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HOMESERVICE MANUALSMITSUBISHI1995MONTERO LS, AUTOMATIC, V4AW3REPAIR AND DIAGNOSISTRANSMISSIONAUTOMATIC TRANSOVERHAUL - V4AW3TRANSMISSION REASSEMBLY
1995 Mitsubishi Montero LS, Automatic, V4AW3

Transmission Reassembly

1995 Mitsubishi Montero LS, Automatic, V4AW3SECTION Transmission Reassembly
NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cut-outs and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with subassembly containing that bushing. Check thrust bearings and races for wear or damage. Use petroleum jelly to hold parts in place. Replace parts as necessary. Clutch discs should be soaked in ATF for 2 hours before installation.
  1. Install new transmission oil seals on side of case. Install new spacer on manual valve lever and install shaft into case. Align shaft hole with manual valve lever and install spring pin. Slide sleeve over spring pin and stake into place.
    NOTE: For thrust bearing installation position, see Fig 6 .
  2. Install 1st and reverse brake piston No. 1 to reaction sleeve. Install piston No. 1 with reaction sleeve on piston No. 2. Align piston No. 2 teeth into proper grooves. Carefully press brake pistons No. 1 and No. 2 into case. Position return spring assembly on piston No. 2. Using spring compressor, compress return spring assembly.
  3. Install snap ring. Ensure snap ring end-gap is not aligned with spring retainer claw. Ensure 1st and reverse brake pistons move smoothly by applying compressed air to case. See Figure .
  4. Install leaf spring. Install rear planetary gear with 1st and reverse brake pack and output shaft. Install flange with rounded edge toward planetary ring gear. Install plate first, then flange. Install plates and discs, starting with disc. Install proper amount of plates and discs.
  5. Install 2nd brake drum assembly. Install thrust bearing in case. Align teeth of 2nd brake drum, flange, discs and plates. Align splines of transmission case, and assembled rear planetary gear, 2nd brake drum, 1st and reverse brake pack and output shaft into case.
  6. Support output shaft on wooden blocks. Install snap ring in case with chamfered edge toward front of transmission. Ensure ends of snap ring are not aligned with cutout area of case. Measure 1st and reverse brake clearance between 2nd brake drum and plate. See Figure . Clearance should be .028-.048" (.70-1.22 mm)
  7. If clearance is not within specification, select a different thickness flange. Install 2nd brake piston sleeve. Install NEW brake gasket in case. Install No. 1 one-way clutch assembly. Install .071" (1.8 mm) flange plate with rounded edge side of plate facing disc. Install plates and discs. Install end flange with rounded edge facing disc. Install snap ring.
  8. Measure 2nd brake clearance between snap ring and flange. See Figure . Clearance should be .024-.078" (.62-1.98 mm). If clearance is not within specification, check for incorrect assembly.
  9. Install planetary sun gear. Turn planetary sun gear clockwise into No. 1 one-way clutch. Ensure all thrust washers are correctly installed. Install front planetary gear bearing and race. Install front planetary gear into sun gear. Install snap ring. Remove wooden block from under output shaft. Install race on front of planetary gear so race tabs align with planetary gear holes.
  10. Install 2nd coast brake band and pin. Pin must be installed so "E" ring is toward front of transmission. Install "E" ring. Coat thrust bearing and race with petroleum jelly and install on forward clutch. Raised portion of race must be toward front.
    NOTE: For thrust bearing installation position, see Fig 6 .
  11. Install race on front planetary ring gear. Smooth flat surface must be toward front. Align disc tabs of forward clutch. Install front planetary ring gear in forward clutch. Ensure gear is aligned with all clutch discs.
  12. Install bearing race and thrust bearing on ring gear. Raised portion of race must be toward rear. Install forward and direct clutch assembly and front planetary ring gear in transmission case. Measure distance between sun gear input drum and direct clutch drum. See Fig 1 . Clearance should be .210-.290" (5.30-7.30 mm). If clearance is not within specifications, check for incorrect installation.
    Fig 1: Measuring Input Drum & Direct Clutch Drum Clearance
    G95C20547Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Install thrust bearing and race on forward clutch assembly with flat side toward the clutch assembly. Install NEW "O" ring on 2nd coast brake cover. Install spring, 2nd coast brake piston assembly and cover to case. Install snap ring.
  14. Place reference mark on 2nd coast brake piston rod. Apply 57-114 psi (4.8 kg/cm squared) of air at opening of transmission case. Using wire gauge, measure clearance between reference mark and case. Clearance should be .059-.118" (1.49-3.00 mm). See Figure .
  15. If stroke is not within specification, install replacement piston rod. Rods are available in lengths of 2.78" (70.7 mm), 2.81" (71.4 mm), 2.84" (72.2 mm) and 2.870" (72.9 mm). If stroke is not within specification, install NEW brake band. Install race on OD support. Align bolt and oil holes of OD support toward valve body side and bolt hole of case and install support.
  16. Ensure support is properly aligned. Install support snap ring with chamfered edge toward front of transmission. End of snap ring must be positioned to valve body side of case within .55-1.34" (14-34 mm) from center line of valve body as viewed from front of transmission.
  17. Using dial indicator, check output shaft end play. See Fig 2 . End play should be 011-.034" (.27-.86 mm). If end play is not within specifications, check for incorrect assembly. Ensure output shaft rotates smoothly.
    Fig 2: Measuring Output Shaft End Play
    G95D20548Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  18. Install a .157" (4.00 mm) thick flange with rounded edge facing disc. Install correct amount of discs and plates, beginning with plate. Install end flange (stepped ring) with flat side toward disc. Install snap ring. Ensure ends of snap ring are not located at cutout areas of case.
  19. Install dial indicator on case and measure piston stroke. Apply 57-114 psi (4-8 kg/cm squared) at opening of transmission case and note piston stroke. See Figure . Piston stroke should be .055-.067 (1.40-1.70).
  20. If piston stroke is not within specifications, check for incorrect installation. Recheck piston stroke. If piston stroke is not within specifications, install different thickness flange. Flanges are available in thicknesses of .130" (3.3 mm) to .157" (4.0 mm) in .008" (.20 mm) increments.
  21. Install thrust bearing and races on OD support. Ensure race tabs align with hole support. Install OD planetary ring gear. Install thrust bearing and race in ring gear. Install race on rear of OD planetary gear, aligning race tabs with holes of gear. Install OD planetary gear with OD clutch and one-way clutch. Install thrust bearing and race onto OD clutch with race flat side toward OD clutch.
  22. Install race on rear of oil pump with raised side toward oil pump. Install NEW "O" ring on outer diameter of oil pump. Ensure seal rings are installed on rear of oil pump. Align holes of oil pump and case. Install oil pump while holding input shaft and lightly pressing on oil pump.
    CAUTION: DO NOT apply excessive pressure on oil pump during installation or seal rings will stick to the direct clutch drum.
  23. Install oil pump bolts. Ensure input shaft rotates smoothly. Install throttle cable. Apply air pressure to specified oil passage to check operating components. See Fig 3 . When air checking the OD clutch, OD accumulator piston hole must be plugged.
    Fig 3: Air Testing Transmission Components
    G95E20549Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Install speed sensor rotor and key on output shaft. Install "E" ring, parking lock pawl, shaft and spring. Connect parking lock rod to manual valve lever. Position parking lock pawl, shaft and spring. Connect parking lock rod to manual valve lever. Position parking lock pawl bracket on case and install. See Figure .
  25. Install accumulator pistons with NEW "O" rings. Install accumulator springs. See Fig 4 . Accumulator pistons and springs must be proper diameter and height. Accumulator pistons are stamped with identification codes. For accumulator piston locations, see Figure -Figure . Determine proper spring free length. See ACCUMULATOR SPRING SPECIFICATIONS table.
    Fig 4: Identifying Accumulator Piston Assemblies
    G95I20550Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    ACCUMULATOR SPRING SPECIFICATIONS

