Disassembling an automatic transmission (Mitsubishi Colt 5)

1. Before disassembling the gearbox, block all openings and clean the outside of the gearbox with a steam cleaner.

2. Place the box on the workbench with the pallet facing down.

3. Remove the gas turbine gearbox.

4. Before disassembling, measure the axial clearance of the input shaft to determine whether the adjusting shim needs to be replaced (this does not apply when replacing important parts). The adjusting shims are located between the reaction shaft support and the rear clutch bracket, and between the reaction shaft support and the front clutch bracket. Mount a dial indicator with a special tool on the transformer housing and position the measuring pointer on the end of the input shaft (Figure 11.115). Press the input shaft with pliers and pull it out to obtain the axial clearance and record it.



5. Remove pulse generators A and B (Figure 11.116a, b).

Figure 11.116a. Remove pulse generators A and B (models before 1992)

Figure 11.116b. Remove pulse generators A and B (models since 1993)

6. Remove the shift lever and starter interlock switch (Figure 11.117a, b).

Figure 11.117a. Remove the shift lever and starter interlock switch (pre-1992 models)

Figure 11.117b. Remove the shift lever and starter interlock switch (models from 1993)

7. Remove the spring retaining ring and servo switch (Figure 11.118a, b).

Figure 11.118a. Remove the snap ring and servo switch (pre-1992 models)

Figure 11.118b. Remove the snap ring and servo switch (1993 and later models)

8. Remove the pan and pan gasket (Figure 11.119).



9. Remove the oil filter (Figure 11.120).



10. Unscrew the oil temperature sensor mounting bolts (Figure 11.121a, b). Using a screwdriver, push out the rubber bushing from the inside of the housing and remove the oil temperature sensor from the housing.

Figure 11.121a. Unscrew the oil temperature sensor mounting bolts (models before 1992)

Figure 11.121b. Unscrew the oil temperature sensor mounting bolts (models since 1993)

11. Remove the clamp from the solenoid valve wiring connector (Figure 11.122).



12. Squeeze the clamps and press the wiring harness end and wiring connector into the gearbox housing (Figure 11.123).



13. Unscrew the valve block mounting bolts indicated by arrows and remove the valve block from the gearbox housing (Figure 11.124a, b).

Figure 11.124a. Unscrew the valve block mounting bolts, indicated by arrows (models up to 1992)

Figure 11.1246. Unscrew the valve block mounting bolts, indicated by arrows (models from 1993)

14. Remove the rear clutch cover (Figure 11.125).



15. Remove the rear clutch (Figure 11.126).



16. Remove the adjusting washer from the end of the input shaft (Figure 11.127).





17. Remove the rear clutch hub and thrust bearing (Figure 11.128).



18. Remove the rear clutch shaft (Figure 11.129).



19. Unscrew the fourteen bolts and remove the torque converter housing and gasket (Fig. 11.130).





20. Unscrew the six oil pump mounting bolts (Figure 11.131).



21. Screw special tools MD998333 into hole A.

22. Secure special tools MD998333 and remove the oil pump (Figure 11.132). Then remove the gasket.



23. Remove the adjusting washer from the automatic transmission housing and remove the differential (Fig. 11.133).





24. Remove the plastic adjusting washer (Figure 11.134).



25. Secure the input shaft and lift it up so that the front and rear clutch assemblies can be removed (Figure 11.135).



26. Remove the thrust bearing (Figure 11.136).



27. Remove the coupling hub (Figure 11.137).



28. Remove the rotating ring of the thrust bearing (bottom) and the thrust bearing (top (Figure 11.138).



29. Remove the brake drum (Figure 11.139).



30. Remove the brake band (Figure 11.140).



31. Using the special tool, compress the servo amplifier and remove the snap ring (Figure 11.141).



32. Remove the special tool, then take out the piston, bushing and spring of the servo amplifier (Figure 11.142).



33. Remove the rigid mount rod (Figure 11.143).



34. Remove the snap ring (Figure 11.144).



35. Install the special tool on the intermediate support and remove it from the crankcase (Figure 11.145).



36. Remove the forward and reverse gear sun gears together with the thrust bearing #9 and a rotating ring of the thrust bearing #10 (Figure 11.146).



37. Remove the planetary gear set and thrust bearing #12 (Figure 11.147).



38. Remove the shaft spring, return spring, reaction discs, brake discs and friction plates (Figure 11.148).



39. Apply sealant to the bearing bracket bolts. Lightly tap the bolt heads to make them easier to remove (Figure 11.149).



40. Using a screwdriver, unscrew the bolts and remove the bearing bracket (Figure 11.150).



41. Remove the intermediate gear shaft lock washer (Figure 11.151).



42. Loosen the intermediate gear shaft using a special tool (Figure 11.152).



43. Remove the intermediate gear shaft, then remove the intermediate gear and two inner bearing rings (Figure 11.153).



44. Remove the adjusting washer (Figure 11.154).



45. Remove the snap ring from the secondary shaft mounting flange (Figure 11.155).



46. Remove the secondary shaft flange from the gearbox housing (Figure 11.156).



47. Remove the secondary shaft cover (Figure 11.157).

The article was taken from the website: MitsubishiMan



48. Straighten the locking plates of the secondary shaft lock nut (Figure 11.158).



49. Fix the secondary shaft in the torque converter housing (Figure 11.159).



50. Unscrew the lock nut (Figure 11.160).

Please note: This nut has a left-hand thread.

51. Press out the secondary shaft in the direction of the torque converter housing and remove the shaft and secondary shaft gear (Figure 11.161).



52. Remove the outer rotating ring of the secondary shaft bearings (Figure 11.162).



53. Remove the drive rod support (only on models before 1992) (Figure 11.163).



54. Remove the set bolt and gearshift lever shaft, then remove the steel ball, stop and spring (pre-1992 models only) (Figure 11.164a).



55. Remove the drive rod mounting bolt and support, as well as the gearshift lever shaft and detent plate (1993 and later models only) (Figure 11.164b).