Mitsubishi Colt Ralliart. Manual — part 289

TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION OVERHAUL

23B-29

ADJUSTMENT OF TRANSMISSION

M1233030400140

SPEACER SELECTION FOR ADJUST-
MENT OF OUTPUT SHAFT BEARING END
PLAY AND DIFFERENTIAL BEARING END
PLAY
<Measurement using Solder>

CAUTION

• If the solder is not available, select the spacer

in accordance with Plastigage method.

• If the spacer appropriate for the standard

value cannot be selected using the solder,
select the spacer in accordance with Plasti-
gage method.

AK402202AD

Solder

Solder

1. Place two pieces of solder (1.0 mm diameter,

about 10 mm long) in the shown locations of the
output shaft ball bearing and the differential ball
bearing.

AK401962

2. Install the converter housing on the transmission

case without applying FIPG. Tighten the mounting
bolts to the specified torque of 48

± 6 N⋅m.

3. Remove the converter housing from the

transmission case and take out the solder pieces
for obtaining the differential bearing end play.

4. Remove the bearing outer race from the converter

housing and take out the solder pieces for
obtaining the output shaft bearing preload.

5. If the solders have not crushed, use thicker

solders (1.6 mm diameter, about 10 mm long) and
repeat steps 2 to 4.

AK305233

6. Measure the thickness of the crushed solder

pieces using a micrometer. Based on the results,
select spacers which adjust the end play and
preload to the following standard values,
respectively, according to the tables below.

Standard value:

Output shaft bearing end play
0.045

− 0.165 mm

Differential bearing end play
0.045

− 0.165 mm

Output shaft bearing spacer

Measurement
mm

Thickness mm Identification

symbol

1.34

− 1.43

1.28

28

1.43

− 1.52

1.37

37

1.52

− 1.61

1.46

46

1.61

− 1.70

1.55

55

1.70

−1.79

1.64

64

1.79

−1.88

1.73

73

1.88

−1.97

1.82

82

Differential bearing spacer

Measurement
mm

Thickness mm Identification

symbol

1.16

− 1.25

1.10

J

1.25

− 1.34

1.19

L

1.34

− 1.43

1.28

N

1.43

− 1.52

1.37

P

1.52

− 1.61

1.46

R

1.61

− 1.70

1.55

T

1.70

− 1.79

1.64

V

1.79

− 1.88

1.73

X

1.88

− 1.97

1.82

Z

Main

Index

Group

TOC

TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION OVERHAUL

23B-30

<Measurement using Plastigage>

AK402202AD

Plastigage

Plastigage

1. Place two pieces of plastigage (about 10 mm

long) in the shown locations of the output shaft
ball bearing and the differential ball bearing.

2. Install the adjusting spacer having minimum

thickness.

AK401962

3. Install the converter housing on the transmission

case without applying FIPG. Tighten the mounting
bolts to the specified torque of 48

± 6 N⋅m.

4. Remove the converter housing from the

transmission case and take out the plastigage
pieces for obtaining the differential bearing end
play.

5. Remove the bearing outer race from the converter

housing and take out the plastigage pieces for
obtaining the output shaft bearing preload.

6. If the plastigages have not crushed, use thicker

adjusting spacer and repeat steps 3 to 5.

AK402081

Plastigage

Spacer

AB

7. Measure the width of the each crushed plastigage

at its widest part using a scale printed on the
plastigage package and record the each
measured value. Based on the results which
calculated by the following formula, select spacers
which adjust the end play and preload to the
following standard values, respectively, according
to the tables below.

T = T1 + T2
T: Clearance mm
T1: The crushed plastigage thickness mm
T2: The adjusting spacer thickness used for
measurement mm
Standard value:

Output shaft bearing end play
0.045

− 0.165 mm

Differential bearing end play
0.045

− 0.165 mm

Output shaft bearing spacer

Measurement
mm

Thickness mm Identification

symbol

1.34

− 1.43

1.28

28

1.43

− 1.52

1.37

37

1.52

− 1.61

1.46

46

1.61

− 1.70

1.55

55

1.70

−1.79

1.64

64

1.79

−1.88

1.73

73

1.88

−1.97

1.82

82

Differential bearing spacer

Measurement
mm

Thickness mm Identification

symbol

1.16

− 1.25

1.10

J

1.25

− 1.34

1.19

L

1.34

− 1.43

1.28

N

1.43

− 1.52

1.37

P

1.52

− 1.61

1.46

R

1.61

− 1.70

1.55

T

1.70

− 1.79

1.64

V

1.79

− 1.88

1.73

X

1.88

− 1.97

1.82

Z

Main

Index

Group

TOC

FORWARD CLUTCH

CONTINUOUSLY VARIABLE TRANSMISSION OVERHAUL

23B-31

FORWARD CLUTCH

DISASSEMBLY AND REASSEMBLY

M1233209000117

AK102832AD

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Apply automatic
transmission fluid
to all moving parts
before installation.

Disassembly steps

1.

Input shaft

2.

Seal ring

>>

E

<<

3.

Bearing

>>

D

<<

4.

Snap ring

>>

C

<<

5.

Forward clutch reaction plate

>>

C

<<

6.

Forward clutch disc

>>

C

<<

7.

Forward clutch plate

<<

A

>>

>>

B

<<

8.

Snap ring

9.

Spring retainer

10. Return spring
11. Clutch piston

>>

A

<<

12. D-ring

>>

A

<<

13. D-ring
14. Clutch retainer

Disassembly steps (Continued)

Main

Index

Group

TOC

FORWARD CLUTCH

CONTINUOUSLY VARIABLE TRANSMISSION OVERHAUL

23B-32

DISASSEMBLY SERVICE POINT
<<A>> SNAP RING REMOVAL

AK202441

MD998924

MD999590

AC

To remove the snap ring, compress the return spring
by holding down the spring retainer using the special
tools.

• Spring compressor retainer (MD998924)

• Spring compressor (MD999590)

REASSEMBLY SERVICE POINTS
>>A<< D-RING INSTALLATION

AK202442

D-ring

AC

Fit new D-rings into the illustrated locations. Coat
them with ATF, blue petrolatum or white vaseline,
then install the clutch piston in the clutch retainer
while taking care not to give damage to the D-rings.

>>B<< SNAP RING INSTALLATION

AK202441

MD998924

MD999590

AC

CAUTION

Do not use ATF or white vaseline.
1. Coat the lip seal of the spring retainer with blue

petrolatum.

2. To install the snap ring, compress the return

spring by holding down the spring retainer using
the special tools.

• Spring compressor retainer (MD998924)

• Spring compressor (MD999590)

>>C<< CLUTCH PLATES/CLUTCH
DISCS/CLUTCH REACTION PLATE
INSTALLATION

AK202443

Round
edge

Clutch plate

Stamped mark side

Clutch reaction plate

AF

Clutch disc

CAUTION

Immerse the clutch discs in ATF before assem-
bling them with the other parts.
Install the clutch plates, clutch discs, and reaction
plate, directing their ends as shown in the illustration.

Main

Index

Group

TOC