is " L eft H and" thread. 8. The front (Gear Side), of the pinion shaft has a hex shaped recess molded into the center of the gear, and requires a special tool to hold the pinion shaft while tightening the nut, as shown in Figure 153. Note: Al len h ead socket size is shown in F igu re 153, for the dif ferent models. 9. Torque specification for the new pinion nut is 167 N·m (123 ft.lb.). 10. After the nut is properly torqued, check the turning torque with a gage type, inch pound torque wrench, as shown in Figure 154. 11. Proper turning torque is 1/2 to 3-1/2 in.lb., as shown in Figure 154. Continued on P age 83

TORQUE PINION SHAFT NUT TO 167 nm(123FT.LB.), WHILE HOLDING SHAFT FROM OTHER SIDE WITHSPECIALTOOL

CORRECT PINION SHAFT PRELOAD 1/2 TO3-1/2 INCH POUNDS INCH POUND TORQUE WRENCH

6

7

8 9

5

0 1

4 3 2


Figure 153

82

1

0


Figure 154


Technic al Service Informat ion PINION SHAFT SELECTIVE SPACER CHART Thickness 1.88 mm (.0740" ) 1.92 mm (.0756" ) 1.96 mm (.0772" ) 2.00 mm (.0787" ) 2.04 mm (.0803" )

I .D. Symbol 88 92 96 00 04

Part N umber MD756579 MD756580 MD756581 MD756582 MD756583

2.08 mm (.0819" ) 2.12 mm (.0835" ) 2.16 mm (.0850" )

08 12 16

MD756584 MD756585 MD756586

2.20 mm (.0866" ) 2.24 mm (.0882" ) 2.28 mm (.0898" ) 2.32 mm (.0913" ) 2.36 mm (.0929" ) 2.40 mm (.0945" ) 2.44 mm (.0961" ) 2.48 mm (.0976" )

20 24 28 32 36 40 44 48

MD756587 MD756588 MD756589 MD756590 MD756591 MD756592 MD756593 MD756594

2.52 mm (.0992" ) 2.56 mm (.1008" ) 2.60 mm (.1024" ) 2.64 mm (.1039" )

52 56 60 64

MD756595 MD756596 MD756597 MD756598

2.68 mm (.1055" ) 2.72 mm (.1071" ) 2.76 mm (.1087" )

68 72 76

MD756599 MD760685 MD760686

FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 12. If turning torque is not correct, choose a new spacer thickness from the chart in Figure 155, based on your turning torque. Note: I f tu r nin g torque is less than 1/2" lb, you wil l need a thi cker spacer. I f tur nin g torqu e is more than 3-1/2" lb, you need thi nner spacer. 13. This procedure was based on you having the spacer in your unit. If the spacer is lost you must start from scratch. You will have to install the small bearing race without the spacer, and torque the nut to specification. Then measure the end play of pinion with a dial indicator, as shown in Figure 156. Then you can choose a spacer from the chart that is approximately .002" thicker than your dial indicator reading. 14. After the turning torque is correct, stake the pinion retaining nut in two places, as shown in Figure 157. Continued on P age 84

Figure 155 DIAL INDICATOR

10

0

10

20

20

30

DRIFTPUNCH

30

40

40 50

0

50

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

T I M K E N

® P 9 0 0

N P 8

8 9

U S A

9 6 7

5B1 K2E 51 F4A


Figure 156


Figure 157


83

Technica l Service Informat ion FINAL ASSEMBLY

INSTALL TOOL MB990931

12

T I M K E N

® P 9

0 0

N P

8 8 9 9

U S A

6 7

12 PINION SHAFTCOVER.


INTERNAL COMPONENTS(CONT'D) 15. Install a new pinion shaft cover/seal into case, as shown in Figure 158, using proper driver. 16. Align the reference marks that you put on the case and bearing housing during disassembly, as shown in Figure 159. Note: I f you neglected to do this, you wil l have to search, as it in stall s in one dir ection only. 17. Install transfer drive gear assembly, as shown in Figure 160, by aligning the reference marks. 18. Install the retaining bolts by rotating the gear as necessary to expose the bolt holes through the access holes in the drive gear. Note: The number of r etaini ng bolts wil l vary dependi ng on model. Th ere coul d be four, seven, or eight bol ts. Continued on P age 84

Figure 158 TRANSFER DRIVE GEAR BOLTS

TRANSFER DRIVE GEAR ASSEMBLY

ALIG N C EN TER PUNC H OR PERM AN ENT M ARKS ON CASE AND BEARING HOUSING TO INSTALL

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

1 E5B K2 51 F4A


Figure 159

84


Figure 160


Technic al Service Informat ion FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 19. Rotate transfer drive gear as necessary so the access holes expose the retaining bolts to get them all installed and tightened. 20. Torque transfer gear drive gear retaining bolts to, 34 N·m (25 ft.lb.), as shown in Figure 161. 21. Rotate transaxle case so front side is facing up, as shown in Figure 164. 22. Inspect all parking pawl parts thoroughly for any wear and/or damage, replace as necessary. Note: A ll par kin g pawl parts are ill ustrated in F igur e 162.

23. Pre-assemble park pawl, return spring, and the bushing, as shown in Figure 163. 24. Install parking pawl, return spring and bushing assembly into the case, as shown in Figure 164, and install the pivot pin. Note: Th e park pawl pi vot pin is the lar ger diameter of the thr ee pin s. 25. Hook the parking pawl return spring in the window of bearing support (See Figure 165). Continued on P age 86

TORQUE ALL BOLTS TO 34 N·M (25FT.LB.) 1 5 A 4

Sn a p -

O n


Figure 163 T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

PARKING PAWL PIVOT PIN

1 A5 F4

PARKING PAWL, BUSHING, AND SPRING ASSEMBLY

1 E5B K2


Figure 161

1 5 A 4

PARKINGPAWLPARTS

1 5 A 4



Figure 162

Figure 164


85

Technic al Service Informat ion INTERNAL COMPONENTS(CONT'D) 26. Install the parking roller support, as shown in Figure 165, and install the retaining pins. Note: A ll of the par kin g pawl pin s are soft and wil l bend easil y. " Do Not" in stall them with hammer. Note: Check once again to ensure that park pawl r etur n spri ng is hooked in th e win dow, as shown in F igu re 165. 27. Push the pins down as far as they will go, by hand onl y , as shown in Figure 166. 28. Install new inner and outer "D" ring seals onto low/reverse piston, as shown in Figure 167, and lube with a small amount of Trans-Jel®. 29. Install the low/reverse piston assembly into the case, as shown in Figure 169. 30. Install the low/reverse piston return spring into the case, as shown in Figure 169.

