In some cases, there are problems in the valve body. In case of failure of valve body should be carried out costly and time-consuming heavy overhaul. Do not require any special service maintenance. It was necessary only regularly change the oil in automatic transmission and the filter elements.
Car owners had to carry out periodic inspection of the pads in the transmission and at the first sign of oil leaks visiting the service center to eliminate the existing overlap. As a general rule, a serious problem and the need for major repairs occur after driving , kilometers. Repair of modified automatic five-speed transmission F5A51 is performed exclusively with the use of special equipment. In the presence of high-quality diagnostic assistant can easily determine the nature of the failure and eliminate the problem at minimal cost.
Install the underdrive clutch plates beginning with a steel plate and alternating with friction plates, as shown in Figure , until you have installed four of each. Note: When installing the steel plates, align them so that the places with no teeth will be aligned with the lube holes in the housing, as shown in Figure Note: Friction plates should be soaked in ATF for 1 hour before installation.
Install the underdrive clutch backing plate, as shown in Figure and , with the rounded edge towards the friction. Install the underdrive backing plate selective snap ring, as shown in Figure Install the clutch compressing tools, as shown in Figure and Note: Underdrive lined plates are "Waved" on all models and must be compressed as shown in Figure to achieve the proper clutch clearance reading. The underdrive friction plates were changed in May, to a friction with a less perceptable wave, but must still be compressed.
Change the selective snap ring as necessary, using the chart in Figure , to obtain proper underdrive clutch clearance. Install the turbine shaft through the underdrive clutch housing, as shown in Figure , install snap ring and ensure that it is fully seated. Install two new turbine shaft sealing rings, as shown in Figure , and ensure rotation. Set the completed underdrive clutch housing aside for the final assembly process.
Clean and inspect the underdrive clutch hub thoroughly. Set the completed underdrive clutch hub aside for the final assembly process, as shown in Figure Disassemble the differential assembly using Figure as a guide. Clean and inspect all of the differential parts thoroughly. If bearing service is required, the tools shown in Figure , or their equivalant will be necessary.
Remove the bearings using the split puller and the appropriate size general service gear puller as shown in Figure Install the tapered roller bearings using the special tools, shown in Figure and using a suitable press. Assemble the differential side gears and pinion gears, as shown in Figure Measure the backlash between the side gears and pinion gears, as shown in Figure If backlash is out of specification, as shown in Figure , select a spacer from the chart and re-measure the backlash.
Note: Adjust until the backlash is equal at both side gears. Set the differential assembly aside for the final assembly process See Figure Disassemble the oil pump assembly using Figure as a guide.
Remove and discard oil pump gasket, "O" ring seal and converter seal See Figure Clean all oil pump parts thoroughly with good cleaning solution and dry with compressed air. Note: Inspect ring lands on the pump cover very carefully, as shown in Figure It is very common to see wear here. Install new oil pump bushing if necessary, as shown in Figure , using the proper bushing driver.
Turn oil pump over and install new converter seal, as shown in Figure , using the proper seal installer. Turn the oil pump over and install pump gears into the pump pocket, as shown in Figure , with the "Dots" facing UP, as shown. Note: Lubricate pump gears and pocket with liberal amount of ATF.
Install the pump alignment tool through the bushing, as shown in Figure , and set the completed oil pump body assembly on flat surface. Install the oil pump cover through and into the pump alignment tool, as shown in Figure Install the oil pump to pump cover retaining bolts, as shown in Figure Note: The oil pump alignment tool "Must" remain in place until the torque process is completed.
Install the underdrive clutch sealing rings, as shown in Figure , and ensure that they are properly hooked and have free rotation. Turn the completed assembly over and remove the pump alignment tool.
Set the completed oil pump assembly aside for the final assembly process See Figure BY Technical Service Information. Remove the two exhaust check balls from the top of the solenoid body and place in a safe location, as shown in Figure Remove the four solenoid body to main valve body retaining bolts, as shown in Figure Remove the solenoid body cover, the solenoid valve body, and solenoid body spacer plate, as shown in Figure Remove the two check balls and springs, and the check ball from the bath tub location, and place in a safe location.
Turn the main valve body over and remove the two main spacer plate retaining bolts, as shown in Figure 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.