    Piston Spring (ID Code) Free Length In. (mm) Diameter In. (mm)
    2nd Brake (B2)
    Inner 2.858 (72.60) .626 (15.90)
    Outer .866 (22.00) .551 (14.00)
    Direct Clutch (C2)
    Inner 2.764 (70.20) .795 (20.20)
    Outer .787 (20.00) .476 (12.10)
    OD Brake (B0)
    Inner 2.441 (62.00) .630 (16.00)
    Outer .571 (14.50) .512 (13.00)
    OD Clutch (C0)
    Inner 1.811 (46.00) .551 (14.00)
    Outer 2.937 (74.60) .823 (20.90)
  26. Install check ball body and spring. See Fig 5 . Install valve body. See CONTROL VALVE ASSEMBLY  under ON-VEHICLE SERVICE. Install speedometer drive gear and lock ball and snap ring on output shaft. Install extension housing and NEW gasket. Shorter mounting bolts go to bottom of extension housing.
  27. Install transmission housing. Install speed sensor and speedometer driven gear. Install front and rear cooler line unions. Install transmission oil temperature sensor. Install neutral safety switch. Tighten nut to 35 INCH lbs. (4 N.m). Align neutral basic line and switch groove. Bend at least 2 lock washer tabs.
  28. Install control shaft lever. If throttle cable is new, stake stopper on inner cable. Install wire harness and throttle cable clamp. Install torque converter. Using straightedge and depth gauge, measure distance from front of torque converter to front mounting surface of transmission housing. Distance should be 1.22" (31.1 mm). See Fig 7 .
Fig 5: Installing Check Ball Body & Spring
G95J20551Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
RENDER: 1.0x

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