31. Install low/reverse piston return spring retainer as shown in Figure 169, on top of the return spring. Continued on P age 87

RETAINING SHAFTS


Figure 166


74

72

73

72 LOW/REVERSECLUTCH APPLYPISTON. 73 LOW/REVERSECLUTCH PISTON OUTER"D" RING SEAL. 74 LOW/REVERSECLUTCH PISTON INNER"D" RING SEAL.


Figure 165

86


Figure 167


Technic al Service Informat ion INTERNAL COMPONENTS(CONT'D) 32. Install a new "Lip" type seal into the groove on back side of the sprag inner race, as shown in Figure 169, with the lip facing down. Note: Th is is a lube seal an d must be in stalled in sprag r ace with li p facin g down as shown. 33. Install the sprag inner race, with the seal side facing down, as shown in Figure 169. 34. Check the placement of the I.D. notches in the sprag inner race, as shown in Figure 168. The sprag inner race must be installed with the I.D. notches along the 6 and 12-O-Clock line, as shown in Figure 168.

67

68

69

Continued on P age 88 70

71

IDENTIFICATION NOTCHES 72

12

67 68 69 70 71 72

6

LOW SPRAG INNERRACE RETAINING SNAP RING. LOW SPRAG INNERRACE. LOW SPRAG INNER RACE LIP TYPE LUBE SEAL. LOW/REVERSECLUTCH RETURN SPRING RETAINER. LOW/REVERSECLUTCH RETURN SPRING. LOW/REVERSECLUTCH APPLYPISTON ASSEMBLY.


Figure 168


Figure 169


87

Technic al Service Informat ion FINAL ASSEMBLY

MD998903 = F4A42 MD998338 = F4A51 MD998924


Figure 170

INTERNAL COMPONENTS(CONT'D) 35. Compress the sprag race, retainer and return spring using special tools shown in Figure 170, and install snap ring. 36. Remove the compression tools. 37. Install the .099" snap ring, the pressure plate with step down, and the selective snap ring only, as shown in Figure 171 and 172. Note: D o not in stall any clutches at thi s tim e. 38. Measure with a feeler gage between pressure plate and the selective snap ring, as shown in Figure 172. 39. Mitsubishi wants maximum of .006" at this location. Specification is 0" - .006". 40. Select a snap ring from the chart in Figure 175 to achieve the desired specification. 41. Now remove the pressure plate and snap rings from the transaxle case. Continued on P age 89

60

61

62 60 61 62

Snap Rin g Clearan ce 0 - 0.16 mm (0" - .006" )

60 LOW/REVERSEPRESSUREPLATESNAP RING (SELEC TIVE). 61 LOW/REVERSESTEPPED PRESSUREPLATE. 62 LOW/REVERSEPRESSUREPLATESNAP RING (.099" THIC K).

60 LOW/REVERSEPRESSUREPLATESNAP RING (SELECTIVE). 61 LOW/REVERSESTEPPED PRESSUREPLATE. 62 LOW/REVERSEPRESSUREPLATESNAP RING (.099" THICK).


Figure 171

88


Figure 172



60

61

62

63

66

64 65

INTERNAL COMPONENTS(CONT'D) 42. Install the low/reverse "Waved" cushion plate, as shown in Figure 173, on top of piston. Note: Th is cushion pl ate is quite often broken and ATSG r ecommends replacement on ever y rebui ld as a pr ecautionar y measur e. 43. Install the low/reverse clutch selective ap ply plate, as shown in Figure 173. 44. Install the low/reverse clutch plates be ginning with a friction and alternating with steel plates, as shown in Figure 173. Note: " Do Not" yet install the last fr iction. 45. Install the .099" snap ring into the case groove, as shown in Figure 173. 46. Now, install the last friction, the pressure plate with step down and the selective snap ring. 47. Check the low/reverse clutch clearance using a feeler gage carefully, between the top friction and pressure plate, as shown in Figure 174. 48. The low/reverse clutch clearance should be, 1.65-2.11 mm (.065"-.083"). 49. Change the selective apply plate using chart in Figure 176, to obtain specified clearance. Continued on P age 91

B

L /R Clutch Clearance 1.65-2.11 mm (.065" -.083" )

60 61 62 63 64 65 66

LOW/REVERSEPRESSUREPLATESNAP RING (SELECTIVE). LOW/REVERSESTEPPED PRESSUREPLATE. LOW/REVERSEPRESSUREPLATESNAP RING (.099" THIC K). LOW/REVERSEFRICTION PLATES. LOW/REVERSEAPPLYPLATE (SELEC TIVE). LOW/REVERSE "WAVED" CUSHION PLATE. LOW/REVERSE STEEL PLATES


Figure 173


Figure 174


89

Technic al Service Informat ion LOW/REVERSE CLUTCH SELECTIVE SNAP RINGCHART F4A41, F4A42 MODELS Thickness 2.2 mm (.087" ) 2.3 mm (.091" ) 2.4 mm (.094" ) 2.5 mm (.098" )

I .D. Color Blue Brown None Blue

F4A51MODELS Part N umber MD754786 MD754785 MD758240 MD758241

Thickness 2.2 mm (.087" ) 2.3 mm (.091" ) 2.4 mm (.094" ) 2.5 mm (.098" )

I .D. Color None Blue Brown None

Part N umber MD756784 MD756785 MD758552 MD758553

Figure 175

B B

IDENTIFICATION

2NDCLUTCHANDLOW/REVERSE CLUTCHSELECTIVEAPPLYPLATECHART F4A41, F4A42 MODELS Thickness 1.6 mm (.063" ) 1.8 mm (.071" ) 2.0 mm (.079" ) 2.2 mm (.087" ) 2.4 mm (.094" ) 2.6 mm (.102" ) 2.8 mm (.110" ) 3.0 mm (.118" )