Disassemble main valve body and place valves, springs, retainers in appropriate trays exactly as they were removed See Figure Clean all valve body parts thoroughly and dry with compressed air. Assemble the main valve body parts exactly, as shown in Figure , and lube with ATF as they are installed. Disassemble solenoid valve body and place the valves, springs, retainers in appropriate trays exactly as they were removed See Figure Clean all solenoid valve body parts thoroughly and dry with compressed air.
Assemble solenoid valve body parts exactly, as shown in Figure , and lube with ATF as they are installed. The OEM part number for all solenoids is MD, and is also available from several aftermarket sources. All solenoids can be air checked using the procedure shown in Figure Install all of the solenoid assemblies into the locations shown in Figure The main valve body and solenoid valve body retainer locations have been provided for you in Figure Lay the assembled main valve body on a flat work surface, as shown in Figure Install the "C" check ball and spring with the spring going in first, as shown in Figure Install the "D" check ball and spring with the spring going in first, as shown in Figure Install new seal on the damping valve "E" and install assembly with the spring going in first, as shown in Figure Note: Spring and check ball dimensions are shown in Figure Install the main valve body spacer plate and bolts, as shown in Figure Note: Install the hollow dowels in valve body to align spacer plate before torquing.
Turn the valve body over with the spacer plate facing down, as shown in Figure Install the "A" check ball and spring with the spring going in first, as shown in Figure Install the "B" check ball and spring with the spring going in first, as shown in Figure Install the last check ball into the bath tub, as shown in Figure Install the solenoid body spacer plate, solenoid body and the solenoid body cover, as shown in Figure Install the four solenoid body to main valve body bolts in locations shown in Figure Note: Hand tighten the bolts as the torque process will follow in final assembly.
Set the completed valve body assembly aside for final assembly process See Figure If it was removed for bearing service, pinion shaft and driven transfer gear assembly must be installed first, as shown in Figure Note: Pinion shaft and driven transfer gear pre-load must be set and checked while not engaged with any other gears. Install the completed pinion shaft and driven transfer gear assembly into the case, as shown in Figure Note: Ensure bearing collar is still in place.
Install the four required new retaining bolts, as shown in Figure , and torque the bolts to: F4A Note: New bolts are required because there is sealer on the threads.
Rotate transaxle case so that rear is facing up, as shown in Figure , and ensure that small bearing cup and spacer are still in place. Install the small tapered roller bearing onto pinion shaft, as shown in Figure Install a new pinion shaft nut, as shown in Figure Special Note: This nut is "Left Hand" thread. 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 Note: This nut is "Left Hand" thread.
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 Note: Allen head socket size is shown in Figure , for the different models. After the nut is properly torqued, check the turning torque with a gage type, inch pound torque wrench, as shown in Figure If turning torque is not correct, choose a new spacer thickness from the chart in Figure , based on your turning torque.
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 Then you can choose a spacer from the chart that is approximately.
After the turning torque is correct, stake the pinion retaining nut in two places, as shown in Figure Align the reference marks that you put on the case and bearing housing during disassembly, as shown in Figure Note: If you neglected to do this, you will have to search, as it installs in one direction only. Install transfer drive gear assembly, as shown in Figure , by aligning the reference marks.
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 retaining bolts will vary depending on model. There could be four, seven, or eight bolts. Rotate transfer drive gear as necessary so the access holes expose the retaining bolts to get them all installed and tightened. Rotate transaxle case so front side is facing up, as shown in Figure Note: All parking pawl parts are illustrated in Figure Pre-assemble park pawl, return spring, and the bushing, as shown in Figure Install parking pawl, return spring and bushing assembly into the case, as shown in Figure , and install the pivot pin.
Note: The park pawl pivot pin is the larger diameter of the three pins. Hook the parking pawl return spring in the window of bearing support See Figure Install the parking roller support, as shown in Figure , and install the retaining pins. Note: All of the parking pawl pins are soft and will bend easily. Note: Check once again to ensure that park pawl return spring is hooked in the window, as shown in Figure Push the pins down as far as they will go, by hand only, as shown in Figure Install a new "Lip" type seal into the groove on back side of the sprag inner race, as shown in Figure , with the lip facing down.
