Mitsubishi Outlander GS45X. Manual — part 1749

TORQUE SPECIFICATIONS

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AUTOMATIC TRANSAXLE OVERHAUL

23D-3

TORQUE SPECIFICATIONS

M1233023101645

Transaxle

Transfer

Size of torque wrench used

Item

N

⋅m

Output gear set mounting bolt

41

± 1 (30 ± 1 ft-lb)

Side cover mounting bolt

27

± 2 (20 ± 1 ft-lb)

Parking plate mounting bolt

7.9 (70 in-lb)

Oil strainer mounting bolt

9.4 (83 in-lb)

Oil pump assembly mounting bolt

21 (15 ft-lb)

Converter housing mounting bolt

47

± 2 (35 ± 1 ft-lb)

ATF adjusting bolt

7.4

± 2.4 (65 ± 21 in-lb)

Detent spring mounting bolt

4.9 (43 in-lb)

Oil temperature sensor mounting bolt

7.9 (70 in-lb)

Control valve assembly mounting bolt

7.9 (70 in-lb)

Control valve cover mounting bolt

9.0

± 0.9 (80 ± 8 in-lb)

Cooler tube eye bolt

33

± 3 (24 ± 2 ft-lb)

Cooler tube mounting bolt

22

± 1 (16 ± 1 ft-lb)

Baffle plate mounting bolt

6.6

± 1.0 (58 ± 9 in-lb)

Pressure test port bolt

7.4 (65 in-lb)

Water-cooled transmission fluid cooler mounting bolt

4.3

± 0.6 (38 ± 5 in-lb)

Manual control lever mounting nut

22

± 3 (16 ± 2 ft-lb)

Park/neutral position switch mounting bolt

5.9 (52 in-lb)

Turbine sensor mounting bolt

5.9 (52 in-lb)

Speed sensor mounting bolt

5.9 (52 in-lb)

Control cable bracket mounting bolt

23

± 3 (17 ± 2 ft-lb)

Oil filler tube mounting bolt

11

± 1 (97 ± 8 in-lb)

Harness bracket mounting bolt

23

± 3 (17 ± 2 ft-lb)

Corrugate clamp bracket mounting bolt

23

± 3 (17 ± 2 ft-lb)

FR roll stopper bracket mounting bolt

90

± 10 (66 ± 7 ft-lb)

RR roll stopper bracket mounting bolt

90

± 10 (66 ± 7 ft-lb)

Final gear mounting bolt

144 (106 ft-lb)

Item

N

⋅m

Transfer mounting bolt

69

± 9 (51 ± 6 ft-lb)

Cover mounting bolt

12

± 2 (106 ± 18 in-lb)

Tool size

Main parts to be used

E16

Side cover

E18

Output gear set

E20

Converter housing

ADJUSTING PLATE, SNAP RING, SHIM, SPACER, NEEDLE BEARING, THRUST WASHER AND BEARING RACE

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AUTOMATIC TRANSAXLE OVERHAUL

23D-4

ADJUSTING PLATE, SNAP RING, SHIM, SPACER, NEEDLE

BEARING, THRUST WASHER AND BEARING RACE

M1233023001068

Retaining plate (For adjustment of Low-reverse brake clearance)

Retaining plate (For adjustment of 2-6 brake clearance)

Differential taper bearing shim (For adjustment of differential preload)

Reduction gear taper bearing shim (For adjustment of reduction gear taper bearing preload))

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

2.9 (0.11)

None

3.7 (0.15)

None

3.1 (0.12)

None

3.9 (0.15)

None

3.3 (0.13)

None

4.1 (0.16)

None

3.5 (0.14)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

2.0 (0.08)

None

2.6 (0.10)

None

2.2 (0.09)

None

2.8 (0.11)

None

2.4 (0.09)

None

3.0 (0.12)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

0.12 (0.005)

None

0.60 (0.024)

None

0.16 (0.006)

None

0.64 (0.025)

None

0.18 (0.007)

None

0.68 (0.027)

None

0.20 (0.008)

None

0.72 (0.028)