I .D. Symbol L 1 0 2 4 6 8 D

F4A51MODELS Part N umber MD759567


MD759414 MD759415 MD759416 MD759417 MD759418 MD759419 MD759420

1.8 mm (.071" ) 2.0 mm (.079" ) 2.2 mm (.087" ) 2.4 mm (.094" ) 2.6 mm (.102" ) 2.8 mm (.110" ) 3.0 mm (.118" )

I .D. Symbol F E D C B A 0 1

Figure 176

90


Part N umber MD759568 MD759425 MD759426 MD759427 MD759428 MD759429 MD759430 MD759431

Technic al Service Informat ion FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 50. Install the 2nd clutch plates, beginning with a friction, followed by the stepped plate with the step facing down, followed by frictions and steels, and finally the selective plate, piston retainer and snap ring. (See Figure 178). Special N ote: N umber of pl ates wil l vary dependi ng on the model. F4A41, 42

3

2

1

1

F4A51

4

3

1

1

50

51

51. Check the 2nd clutch clearance with a feeler gage, between the selective apply plate and the 2nd clutch piston, as shown in Figure 177. 52. The 2nd clutch clearance should be: F4A41, F4A42 = 0.79-1.25 mm (.031"-.049") F4A51 = 1.09-1.55 mm (.043"-.061"), and is also shown in Figure 177. 53. Change selective apply plate as necessary to obtain correct 2nd clearance, using the chart in Figure 176. 54. Now, remove the complete 2nd clutch pack using Figure 178, as a guide.

55

56


C

57 59

3

3

58 STEP DOWN

2ND CLUTCH CLEARANCE

F 4A41, F 4A42 0.79-1.25 M M (.031" -.049" )

F4A51 1.09-1.55 M M (.043" -.061" )

50 51 55 56 57 58 59

2ND CLUTCH RETAINERSNAP RING. 2ND CLUTCH RETAINER. 2ND C LUTCH PISTON RETURN SPRING. 2ND CLUTCH APPLYPLATE(SELEC TIVE). 2ND CLUTCH FLATSTEEL PLATES. 2ND C LUTCH STEPPED PLATE (STEP FAC ING DO WN ). 2ND CLUTCH FRICTION PLATES.


Figure 177


Figure 178


91

Technica l Service Informat ion FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 55. Install the pre-assembled planetary gear set and the low sprag assembly into the case, as shown in Figure 179, by rotating back and forth to engage the low/reverse frictions and the sprag onto the inner race. 56. Ensure proper sprag installation, as shown in Figure 180. Note: Pl anetary should f r eewheel coun terclockwise and l ock clockwi se, as shown in F igu r e 180. Sprag not used in all models. Refer to Page 117 for specif ic details. 57. Install the pre-assembled sun gear and shell assembly, as shown in Figure 181. Note: Ensure that nu mber 5 thr ust beari ng is stil l in place and i nstall ed corr ectly, as shown in F igur e 181.

PLANETARYSHOULD FREEWHEEL COUNTER-CLOCKWISE AND LOCK CLOCKWISE

F REEWHEEL



PLANETARY GEAR SET ASSEMBLY

Figure 180

NUMBER 5 THRUST BEARING SUN GEAR SHELL


Figure 179

92


Figure 181


Technic al Service Informat ion FINAL ASSEMBLY 50

51

LOCATING TAB 55

INTERNAL COMPONENTS(CONT'D) 58. Now re-install the 2nd clutch plates beginning with 1 friction plate, as shown in Figure 182. 59. Install the "Stepped" apply plate, as shown in Figure 182, with the step facin g down. 60. Install the remaining friction and steel plates, as shown in Figure 182. Special N ote: Nu mber of pl ates wil l var y dependi ng on model, as shown in the char t on Page 91. 61. Install the selective apply plate, as shown in Figure 182. 62. Install the 2nd clutch piston return spring, as shown in Figure 182. 63. Install 2nd clutch piston and retainer assembly, as shown in Figure 182, and install snap ring. Note: E nsure that locatin g tab is engaged in to the case gr oove (See F igur e 182). 64. Install the overdrive clutch hub, as shown in Figure 183, and ensure that number 6 thrust bearing is installed correctly.

56

Continued on P age 94 C

57 59

NUMBER 6 THRUST BEARING

3

3

58 STEP DOWN

OVERDRIVE CLUTCH HUB

50 51 55 56 57 58 59

2ND CLUTCH RETAINERSNAP RING. 2ND CLUTCH RETAINER. 2ND C LUTCH PISTON RETURN SPRING. 2ND CLUTCH APPLYPLATE(SELEC TIVE). 2ND CLUTCH FLATSTEEL PLATES. 2ND C LUTCH STEPPED PLATE (STEP FAC ING DO WN ). 2ND CLUTCH FRICTION PLATES.

C 3 3


Figure 182


Figure 183


93

Technic al Service Informat ion FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 65. Install the overdrive/reverse clutch housing, as shown in Figure 184, by rotating the housing back and forth until all overdrive clutches are engaged with the hub and all reverse clutches are engaged on sun shell, and the housing is fully seated. 66. Install the number 7 thrust bearing, as shown in Figure 184. Note: D o not i nstall the selective nu mber 8 thr ust plate. I t is shown in F igur e 184 for reference onl y as to where it goes when it is tim e to in stall the washer.

