Mitsubishi Outlander XL. Manual - part 530

ZK602920AA00

L2

ZK603040AA00

A

ZK602921AA00

L4

ZK602922AA00

L5

ZK602923AA00

L6

L3 = L5 - (L4 + L6) -Thickness of straight bar

(4)

Calculate the end play using the following formula.

End play = L3 - (L1 - L2) - Thickness of straight
bar - Thickness of spacer

(5)

Select an appropriate needle bearing so that the specified
end  play  is  obtained.  Refer  to  "SERVICE  DATA"  for
selecting the needle bearing.

AUTOMATIC TRANSAXLE OVERHAUL

23B-55

TRANSAXLE

ZK602205AA00

38.

Install the high clutch assembly.

ZK602291AA00

Driven plate 

Retaining
plate

Brake piston

2-6 

Drive plate

Retaining
plate

Ensure that the various plates are installed in the correct
order.

39.

Install  the  2-6  brake  drive  plate,  driven  plate  and  selected
retaining plate on the transaxle case.

ZK602204AA00

｠

Never reuse the O-rings.

｠

Apply ATF to the O-rings before installation.

40.

Install an O-ring on the transaxle case.

ZK602203AA00

Spacer

Needle

bearing

｠

Never reuse the spacer.

｠

Apply Vaseline to the spacer and needle bearing before
installation.

｠

Ensure that the needle bearing faces the correct direction.

41.

Install an appropriate spacer and the needle bearing on the
side cover.

23B-56

AUTOMATIC TRANSAXLE OVERHAUL

TRANSAXLE

ZK602941

L1

L2

AA00

｠

Before  applying  the  sealant,  thoroughly  clean  the
mounting surface so that it is completely free of moisture,
lubricant and the old sealant.

｠

The start and finish of the bead should be close to the
middle of any pair of the adjoining bolt holes.

42.

Apply  Three  Bond  1216B  to  the  transaxle  case  mounting
surface  of  the  side  cover  (almost  the  center  line  of  the
surface).

L1 mm (in)

3  -  5  (0.1  -
0.2)

L2 mm (in)

2.3 (0.09)

ZK602984AA00

Mounting bolts are Torx E16 bolts.

43.

Install the side cover on the transaxle case. Refer to the table
below or the exploded view for tightening torque.

No. of bolts

14

Tightening torque: 27 N·m (20 ft-lb)

ZK602939AA00

Transaxle 

Drum support 

Thrust washer

FR Carrier 

Low clutch
 

3-5 Reverse

A

clutch

case

Measure the end play at more than two locations and obtain
the average of the measurements.

44.

Measure the drum support end play (A) using the following
procedure. Refer to "SERVICE DATA" for the specified drum
support end play (A).

(1)

Measure  distance  L1  between  the  end  face  of  the  RR
internal gear splines and the oil pump mounting surface
of the transaxle case.

(2)

Measure  distance  L2  between  the  thrust  washer
mounting surface of the drum support and the oil pump
mounting surface of the transaxle case.

(3)

Measure distance L3 using the following procedure.

a.

Install the FR carrier on the low clutch assembly.

｠

Apply  Vaseline  to  the  needle  bearing  before
installation.

｠

Ensure  that  the  needle  bearing  faces  the  correct
direction.

AUTOMATIC TRANSAXLE OVERHAUL

23B-57

TRANSAXLE

ZK602924

L1

AA00

ZK602925

L2

AA00

ZK602926AA00

FR Carrie

Low clutch

ZK602927AA00

FR Carrier

Needle bearing 

ZK602928AA00

FR Internal gear

FR carrier

b.

Install the needle bearing on the FR carrier.

c.

Install the FR internal gear on the FR carrier.

｠

Apply  Vaseline  to  the  needle  bearing  before
installation.

｠

Ensure  that  the  needle  bearing  faces  the  correct
direction.

d.

Install the needle bearing on the FR sun gear.

e.

Install the FR sun gear.

｠

Apply  Vaseline  to  the  needle  bearing  before
installation.

｠

Ensure  that  the  needle  bearing  faces  the  correct
direction.

f.

Install the needle bearing on the FR sun gear.

g.

Install the 3-5 reverse clutch assembly.

h.

Measure distance L3 between A and B.

(4)

Calculate the end play using the following formula.

End play = L3 - (L1 - L2) - Thrust washer thickness

(5)

Select an appropriate thrust washer so that the specified
end  play  is  obtained.  Refer  to  "SERVICE  DATA"  for
selecting the thrust washer.

23B-58

AUTOMATIC TRANSAXLE OVERHAUL

TRANSAXLE