Note: This is a lube seal and must be installed in sprag race with lip facing down as shown. Install the sprag inner race, with the seal side facing down, as shown in Figure Check the placement of the I. The sprag inner race must be installed with the I. Compress the sprag race, retainer and return spring using special tools shown in Figure , and install snap ring.
Remove the compression tools. Install the. Note: Do not install any clutches at this time. Measure with a feeler gage between pressure plate and the selective snap ring, as shown in Figure Mitsubishi wants maximum of. Specification is 0" -. Select a snap ring from the chart in Figure to achieve the desired specification. Now remove the pressure plate and snap rings from the transaxle case. Continued on Page 89 60 61 62 60 61 62 Snap Ring Clearance 0 - 0. Note: This cushion plate is quite often broken and ATSG recommends replacement on every rebuild as a precautionary measure.
Note: "Do Not" yet install the last friction. Now, install the last friction, the pressure plate with step down and the selective snap ring. Change the selective apply plate using chart in Figure , to obtain specified clearance.
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 Special Note: Number of plates will vary depending on the model. Check the 2nd clutch clearance with a feeler gage, between the selective apply plate and the 2nd clutch piston, as shown in Figure Change selective apply plate as necessary to obtain correct 2nd clearance, using the chart in Figure Now, remove the complete 2nd clutch pack using Figure , as a guide.
Ensure proper sprag installation, as shown in Figure Note: Planetary should freewheel counterclockwise and lock clockwise, as shown in Figure Sprag not used in all models. Install the pre-assembled sun gear and shell assembly, as shown in Figure Note: Ensure that number 5 thrust bearing is still in place and installed correctly, as shown in Figure Now re-install the 2nd clutch plates beginning with 1 friction plate, as shown in Figure Install the "Stepped" apply plate, as shown in Figure , with the step facing down.
Install the remaining friction and steel plates, as shown in Figure Special Note: Number of plates will vary depending on model, as shown in the chart on Page Install the selective apply plate, as shown in Figure Install the 2nd clutch piston return spring, as shown in Figure Install 2nd clutch piston and retainer assembly, as shown in Figure , and install snap ring.
Note: Ensure that locating tab is engaged into the case groove See Figure Install the overdrive clutch hub, as shown in Figure , and ensure that number 6 thrust bearing is installed correctly. Install the number 7 thrust bearing, as shown in Figure Note: Do not install the selective number 8 thrust plate. It is shown in Figure for reference only as to where it goes when it is time to install the washer. Install "H" gage on transaxle case, as shown in Figure , and set adjustment rod on roller surface of the number 7 bearing, as shown in Figure Lock the adjustment rod in place.
Adjustment rod must be on the roller surface of the bearing, as shown in Figure Now, turn "H" gage over and set on the rear cover, as shown in Figure Measure with feeler gage between number 8 thrust plate and adjustment rod, as shown in Figure , for proper rear end clearance.
Rear end clearance should be as follows: 0. Change the selective plate as necessary to obtain the proper specification, using the chart in Figure Apply a 2 mm. Note: Install the cover within 15 minutes while the sealant is still wet.
Ensure that "O" rings are in place on the case and install rear cover, as shown in Figure Install the ten rear cover to case retaining bolts as shown in Figure Rotate the transaxle case so that front side is facing up, as shown in Figure Install the underdrive clutch hub, as shown in Figure Ensure that the number 2 thrust bearing is installed in the proper direction, as shown in Figure Install the original selective shim and new bearing cone,as shown in Figure , into the converter housing using proper drivers.
Note: If for any reason you do not know what spacer goes here, you must install the bearing cup without the spacer. Install a dial indicator with the stem resting on the socket, as shown in Figure , and zero the dial indicator. 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.
Choose a spacer from the chart in Figure that is approximately. Remove the converter housing and the bearing cup, install the selected spacer and re-install the bearing cup, as shown in Figure Install the underdrive clutch housing and the number 1 selective thrust washer, as shown in Figure Install the "H" gage on transaxle, as shown in Figure , and let the adjustment leg down to rest on the selective thrust washer. Turn the "H" gage over and set it on oil pump assembly, as shown in Figure Measure with a feeler gage between the pump surface and "H" gage adjustment leg, as shown in Figure , for proper front end play.