67. Install "H" gage on transaxle case, as shown in Figure 185, and set adjustment rod on roller surface of the number 7 bearing, as shown in Figure 186. 68. Lock the adjustment rod in place. 69. Adjustment rod must be on the roller surface of the bearing, as shown in Figure 186. Continued on P age 95

22 21

20


Figure 185

SET ADJUSTM ENT RO D O N RO LLER SURFAC E OF THE NUM BER 7 THRUST BEARING AS SHOWN HERE

C 3 3

20 OVERDRIVE/REVERSECLUTCH RETAINER ASSEMBLY. 21 NUMBER 7 THRUSTBEARING ASSEMBLY. 22 NUMBER8 THRUSTPLATE (SELEC TIVE).




Figure 184

94

Figure 186


Technic al Service Informat ion INTERNAL COMPONENTS(CONT'D) 70. Install number 8 selective thrust plate onto the rear cover, as shown in Figure 187, and retain with small amount of Trans-Jel®. 71. Now, turn "H" gage over and set on the rear cover, as shown in Figure 188. 72. Measure with feeler gage between number 8 thrust plate and adjustment rod, as shown in Figure 188, for proper rear end clearance. 73. Rear end clearance should be as follows: 0.25 - 0.45 mm (.010" - .018"). 74. Change the selective plate as necessary to obtain the proper specification, using the chart in Figure 187.

75. Install the 3 "O" ring seals into the pockets of the case, as shown in Figure 189, and retain with a small amount of Trans-Jel®. Continued on P age 96

NUMBER 8THRUSTPLATECHART

THICKNESS

PART NUMBER

1.6 mm (.063")

MD707267

1.7 mm (.067")

MD759681

1.8 mm (.071")

MD723064

1.9 mm (.075")

MD754794

2.0 mm (.079")

MD707268

2.1 mm (.083")

MD754795

2.2 mm (.087")

MD723065

2.3 mm (.091")

MD754796

2.4 mm (.094")

MD724358

2.5 mm (.098")

MD754797

2.6 mm (.102")

MD754798


Figure 188

"O" RING SEALS (3 REQUIRED)

NUMBER 8 THRUSTPLATE (SELEC TIVE)


Figure 187


Figure 189


95

Technica l Service Informat ion FINAL ASSEMBLY

2 mm (.080") BEAD OF MITSUBISHI SEALANT

Figure 190

RETAINING BOLTS (10 REQUIRED)

INTERNAL COMPONENTS(CONT'D) 76. Apply a 2 mm (.080") bead of the Mitsubishi sealant, part number MD974421, or equivalent, to the rear cover, as shown in Figure 190. Note: I nstall the cover withi n 15 mi nutes whi le the sealant is stil l wet. 77. Ensure that "O" rings are in place on the case and install rear cover, as shown in Figure 191. 78. Install the ten rear cover to case retaining bolts as shown in Figure 191. 79. Torque the ten rear cover retaining bolts to 23 N·m (17 ft.lb.), as shown in Figure 192. 80. Rotate the transaxle case so that front side is facing up, as shown in Figure 193. 81. Install the underdrive clutch hub, as shown in Figure 193. 82. Ensure that the number 2 thrust bearing is installed in the proper direction, as shown in Figure 193. Continued on P age 97

TORQUE REARCOVER BOLTS TO23N·M (17 FT.LB.) F 4 A5 1 A51

500766

REAR COVER

F4 F 4 A5 A51 1

500766


Figure 191

96


Figure 192


Technic al Service Informat ion NUMBER 2 THRUSTBEARING

UNDERDRIVE CLUTCH HUB

TRANSFER DRIVE GEAR

INTERNAL COMPONENTS(CONT'D) 83. Install the original selective shim and new bearing cone,as shown in Figure 194, into the converter housing using proper drivers. Note: I f for any reason you do not know what spacer goes here, you must i nstall the beari ng cup with out the spacer. 84. Install the differential into case, install the converter housing, as shown in Figure 195, and torque the converter housing bolts to 48 N·m (35 ft.lb.). Continued on P age 98

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

CONVERTER HOUSING

5B1 K2E 51 F4A


Figure 193

DIFFERENTIAL ASSEMBLY

DIFFERENTIAL BEARING CUP SELECTIVE SPACER

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

5B1 K2E 51 F4A


Figure 194


Figure 195


97

Technic al Service Informat ion DIFFERENTIAL CASE SELECTIVE SPACER CHART Thickness 0.71 mm (.0280" ) 0.74 mm (.0291" ) 0.77 mm (.0303" ) 0.80 mm (.0315" ) 0.83 mm (.0327" )

I .D. Symbol 71 74 77 80 83


0.86 mm (.0339" ) 0.89 mm (.0350" ) 0.92 mm (.0362" )

86 89 92

MD720938 MD720939 MD720940

0.95 mm (.0374" ) 0.98 mm (.0386" ) 1.01 mm (.0398" ) 1.04 mm (.0409" ) 1.07 mm (.0421" ) 1.10 mm (.0433" ) 1.13 mm (.0445" ) 1.16 mm (.0457" )

95 98 01 04 07 J D K

MD720941 MD720942 MD720943 MD720944 MD720945 MD710454 MD700270 MD710455

1.19 mm (.0469" ) 1.22 mm (.0480" ) 1.25 mm (.0492" ) 1.28 mm (.0504" )

L G M N

MD710456 MD700271 MD710457 MD710458

1.31 mm (.0516" ) 1.34 mm (.0528" ) 1.37 mm (.0539" )

E O P

MD706574 MD710459 MD710460 10

0

INTERNAL COMPONENTS(CONT'D) 85. Install 1-1/8", 1/2" drive socket through the axle seal, as shown in Figure 196. 86. Install a dial indicator with the stem resting on the socket, as shown in Figure 196, and zero the dial indicator. 87. With a large screwdriver coming through the axle seal on the opposite side and against the differential cross shaft, move the differential up and down to determine end play. 88. Choose a spacer from the chart in Figure 196 that is approximately .002" thicker than your end play reading. 89. Remove the converter housing and the bearing cup, install the selected spacer and re-install the bearing cup, as shown in Figure 194. 90. Install the underdrive clutch housing and the number 1 selective thrust washer, as shown in Figure 197. Continued on P age 99

NUMBER 1 THRUSTWASHER (SELECTIVE)

UNDERDRIVE CLUTCH HOUSING

10

20

20

30

30

40

40 50

0

50

T I M K E N

® P 9 0 0

T I M

N

K E N

P 8 8 9

® P 9

0 0

U

S A

N

P 8 8 9

U S A

9 6 7

9 6 7

1 E5B K2 51 F4A

1 E5B K2 A51 F4


Figure 196

98

Figure 197


Technic al Service Informat ion INTERNAL COMPONENTS(CONT'D) 91. Install the "H" gage on transaxle, as shown in Figure 198, and let the adjustment leg down to rest on the selective thrust washer. 92. Turn the "H" gage over and set it on oil pump assembly, as shown in Figure 199. 93. Measure with a feeler gage between the pump surface and "H" gage adjustment leg, as shown in Figure 199, for proper front end play. 94. Proper front end play should be as follows; .045 - .105 mm (.028" - .057"). 95. Change selective thrust washer as necessary using the chart in Figure 199, to obtain proper input shaft end play.