None

0.24 (0.009)

None

0.76 (0.030)

None

0.28 (0.011)

None

0.80 (0.032)

None

0.32 (0.013)

None

0.84 (0.033)

None

0.36 (0.014)

None

0.88 (0.035)

None

0.40 (0.016)

None

0.92 (0.036)

None

0.44 (0.017)

None

0.96 (0.038)

None

0.48 (0.019)

None

1.00 (0.039)

None

0.52 (0.021)

None

1.22 (0.050)

None

0.56 (0.022)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

0.12 (0.005)

None

0.56 (0.022)

None

0.14 (0.006)

None

0.60 (0.024)

None

0.16 (0.006)

None

0.64 (0.025)

None

0.20 (0.009)

None

0.68 (0.027)

None

0.24 (0.009)

None

0.72 (0.028)

None

0.28 (0.011)

None

0.76 (0.030)

None

0.32 (0.013)

None

0.80 (0.032)

None

0.36 (0.014)

None

0.84 (0.033)

None

0.40 (0.016)

None

0.88 (0.035)

None

SEALANTS

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AUTOMATIC TRANSAXLE OVERHAUL

23D-5

Spacer (For adjustment of reduction sun gear end play)

Needle bearing (For adjustment of side cover)

Thrust washer (For adjustment of drum support)

Bearing race (For adjustment of 3-5 reverse clutch)

SEALANTS

M1233000501169

Transaxle

Transfer

.

0.44 (0.017)

None

0.92 (0.036)

None

0.48 (0.019)

None

0.98 (0.039)

None

0.52 (0.021)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

1.0 (0.04)

None

1.8 (0.07)

None

1.2 (0.05)

None

2.0 (0.08)

None

1.4 (0.06)

None

2.2 (0.09)

None

1.6 (0.06)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

2.8 (0.11)

None

3.6 (0.14)

None

3.0 (0.12)

None

3.8 (0.15)

None

3.2 (0.13)

None

4.0 (0.16)

None

3.4 (0.13)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

1.5 (0.06)

None

2.3 (0.09)

None

1.7 (0.07)

None

2.5 (0.10)

None

1.9 (0.07)

None

2.7 (0.11)

None

2.1 (0.08)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

2.0 (0.08)

None

2.6 (0.10)

None

2.2 (0.09)

None

2.8 (0.11)

None

2.4 (0.09)

None

3.0 (0.12)

None

Thickness mm (in)

Identification symbol

Thickness mm (in)

Identification symbol

Item

Specified sealant

Side cover

Three bond 1216B

Converter housing

Item

Specified sealant

Cover

3M

TM

ATD part No. 8660 or equivalent

LUBRICANTS

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AUTOMATIC TRANSAXLE OVERHAUL

23D-6

FORM-IN-PLACE GASKET (FIPG)

This transaxle has several areas where the
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when apply-
ing it. Bead size, continuity and location are of para-
mount importance.
Too thin a bead could cause leaks. Too thick a bead,
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To
prevent leaks or blocking of passages, therefore, it is
absolutely necessary to apply the FIPG evenly with-
out a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.

CAUTION

When re-applying liquid gasket (FIPG), be sure
that:

1. Residues of FIPG are cleared from all the ins

and outs of parts;

2. Use Mitsubishi genuine parts cleaner

(MZ100387) or equivalent to well degrease the
FIPG-applied surface.

3. FIPG is correctly applied in accordance with

FIPG Application.

.

Disassembly

Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.

.

Surface Preparation

Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surfaces is flat
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.

.

FIPG Application

Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet. Do not
allow FIPG to spread beyond the sealing areas dur-
ing installation. Avoid operating the transaxle or let-
ting oils or water come in contact with the sealed
area before a time sufficient for FIPG to harden
(approximately one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.

LUBRICANTS

M1233000400501

Transaxle

Transfer

Item

Specified lubricant

Transmission fluid

DiaQueen ATF-J3

Item

Specified lubricant

Grease application parts

Retinax A

Hypoid gear oil application parts

Hypoid gear oil API classification GL-5 SAE 80