Proper front end play should be as follows;. Change selective thrust washer as necessary using the chart in Figure , to obtain proper input shaft end play. Install the oil pump gasket on transaxle case, as shown in Figure Install the pre-assembled oil pump assembly, as shown in Figure Install the filter assembly into the transaxle case, as shown in Figure Install the differential assembly into the case, as shown in Figure Install dial indicator, as shown in Figure , to ensure that front transaxle clearance is;.
Install the converter housing, as shown in Figure , while the sealant is still wet. Assemble the park actuating rod to the inside detent lever, as shown in Figure and Install the inside detent lever assembly into the case, as shown in Figure , and install the retaining pin through the pan rail and shaft. Install new "O" ring on case connector, as shown in Figure , and lube with a small amount of Trans-Jel. Install the internal wire harness from inside the case and through the case bore, as shown in Figure , and install snap ring.
Lay internal harness back over the pan rail, as shown in Figure , so that it is out of the way for accumulator piston and valve body installation. Install new scarf cut accumulator piston seals on each of the four accumulator pistons, as shown in Figure Install each accumulator piston, seal and the proper springs, as shown in Figure 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. Install the case oil screen into the worm track as shown in Figure Install a new 2nd clutch case seal assembly, as shown in Figure Ensure that the two steel exhaust balls are still in place in the top of valve body, as shown in Figure Install the pre-assembled valve body assembly over the hollow dowels in the case, as shown in Figure Note: Ensure that manual valve is engaged into the slot in the inside detent lever as you install the valve body.
Install all valve body bolts in their proper locations, as shown in Figure Note: Refer to Figure for proper bolt location, length and identification. Hand tighten only at this time. Body To Case 1 70mm Sol. Install a new "O" ring on the transaxle temp sensor, as shown in Figure Install the temperature sensor and retaining bolt, as shown in Figure Check once again to ensure that manual valve is connected to inside detent lever, and install the detent spring, as shown in Figure Connect the internal harness connectors to the individual solenoids, and connect the temp sensor, as shown in Figure Note: Install oil pan while sealant is still wet.
This would be a good time to ensure that the manual valve is properly hooked, all solenoid connectors and temp sensor are connected. Note: None of the sealant surfaces or fresh sealant can be exposed to ATF for 1 hour, to give sealant time to dry properly. Install the fluid level indicator into tube, as shown in Figure Install new external oil filter on transaxle, as shown in Figure Do not over-tighten.
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 Install new speedometer driven gear shaft seal with lip facing gear, as shown in Figure , install retaining clip and driven gear. Install the torque converter into the transaxle, as shown in Figure , and ensure that hub is engaged properly in pump gear.
Note: Apply ATF to converter hub and also prime converter to soak the converter clutch before installing, and use care not to damage converter seal during installation. Ensure that converter is engaged into pump gear by measuring from face of bell housing to converter pad surface See Figure On these units the transfer drive gear housing can be removed through the front of the case by removing just the four bolts. Units that are equipped with a one-way clutch, will have either 7 or 8 transfer drive gear bearing housing mounting bolts.
F4A41 and F4A42 will have 7. The F4A51 will have 8. On these units the housing cannot be removed by just removing the bolts. The one-way clutch inner race must be disassembled and removed first, which is basically the rear end of the unit. It is held in place with a snap ring. This prevents removal of the transfer drive gear and housing, without first dis-assembling the rear end of the unit. The bottom of the one-way clutch inner race, has a groove that a "Lip Type" seal fits into.
This seal "must" be installed, and installed in the right direction for proper sprag lubrication. The top of the one-way clutch inner race has two half-moon shaped notches, degrees apart. These half-moon notches must be placed at the 6 and 12 o'clock positions during assembly, again for proper one-way clutch lubrication. The TCM and the transaxles "are not interchangeable" with one another. If they happen to be interchanged, the following will occur: Late "Plastic" TCM installed in early production non one-way clutch unit, will produce neutral condition at 6mph when taking off from a stop.
Early "Metal" TCM installed in late production unit, equipped with one-way clutch, will result in harsh coasting downshift, just before coming to a stop. OR 1 NO. With TCC fully applied pressure should be approximately psi. Get notified when we add a new MitsubishiOther Model Manual. Notify me. We cover 60 Mitsubishi vehicles, were you looking for one of these?
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