| Mitsubishi PAJERO 4G 2009 DIY Repair Guide

1.	Torque Converter assy
2.	Breather tube
3.	Breather hose
4.	Breather plug No. 1
5.	Tube
6.	Speed sensor (input)
7.	Speed sensor (output)
8.	Control shaft lever LH
9.	Elbow
10.	Inhibitor switch
11.	Converter housing
12.	Transmission case RR adapter
13.	Oil seal

14.	Overflow plug
15.	Drain plug
16.	Oil pan sub-assy
17.	Oil pan gasket
18.	Oil cleaner magnet
19.	Oil strainer assy
20.	Temperature sensor clamp
21.	Temperature sensor clamp
22.	Harness
23.	Manual detent spring cover
24.	Manual detent spring sub-assy
25.	Valve body wire harness clamp
26.	Valve body assy
27.	Check valve sub-assy
28.	Spring
29.	Gasket
30.	Gasket
31.	Accumulator piston
32.	Accumulator spring
33.	Snap ring
34.	Spring
35.	O-ring
36.	Accumulator valve
37.	Spring
38.	Parking lock pawl bracket
39.	Parking lock rod sub-assy
40.	Snap ring
41.	Parking lock pawl shaft
42.	Torsion spring
43.	Parking lock pawl
44.	Spacer
45.	Spring pin
46.	Manual valve lever shaft
47.	Manual valve lever sub-assy
48.	Oil seal
49.	Oil seal

50.	Oil pump assy
51.	O-ring
52.	Thrust bearing race No. 1
53.	Thrust needle roller bearing
54.	Thrust bearing race
55.	Thrust needle roller bearing
56.	Forward clutch assy & direct clutch assy
57.	Clutch drum thrust washer No. 2
58.	One-way clutch No. 2
59.	Clutch hub thrust washer
60.	Hole snap ring
61.	Brake flange No. 3
62.	Brake disc No. 3
63.	Brake plate No. 3
64.	Brake cushion plate
65.	Hole snap ring
66.	Brake piston return spring sub-assy No. 3 & second brake piston & second brake cylinder
67.	One-way clutch No. 1
68.	Planetary carrier thrust washer No. 1
69.	One-way clutch inner race sub-assy
70.	FR planetary gear assy
71.	Planetary carrier thrust washer No. 2
72.	Thrust bearing race No. 3
73.	Thrust needle roller bearing
74.	FR planetary gear & FR planetary gear flange & Middle planetary ring gear
75.	Thrust needle roller bearing
76.	Thrust bearing race No. 4
77.	Middle planetary gear assy
78.	Planetary sun gear

79.	Brake flange No. 1
80.	Brake disc No. 1
81.	Brake plate No. 1
82.	Hole snap ring
83.	Brake piston return spring sub-assy
84.	Brake piston No. 1 & brake cylinder No. 1
85.	Hole snap ring
86.	Brake flange No. 2
87.	Brake disc No. 2
88.	Brake plate No. 2
89.	Brake flange No. 2
90.	Brake piston return spring sub-assy No. 2
91.	Brake piston No. 2 & brake cylinder No. 2
92.	Hole snap ring
93.	One-way clutch inner race
94.	One-way clutch No. 3
95.	RR planetary gear flange sub-assy & RR planetary ring gear
96.	Thrust bearing race No. 7
97.	Thrust needle roller bearing
98.	Thrust bearing race No. 8
99.	Intermediate shaft

100.	Brake flange No. 4
101.	Brake disc No. 4
102.	Brake plate No. 4
103.	Brake flange No. 4
104.	Thrust needle roller bearing
105.	RR planetary gear assy
106.	Thrust bearing race No. 9
107.	Thrust needle roller with race bearing
108.	Shaft snap ring
109.	low/reverse brake return spring sub-assy
110.	low/reverse brake piston
111.	O-ring
112.	Brake reaction sleeve
113.	O-ring
114.	O-ring
115.	Inner brake piston No. 4
116.	O-ring
117.	O-ring
118.	Plate stopper spring

DISASSEMBLY

1. TORQUE CONVERTER ASSY REMOVAL

caution

Be careful not to damage the oil seal.
Be careful not to drop the torque converter assy.

Remove the torque converter assy from the transmission assy.

2. BREATHER TUBE REMOVAL

1.Remove the bolt in order to remove the breather tube, breather hose, and breather plug No. 1 from the transmission case.
SIZE: Bolt
M6 x 1.0 x 10 mm
2.Remove the O-ring from the breather tube.
3.Remove the O-ring from breather plug No. 1.

3. TUBE REMOVAL

caution

Be careful not to damage the case or adaptor.
Be careful not to bend the tube.
Never reuse the removed tube.

Remove the tube from the transmission case.