INPUT SHAFT SELECTIVE SPACER CHART Thickness 1.8 mm (.071" ) 2.0 mm (.079" ) 2.2 mm (.087" ) 2.4 mm (.094" ) 2.6 mm (.102" )

I .D. Symbol 18 20 22 24 26


2.8 mm (.110" )

28

MD753795

"H" GAGE

Continued on Page 100

2 8 2 0 0 5

9 -

"H" GAGE


Figure 199

T I M K E N

® P 9 0 0

N

P 8 8 9

9

U

S A

6 7

5B1 K2E 51 F4A


Figure 198


99

Technica l Service Informati on FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 96. Install the oil pump gasket on transaxle case, as shown in Figure 200. 97. Install the pre-assembled oil pump assembly, as shown in Figure 200.

OIL PUMP BOLTS (6 REQUIRED)

98. Install and torque the 6 oil pump to case bolts to 23 N·m (17 ft.lb.) (See Figure 200). 99. Install new "O" ring on new filter and lube the "O" ring with small amount of Trans-Jel®. 100. Install the filter assembly into the transaxle case, as shown in Figure 201. 101. Install the differential assembly into the case, as shown in Figure 201. 102. Install dial indicator, as shown in Figure 202, to ensure that front transaxle clearance is; .045-.105mm (.028" - .057") Continued on Page 101

OIL PUMP ASSEMBLY DIFFERENTIAL ASSEMBLY

OIL FILTER

OIL PUMP TO CASE GASKET

"O" RING

T I M K E N

T I M K E N

® P 9

®

0 0

P 9

N

P 8 8 9

0 0

N

P 8 8 9

U

S A

9 6 7

U

S A

1 E5B K2 51 F4A

1 5B K2E 51 F4A


Figure 200

100

9 6 7


Figure 201


Technic al Service Informat ion INTERNAL COMPONENTS(CONT'D) 103. Install two new "O" rings into the pockets in transaxle case, as shown in Figure 204, and retain with small amount of Trans-Jel®. 104. Apply a 2 mm (.080") bead of sealant to the converter housing, as shown in Figure 203. 105. Install the converter housing, as shown in Figure 204, while the sealant is still wet.

106. Install the eighteen converter housing bolts, as shown in Figure 204, and torque all bolts to 48 N·m (35 ft.lb.). Continued on Page 102

28

29

DIAL INDICATOR

10

0

10

20

20

30

30

40

40 50

0

50

T I M K E N

® P 9 0 0

N

P 8 8 9

U

S A

9 6 7

27

1 E5B K2 51 F4A

Copyr ight © 2005 ATSG T I M K E N

® P 9

Figure 202

0 0

N

P 8 8 9

U

S A

9 6 7

2 MM BEAD OF SEALANT 5B1 K2E 51 F4A

27 CONVERTERCOVERTO CASE"O" RINGS (2 REQUIRED). 28 CONVERTERCOVERTO CASERETAINING BOLTS (18 REQ.). 29 TORQUECONVERTERHOUSING.


Figure 203


Figure 204


101


3 2

4 1

5 1 2 3 4 5

MANUAL LINKAGESHAFTAND INSIDEDETENTLEVERASSEMBLY. MANUALSHAFTLARGE "O" RING. MANUALSHAFTSMALL"O" RING. PARK ACTUATING ROD ASSEMBLY. MANUALSHAFTRETAINING PIN.


Figure 205

INTERNAL COMPONENTS(CONT'D) 107. Install two new "O" rings onto manual shaft, as shown in Figure 205, and lube with small amount of Trans-Jel®. 108. Assemble the park actuating rod to the inside detent lever, as shown in Figure 205 and 206. 109. Install the inside detent lever assembly into the case, as shown in Figure 206, and install the retaining pin through the pan rail and shaft. 110. Install new "O" ring on case connector, as shown in Figure 207, and lube with a small amount of Trans-Jel. 111. Install the internal wire harness from inside the case and through the case bore, as shown in Figure 207, and install snap ring. 112. Lay internal harness back over the pan rail, as shown in Figure 210, so that it is out of the way for accumulator piston and valve body installation. Continued on Page 103

SNAP RING CASE CONNECTOR "O" RING

INTERNAL WIRE HARNESS ASSEMBLY

INSIDE DETENTLEVER AND PARK ROD ASSEMBLY

RETAINING PIN



Figure 206

102

Figure 207


Technic al Service Informat ion INTERNAL COMPONENTS(CONT'D) 113. Install new scarf cut accumulator piston seals on each of the four accumulator pistons, as shown in Figure 208. 114. Install each accumulator piston, seal and the proper springs, as shown in Figure 210. Note: Th e accumulator spr in gs we observed wer e identif ied wit h blu e dye, as shown in F igur e 209.

115. The accumulator pistons and piston seals are common parts, but the accumulator springs must be installed in their proper positions. Double check all of your accumulator spring positions at this time, as we are getting ready to install the valve body and cover them up. Continued on Page 104

ACCUMULATOR PISTON SEAL (SCARF CUT)

INTERNAL WIRE HARNESS

ACCUMULATOR PISTON


Figure 208 ACCUMULATOR SPRINGIDENTIFICATION NOT E: The shaded areas are the identification " Bluing" .

OR

4 3

1

2

3

4

NO.

