2004 Mitsubishi Truck Endeavor V6-3.8L SOHC Vehicle > Transmission and Drivetrain > Automatic Transmission/Transaxle > Service and Repair > Overhaul > F4A5A > Disassembly and Assembly DISASSEMBLY TRANSAXLE DISASSEMBLY AND ASSEMBLY Part 1 Of 3 https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 1/37
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Part 3 Of 3 [F4A5A] Part 1 Of 4 https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 4/37
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Part 3 Of 4 https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 6/37
Part 4 Of 4 https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 7/37
[W4A5A> https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 8/37
DISASSEMBLY CAUTION: ^ Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly. ^ The working area should be covered with a rubber mat to keep it clean at all times. ^ Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material. ^ Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air. ^ Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid ( ATF ). ^ If the transaxle body has been damaged, disassemble and clean the cooler system. 1. Remove the transfer and O-ring [W4A5A> 2. Use a dial gauge to measure the input shaft end play. 3. Remove the torque converter. 4. Remove each bracket. 5. Remove the dipstick. 6. Remove the eye bolt, gaskets and the oil cooler feed tube. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 9/37
7. Remove the input shaft speed sensor and output shaft speed sensor. CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 10/37
8. Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch. 9. Remove the sealing cap and O-ring. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 11/37
10. Remove the valve body cover. 11. Remove the manual control shaft detent. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 12/37
12. Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors. CAUTION: ^ Make sure that the manual control lever and the park/neutral position switch are removed. See step 8. ^ Do not remove the bolts (four pieces) shown in the illustration. 13. Remove the valve body mounting bolts (twenty seven pieces). https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 13/37
CAUTION: Do not lose the two steel balls. 14. Remove the valve body, gasket and the two steel balls. 15. Remove the snap ring from the connector and then push the connector into the transaxle case and remove the solenoid valve harness. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 14/37
16. Remove the strainer and the second brake retainer oil seal. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 15/37
17. Remove each accumulator piston and spring. 18. Remove the manual control lever shaft roller. 19. Remove the manual control lever shaft and the parking pawl rod. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 16/37
20. Remove the torque converter housing mounting bolts (18 pieces), and then remove the torque converter housing. 21. Remove the differential bearing outer race and spacer from the torque converter housing. 22. Remove the O-rings (two pieces). https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 17/37
23. Remove the differential. 24. Remove the differential bearing outer race from the transaxle case. 25. Remove the oil filter. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 18/37
26. Remove the oil pump mounting bolts (six pieces). 27. Install special tool MD998333 in hole "A." https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 19/37
28. Turn special tools MD998333 to remove the oil pump. 29. Remove the oil pump gasket. 30. Remove thrust washer number 1. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 20/37
31. Holding the input shaft, remove the underdrive clutch and input shaft. 32. Remove thrust bearing number 2. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 21/37
33. Remove the underdrive clutch hub. 34. Remove the rear cover. 35. Remove thrust race number 8. 36. Remove the seal rings (four pieces). 37. Remove the input shaft rear bearing. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 22/37
38. Remove the O-rings (three pieces). 39. Remove the reverse and overdrive clutch and thrust bearing number 7. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 23/37
40. Remove overdrive clutch hub and thrust bearing number 6. 41. Remove thrust bearing number 5. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 24/37
42. Remove the planetary reverse sun gear. 43. Remove the snap ring. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 25/37
44. Remove the second brake piston and the return spring. 45. Remove the pressure plate, brake discs and brake plates. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 26/37
46. Remove the planetary carrier assembly. 47. Remove the snap ring. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 27/37
48. Remove the reaction plate and the brake disc. 49. Remove the snap ring. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 28/37
50. Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate. 51. Remove the wave spring. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 29/37
52. Remove the parking pawl shaft, and then remove the spacer and spring. 53. Remove the two parking roller support shafts, and then remove the parking roller support. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 30/37
54. Remove the one-way clutch inner race and low-reverse brake piston as follows: 1. Using special tools MD998338 and MD998924, compress the one-way clutch inner race. NOTE: This illustration shows F4A5A. 2. Remove the snap ring. 3. Remove the special tools. 4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 31/37
55. Remove the four transfer drive gear bearing mounting bolts. Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts. 56. Remove the transfer drive gear. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 32/37
57. Remove the cap by inserting a screw driver into the center of the cap and prying it up. 58. Using a chisel, remove the staked nut from the output shaft. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 33/37
CAUTION: The jam nut is reverse threaded. 59. Use special tools MB991625 and MB990607 to remove the output shaft jam nut. 60. Remove the bearing retainer mounting bolts. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 34/37
61. Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar. 62. Remove the outer race and the spacer. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 35/37
63. Remove the snap ring. https://my.alldata.com/repair/#/repair/article/39258/component/844/itype/402/nonstandard/1480043 36/37
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