Mitsubishi L200. Manual — part 319

AK403457AB

Transmission
side

Identification
symbol A

TRANSMISSION

AUTOMATIC TRANSMISSION OVERHAUL <R4A5>

23B-40

CAUTION

• Install the parking gear so that the side with-

out the spline cut faces the transmission side.

• Heat the parking gear to 160 − 180 °C and

shrink fit up to the stepped section of the out-
put shaft. Do not heat for longer than neces-
sary at this time.

AK800430AB

Snap ring

Parking gear

65.Install the parking gear and snap ring.

AK601368AC

Inhibitor switch

66.Install the inhibitor switch, and fix the fastening

bolts temporarily.

AK403343

Inhibitor switch

Manual control lever

AB

67.Install the manual control lever.
68.Tighten the manual control lever mounting bolts to

the specified torque 21.5

± 3.5 N⋅m.

AK403342

69.Install the output shaft speed sensor.
70.Tighten the output shaft speed sensor mounting

bolt to the specified torque 11

± 1 N⋅m.

AK403341

71.Install the input shaft speed sensor.
72.Tighten the input shaft speed sensor mounting

bolt to the specified torque 11

± 1 N⋅m.

CAUTION

Apply ATF to the oil pump drive hub before
installing the torque converter. Be careful not to
damage the oil seal lip when installing the torque
converter.

AK503859

A

AB

73.Install the torque converter, and secure it so that

the dimension (A) indicated in the illustration
meets the reference value.

Reference value: 20.9 mm

REVERSE AND OVERDRIVE CLUTCH

AUTOMATIC TRANSMISSION OVERHAUL <R4A5>

23B-41

REVERSE AND OVERDRIVE CLUTCH

DISASSEMBLY AND REASSEMBLY

M1233021200483

AK700992

4

5

6

1

2

3

7

8

9

14

15

16

11

12

13

17

18

21

22

10

20

4

5

6

1

2

3

7

8

9

14

15

16

11

12

13

17

18

19

21

22

10

20

19

AB

Apply automatic
transmission fluid
to all moving parts
before installation.

Disassembly steps

1.

Seal ring

2.

Snap ring

3.

Input shaft

>>

H

<<

4.

Snap ring

>>

G

<< 5.

Reaction plate

>>

G

<< 6.

Clutch disc

>>

G

<< 7.

Clutch plate

>>

F

<<

8.

Snap ring

>>

E

<<

9.

Reaction plate

>>

E

<<

10. Clutch disc

>>

E

<<

11. Clutch plate

<<

A

>>

>>

D

<<

12. Snap ring
13. Spring retainer

>>

A

<<

14. D-ring

>>

C

<<

15. Return spring
16. Overdrive clutch piston

>>

A

<<

17. D-ring

>>

B

<<

18. Reverse clutch piston

>>

A

<<

19. D-ring

>>

A

<<

20. D-ring

>>

A

<<

21. D-ring
22. Reverse clutch retainer

Disassembly steps (Continued)

REVERSE AND OVERDRIVE CLUTCH

AUTOMATIC TRANSMISSION OVERHAUL <R4A5>

23B-42

DISASSEMBLY SERVICE POINT

<<A>> SNAP RING REMOVAL

AK403382AB

Snap ring

MD999590

MD998924

1. Set special tools as shown in the illustration.

• Spring compressor (MD999590)

• Spring compressor retainer (MD998924)

2. Compress the return spring, and remove the snap

ring.

REASSEMBLY SERVICE POINTS

>>A<< D-RING INSTALLATION
1. Apply ATF to the D-ring.
2. Install the D-ring in the reverse clutch retainer,

piston, overdrive clutch piston and spring retainer
grooves. Make sure that the D-ring is not twisted
or damaged when installing.

>>B<< REVERSE CLUTCH PISTON
INSTALLATION

AK705065AB

B

A

Align the reverse clutch piston and reverse clutch
retainer holes (A and B), and then assemble.

>>C<< RETURN SPRING INSTALLATION

AK700994

AB

Align the two return spring holes with the two projec-
tions on the overdrive clutch piston, and then assem-
ble.

>>D<< SNAP RING INSTALLATION

AK403382AB

Snap ring

MD999590

MD998924

1. Set special tools as shown in the illustration.

• Spring compressor (MD999590)

• Spring compressor retainer (MD998924)

2. Tighten the special tool nut, and press the spring

retainer against the reverse clutch retainer.

3. Install the thickest snap ring that can be fitted in

the snap ring groove of reverse clutch retainer.

AK403386

4. Check the clearance between the snap ring and

spring retainer. If the clearance is not within the
standard value range, make adjustment by
selecting a snap ring of an appropriate thickness.

Standard value: 0

− 0.09 mm

(For overdrive clutch return spring retainer
end play)

REVERSE AND OVERDRIVE CLUTCH

AUTOMATIC TRANSMISSION OVERHAUL <R4A5>

23B-43

>>E<< CLUTCH PLATE / CLUTCH DISC /
REACTION PLATE INSTALLATION

AKX00126

Clutch plates

Rounded edge

Clutch discs

Reaction
plate

R1
stamp

AE

1. Alternately assemble the clutch disc and clutch

plate in the reverse clutch piston.

2. Install the reaction plate so that it is oriented as

shown in the illustration.

>>F<< SNAP RING INSTALLATION
1. Install the snap ring in the reverse clutch piston

groove.

AK403634AB

MD998924

MB991629

2. Set special tools as shown in the illustration, and

compress the clutch element

• Spring compressor (MB991629)

•

AKX00129

Snap ring

Standard value

Reaction plate

AC

Spring compressor retainer (MD998924)

3. Check the clearance (overdrive clutch end play) of

the snap ring and reaction plate is the standard
value. If the clearance is not at the standard
value, select the snap ring and adjust so that the
clearance is within the standard value.

Standard value: 2.0

− 2.2 mm

(For overdrive clutch end play)

>>G<< CLUTCH PLATE / CLUTCH DISC /
REACTION PLATE INSTALLATION

CAUTION

Soak the clutch discs in ATF before installing
them.

AKX00130

B

A

AC

1. Alternately assemble the clutch plate and clutch

disc in the reverse clutch retainer. Align and
assemble both clutch plates (where there are no
teeth) (A in the illustration) with the reverse clutch
retainer hole (B in the illustration).

AKX00131

Reaction plate

Clutch plates

Rounded edge

R stamp

Clutch discs

AC

2. Install the reaction plate so that it is oriented as

shown in the illustration. Assemble in the same
manner as the clutch plate so the section with no
teeth (A in the illustration) matches the retainer
hole (B in the illustration).

>>H<< SNAP RING INSTALLATION

AKX00384

MD998924

MB991789

Standard
value

AD