ACC UMUL ATO R

1

L ow/Reverse Clutch

None

2

Un derdr ive Clu tch

H alf or 2/3rds

3

2nd Clutch

Ful l Surf ace

4

Overdri ve Clu tch

None

Figure 209

2

I.D. " Bluing"

1 1 2 3 4

LOW/REVERSE CLUTCH ACCUMULATOR PISTON AND SPRINGS. UNDERDRIVE CLUTCH ACCUMULATORPISTON AND SPRINGS. 2ND CLUTCH ACCUMULATOR PISTON AND SPRINGS. OVERDRIVECLUTCH ACCUMULATOR PISTON AND SPRING.


Figure 210


103

Technica l Service Informat ion FINAL ASSEMBLY INTERNALCOMPONENTS(Cont'd) 116. Install the case oil screen into the worm track as shown in Figure 211. 117. Install a new 2nd clutch case seal assembly, as shown in Figure 211. 118. Ensure that the two steel exhaust balls are still in place in the top of valve body, as shown in Figure 212. 119. Install the pre-assembled valve body assembly over the hollow dowels in the case, as shown in Figure 212. Note: E nsure that manual valve is engaged in to the slot in the inside detent lever as you install the valve body. 120. Install all valve body bolts in their proper locations, as shown in Figure 212. Note: Refer to F igur e 213 for proper bolt location, length and identif ication. 121. Hand tighten only at this time.

6

7

6 2ND CLUTCH CASESEALASSEMBLY. 7 CASEOIL SCREEN.

Continued on Page 106


Figure 211

HOLLOW DOWEL .375" DIAMETER CHECKBALLS (2 REQUIRED)

REFER TO FI GURE 213 FOR VALV E BODY TO CASE BOLTS AND L OCATI ONS

VALVE BODY TO CASE BOLTS

HOLLOW DOWEL


Figure 212

104


Technic al Service Informat ion VALVEBODYBOLTCHARTANDLOCATIONS 10 mm

10 mm

10 mm

10 mm

10 mm

10 mm

A

B

C

D

E

F

Valve Body To Case (2) (20mm)

10 mm

G

Valve Body Temp Sensor To Case To Case (13) (1) (37.5mm) (44.5mm)

Sol. B ody To Case (1) (70mm)

Sol. Body To M ain (4) (70mm)


A E

E

E

A


B

B

G

G

G

G

G

G

B

B

B

B

B B

B B

B

E

B

G

G

C F

G

G

D

B


Figure 213


105

Technica l Service Informat ion FINAL ASSEMBLY INTERNAL COMPONENTS(CONT'D) 122. Install a new "O" ring on the transaxle temp sensor, as shown in Figure 214. 123. Install the temperature sensor and retaining bolt, as shown in Figure 214. 124. Now, torque all valve body bolts to 11 N·m (95 in.lb.), beginning in the center and work in a circular pattern. 125. Check once again to ensure that manua l valve is connected to inside detent lever, and install the detent spring, as shown in Figure 214. 126. Torque the bolt to 6 N·m (52 in.lb.). 127. Connect the internal harness connectors to the individual solenoids, and connect the temp sensor, as shown in Figure 215. Note: Th e colors shown i n F igu r e 215 wer e observed on M itsubishi Galant and Dodge Stratus. H yundai and Ki a colors may vary. Continued on Page 107

BLACK CONNECTOR WITH WHITE GROUND WIRE

WHITE CONNECTOR WITH GREEN GROUND WIRE

BLACK CONNECTOR WITH BLUE GROUND WIRE

TFT SENSOR

BLACK CONNECTOR WITH ORANGE GROUND WIRE WHITE CONNECTOR WITH BROWN GROUND WIRE

NOTE : Colors li sted here were observed colors in Galant and Stratu s onl y. H yundai and Kia color s may vary. Copyr ight © 2005 ATSG

DETENT SPRING

Figure 215

RETAINING BOLT

RETAINING BOLT "O" RING SEAL

TEMP SENSOR


Figure 214

106



2 MM (.080") BEAD OF SEALANT

INTERNAL COMPONENTS(CONT'D) 128. Apply a 2 mm (.080") bead of sealant around the oil pan, as shown in Figure 216. Note: I nstall oil pan whil e sealant i s stil l wet. 129. This would be a good time to ensure that the manual valve is properly hooked, all solenoid connectors and temp sensor are connected. 130. Install the oil pan onto transaxle, as shown in Figure 217, and torque all pan bolts to; 11 N·m (95 in.lb.). Note: N one of th e sealant sur faces or fresh sealant can be exposed to ATF for 1 hour, to give sealan t ti me to dry pr oper ly. Continued on Page 108


Figure 216

PAN BOLT (15 REQUIRED)

Figure 217


107

Technic al Service Informat ion FINAL ASSEMBLY EXTERNAL COMPONENTS 131. Install a new "O" ring on output shaft speed sensor, lube with small amount of Trans-Jel®, and install the assembly into case, as shown in Figure 218. 132. Torque the output shaft speed sensor bolt to; 11 N·m (95 in.lb.). 133. Install a new "O" ring on input shaft speed sensor, lube with small amount of Trans-Jel®, and install the assembly into case, as shown in Figure 218. 134. Torque the input shaft speed sensor bolt to; 11 N·m (95 in.lb.).

135. Install the fluid level indicator into tube, as shown in Figure 218. 136. Install new external oil filter on transaxle, as shown in Figure 218. Do not over-tighten. Note: Th e extern al oil fil ter i s not used on all model tr ansaxles. Continued on Page 109

RETAINING BOLT

OUTPUTSHAFT SPEED SENSOR

RETAINING BOLT

EXTERNAL OIL FILTER (NO T USED ALL M O DELS)

INPUTSHAFT SPEED SENSOR

"O" RING

"O" RING

FLUID LEVEL INDICATOR

A TF

0 0 9 P

N P8 8 9 96 7

U S A

®

N

E K M I

T

1 B 5 E 2 K 1 5 A 4 F

T O H T A T S U J D A

T O H


Figure 218

108


Technic al Service Informat ion FINAL ASSEMBLY EXTERNALCOMPONENTS(CONT'D) 137. Install a new "O" ring on speedometer adapter, pulse generator, or the sealing cap, depending on how the transaxle is equipped, as shown in Figure 220. 138. Install new speedometer driven gear shaft seal with lip facing gear, as shown in Figure 219, install retaining clip and driven gear. Note Lu be seal and gear wi th Tr ans-Jel® . 139. Install speedometer adapter, pulse generator, or sealing cap, depending on how transaxle is equipped, as shown in Figure 220, torque bolt as follows: Sealing Cap = 5 N·m (9 in.lb.). Speedometer Adapter = 11 N·m (95 in.lb.). Pulse Generator = 11 N·m (95 in.lb.).

140. Install the P/N position switch and torque the bolts to 11 N·m (95 in.lb.). 141. Install the manual control lever and torque the nut to 22 N·m (16 ft.lb.). Continued on Page 110 SPEEDO ADAPTER

SPEEDO DRIVEN GEAR

SHAFT SEAL

SEAL RETAINER


Figure 219

SPEEDO ADAPTER PULSE GENERATOR

RETAINING BOLT

SEALING CAP "O" RING

"O" RING 0 0 9 P

P8 8 9 96 7 N

U S A

®

N

E K M I

T

1 B 5 E 2 K 1 5 A 4 F


Figure 220


109

Technic al Service Informat ion FINAL ASSEMBLY EXTERNALCOMPONENTS(CONT'D) 142. Install the torque converter into the transaxle, as shown in Figure 222, and ensure that hub is engaged properly in pump gear. Note: Apply ATF to converter hub and also pri me converter to soak the converter clut ch before install ing, and use care not to damage conver ter seal dur in g install ation. 143. Ensure that converter is engaged into pump gear by measuring from face of bell housing to converter pad surface (See Figure 221). This dimension should be as follows: F4A41,42 = 12.2 mm (.480"). F4A51 = 9.4 mm (.370").

" A"

Dimension " A" F 4A41, 42 = .480" F 4A51 = .370"

CONGRATULATIONS, YOU ARE FINISHED.

Figure 221

0 0 9 P

P8 8 9 96 7 N

U S A

®

N

E K M I

T

1 B 5 E 2 K 1 5 A 4 F

A TF

TORQUE CONVERTER


Figure 222

110


Technic al Service Informat ion ALLEXCEPTVALVEBODYBOLTCHART

8 mm

10 mm

10 mm

Oil Pan (15) (12mm)

Speed Sensor (2) (14mm)

12 mm

12 mm

12 mm

8 mm

Detent Spring (1) (11.5mm)

Solenoid Bracket (6) (18mm)

Bolts Dr awn Actual Size

Oil Pump To Case (6) (30mm)

Rear Cover Pinion To Case Housing (10) To Case (25mm) F 4A40 Ser ies (4) (25mm)

14 mm 50 Torx

Converter Cover To Case (18) (40mm)

Pinion Housing To Case F 4A50 Seri es (4) (25mm)

40 Torx

Drive Sprk t Supp (4), (7), (8) (27mm)

30 Torx

Pump Cover To Pump Body (7) (20mm)

VALVEBODYBOLTCHART FOUNDONPAGE105 Copyr ight © 2005 ATSG

Figure 223


111

Technica l Service Informati on SPECIAL SERVICE TOOLS FUNCTION

40 SERIES

50 SERIES

X A N N S O

P T M E N P U M L O M N O K L I G T A

OIL PUMP ALIGNMENT

SONNAX® 41005-TL

SONNAX® 41005-TL

OIL PUMP REMOVAL

MITSUBISHI MD998333

MITSUBISHI MD998333

UNIVERSAL SPRING COMPRESSOR

MITSUBISHI MD998924

MITSUBISHI MD998924

REMOVE AND INSTALL ONE-WAY CLUTCH INNER SNAP RING ON F4A40 SERIES

MITSUBISHI MD998903

REMOVE AND INSTALL ONE-WAY CLUTCH INNER SNAP RING ON F4A50 SERIES

REMOVE AND INSTALL OVERDRIVE CLUTCH SNAP RING

MITSUBISHI MD998338

MITSUBISHI MD999590

MITSUBISHI MD999590


Figure 224

112


Technic al Service Informat ion SPECIAL SERVICE TOOLS FUNCTION

40 SERIES

50 SERIES

HOLDS PINION GEAR TO REMOVE AND INSTALL PINION SHAFTNUT

UNIVERSAL 3/4" (19MM) ALLEN HEAD SOCKET

ALIGNMENTDOWEL FOR OIL PUMP AND TRANSFER DRIVE GEAR

MITSUBISHI MD998412

MITSUBISHI MD998412

CLEARANC E DUMMY PLATE FOR LOW/REVERSE AND 2ND CLUTCH CLEARANCE

MITSUBISHI MD991631

MITSUBISHI MD991632

REMOVE AND INSTALL UNDERDRIVE CLUTCH SNAP RING

MITSUBISHI MD998907

MITSUBISHI MD998907

MEASUREMENT OF REVERSE CLUTCH END PLAY

MITSUBISHI MB991790

MITSUBISHI MB991789

MEASUREMENT OF OVERDRIVE CLUTCH AND UNDERDRIVE CLUTCH END PLAY

MITSUBISHI MB991628

MITSUBISHI MB991629

UNIVERSAL 15/16" (24MM) ALLEN HEAD SOCKET


Figure 225


113


40 SERIES

50 SERIES

UNIVERSAL OR MITSUBISHI MD998917


BEARING REMOVER



INSTALLER CAP



INSTALLER ADAPTER FOR INSTALLATION OF DIFFERENTIAL TAPERED ROLLER BEARINGS

MITSUBISHI MD998820

INSTALLER ADAPTER FOR INSTALLATION OF PINION LARGE TAPERED BEARING AND THE TRANSFER DRIVEN GEAR

MITSUBISHI MD998823

BEARING REMOVER

INSTALLER ADAPTER FOR INSTALLATION OF PINION LARGE TAPERED BEARING

MITSUBISHI MD998827


Figure 226

114



40 SERIES

INSTALLER ADAPTER FOR INSTALLATION OF DIFFERENTIAL TAPERED ROLLER BEARINGS AND TRANSFER DRIVEN GEAR

INSTALLER ADAPTER LONG EXTENSION FOR USE WITH CAP AND ADAPTERS ON PINION SHAFT

INSTALLER ADAPTER SHORT EXTENSION FOR USE WITH CAP AND ADAPTERS

7

0

M M

4

1

M M

50 SERIES

MITSUBISHI MD998824

MITSUBISHI MD998814

MITSUBISHI MD998814

MITSUBISHI MD998813

MITSUBISHI MD998813

REMOVE AND INSTALL BALL BEARING STYLE TRANSFER DRIVE GEAR JAM NUT (70 MM SOCKET)

MITSUBISHI MD991626

REMOVE AND INSTALL PINION SHAFTJAM NUT (41 MM SOCKET)

MITSUBISHI MD991625

MITSUBISHI MD991625

I n addition to the tools li sted above, you wil l need standard bu shi ng and seal dr ivers, and " H " gage for end play measur ements.


Figure 227


115

Technica l Service Informati on TORQUESPECIFICATIONS Description

N•m

lb.ft.

lb.in.

Oil Pump Stator to Oil Pump Body

9

85

Oil Pump to Case

23

Valve Body to Case (Al l)

11

95

Detent Spring to Valve Body

6

55

Spacer Plate to Valve Body

6

55

Solenoi d Retainer Plates to Valve Body

6

55

17

Transfer D ri ve Gear N ut (B all Beari ng Style)

191

141

Transfer Dr ive Gear H ousin g to Case

34

25

Pinion Shaft N ut

167

123

Transfer Dr iven Gear H ousin g to Case (F4A 40 Ser ies)

23

17

Transfer Dr iven Gear H ousin g to Case (F4A 50 Ser ies)

54

40

Di ff erential Ring Gear Bolts

135

100

Conver ter H ousin g to Case

48

35

Rear Cover to Case

23

17

Oil Pan to Case

11

95

I nput An d Out put Shaf t Speed Sensor

11

95

Tr ansaxle Range Sensor to Case

11

95

External M anual L ever to Shaft N ut

22

Speedometer A dapter to Case

11

95

Pul se Generator to Case

11

95

Seali ng Cap to Case

5

9

These Units Ar e Ver y Sensitive To F luid Requir ements

16

M itsubishi Diamond SP I I I


Figure 228

116


Technic al Service Informat ion IMPORTANTSPRAGINFORMATION Un its " without" a one-way clu tch, earl y design F 4A41, F4A42, and F 4A51 have a 4 bolt transfer dri ve gear beari ng housing that mounts it to the case. On these units the tr ansfer dr ive gear housing can be removed thr ough th e front of the case by removing j ust the four bolts. Un its that are equi pped with a one-way clu tch, wil l h ave eith er 7 or 8 tr ansfer dri ve gear bear in g housing mounti ng bolts. F 4A41 and F4A 42 wil l have 7. Th e F 4A51 wil l have 8. On these units the hou sing cannot be r emoved by just removing the bolts. Th e one-way clu tch in ner r ace must be dis- assembled and r emoved f ir st, whi ch i s basicall y the rear end of the uni t. Th e one-way clutch in ner r ace is spli ned onto the back of th e tr ansfer dr ive gear an d is used as a retain er f or th e low/r ever se piston r etur n spri ng and retainer plate. I t is held in place with a snap rin g. This prevents r emoval of the transfer dri ve gear and hou sin g, without f ir st dis-assembli ng the rear end of the uni t. The bottom of th e one-way clu tch in ner r ace, has a groove that a " L ip Type" seal f its in to. This seal " must" be in stalled, and in stalled in the r ight dir ection for proper sprag lu bri cation. Th e top of th e one-way clut ch inn er race has two half -moon shaped notches, 180 degrees apart. Th ese hal f-moon notch es must be placed at the 6 and 12 o'clock positi ons dur in g assembly, again for proper one-way clu tch lu bri cation. 1997 Di amonte with the F 4A51, without a one-way clu tch, use a TCM with a " M etal" case. 1997-1/2 and later with F 4A51, wit h a one-way clut ch, use a TCM with a " Plastic" case. The TCM and the tr ansaxles " are not interchan geable" with one another. I f they happen to be in terchanged, the foll owing wil l occur: L ate " Plastic" TCM i nstalled in earl y production non one-way clutch uni t, wil l pr oduce neutr al condition at 6mph when taking off fr om a stop. Earl y " M etal" TCM in stalled in late production uni t, equipped with one-way clutch, wil l resul t in har sh coastin g 2-1 downshi ft, ju st befor e coming to a stop.


Figure 229


117


4

3

2

1

1 2 3 4

LOW/REVERSE CLUTCH ACCUMULATOR PISTON AND SPRINGS. UNDERDRIVE CLUTCH ACCUMULATORPISTON AND SPRINGS. SECOND C LUTCH ACCUMULATOR PISTON AND SPRINGS. OVERDRIVECLUTCH ACCUMULATOR PISTON AND SPRING.

ACCUMULATOR SPRINGIDENTIFICATION

ACCUMULATOR SPRINGPART NUMBERS SPRINGANDLOCATION

NOT E: The shaded areas are the identification " Bluing" .

OR

L ow/Reverse Outer

MD757750

L ow/Reverse I nn er

MD758139

Un derdri ve Outer

MD758143

Un derdr ive I nner

MD758144

2nd Clutch Ou ter

MD758138

2nd Clutch I nner

MD758140

Overdri ve Outer

MD757750

Overdr ive I nner 1

2

3

Not Used

4

NO.

ACC UMUL ATO R

1

L ow/Reverse Clutch

None

2

Un derdr ive Clu tch

H alf or 2/3rds

3

2nd Clutch

Ful l Surf ace

4

Overdri ve Clu tch

None

I.D. " Bluing"


Figure 230

118

PART NUMBER


Technic al Service Informat ion PRESSURE TAP LOCATIONS

0 0 9 P

P8 8 9 9 6 7 N

U S A

®

N

E K

M I

T

1 B 5 E 2 K 1 5 A 4 F

A TF

TCC Apply

TCC Release Reverse Clutch

Overdrive Clutch

F 4 A5 A51 1

500766

Second Cl utch Un derdr ive Clu tch L ow/Rever se Clutch Copyr ight © 2005 ATSG

Figure 231


119

ATSG F4A41.pdf

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