4. SPEED SENSOR (INPUT) REMOVAL

caution

Be careful not to damage the speed sensor.

Remove the bolt to remove the speed sensor from the transmission case.
SIZE: Bolt
M6 x 1.0 x 14 mm

5. SPEED SENSOR (OUTPUT) REMOVAL

caution

Be careful not to damage the speed sensor.

Remove the bolt to remove the speed sensor from the transmission case.
SIZE: Bolt
M6 x 1.0 x 14 mm

6. TRANSMISSION CONTROL SHAFT LEVER LH REMOVAL

Remove the nut and spring washer in order to remove the transmission control shaft lever LH from the manual valve lever shaft.

7. ELBOW REMOVAL

1.Remove the 2 elbows.
2.Remove the 2 O-rings from the elbows.

8. INHIBITOR SWITCH REMOVAL

1.Using a screwdriver, pry off the washer.
2.Remove the nut to remove the washer from the inhibitor switch.

caution

Be careful not to damage the inhibitor switch.

Remove the bolt (seal bolt) to remove the inhibitor switch from the transmission case.
SIZE: Bolt
M8 x 1.25 x 30 mm (Seal bolt)

9. CONVERTER HOUSING REMOVAL

1.Remove the 10 bolts.
SIZE: Bolt
A: M10 x 1.5 x 35 mm
B: M10 x 1.5 x 35 mm (Seal bolt)
C: M12 x 1.75 x 38 mm (Seal bolt)

caution

Be careful not to damage the fitting surface of the converter housing and the transmission case.

Using a plastic hammer, tap the converter housing to remove it.

10. TRANSMISSION CASE RR ADAPTOR REMOVAL

1.Remove the 8 bolts.
SIZE: Bolt
A: M10 x 1.5 x 40 mm (Seal bolt)
B: M10 x 1.5 x 50 mm (Seal bolt)

caution

Be careful not to damage the fitting surface of the transmission case RR adaptor and the transmission case.

Using a plastic hammer, tap the transmission case RR adaptor to remove it.

11. OIL SEAL REMOVAL

caution

Be careful not to damage the transmission case RR adaptor.

Remove the oil seal from the transmission case RR adaptor.

12. OIL PAN SUB-ASSY REMOVAL

1.Remove the 20 bolts.
SIZE: Bolt
M6 x 1.0 x 14.5 mm

caution

Be careful not to damage the fitting surface of the transmission case and the oil pan sub-assy.
Be careful not to deform the oil pan sub-assy.

Using a plastic hammer, tap the oil pan sub-assy to remove it.
3.Remove the oil pan gasket.

13. OIL CLEANER MAGNET REMOVAL

Remove the 4 oil cleaner magnets from the oil pan sub-assy.

note

Examine the chips and particles in the oil pan sub-assy and on the oil cleaner magnet to determine what type of wear has occurred in the transmission.
Steel (magnetic) = bearing, gear and plate wear.
Brass (non-magnetic) = bushing wear.

14. OIL STRAINER ASSY REMOVAL

1.Remove the 4 bolts to remove the oil strainer assy from the valve body assy.
SIZE: Bolt
M6 x 1.0 x 12 mm
2.Remove the O-ring from the oil strainer assy.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

31.00
2.72

15. HARNESS REMOVAL

1.Disconnect the 7 solenoid assy connectors from the solenoid assy.
2.Disconnect the harness from the valve body wire harness clamp.

3.Remove the 2 bolts and 2 temperature sensor clamps and then pull out the temperature sensor from the valve body assy.
SIZE: Bolt
A: M6 x 1.0 x 12 mm
B: M6 x 1.0 x 36 mm

4.Remove the bolt from the transmission case.
SIZE: Bolt
M6 x 1.0 x 16 mm
5.Remove the harness from the transmission case.
6.Remove the O-ring from the harness.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

21.80
2.40

16. MANUAL DETENT SPRING REMOVAL

Remove the flange bolt to remove the manual detente spring and the manual detente spring cover from the valve body assy.
SIZE: Flange bolt
M6 x 1.0 x 14 mm

17. VALVE BODY ASSY REMOVAL

1.Remove the 19 bolts from the transmission case as shown in the illustration.
SIZE: Bolt
A: M6 x 1.0 x 25 mm
B: M6 x 1.0 x 36 mm
2.

caution

Be careful not to drop the valve body assy.

Disconnect the manual valve link and remove the valve body assy.

18. CHECK VALVE SUB-ASSY REMOVAL

Remove the check valve sub-assy and the spring from the transmission case as shown in the illustration.

SIZE: Spring

Free (mm)
Outer (mm)

38.55
4.861

19. GASKET REMOVAL

Remove the 3 gaskets and the 3 gaskets from the transmission case as shown in the illustration.

20. ACCUMULATOR PISTON (DIRECT CLUTCH, B3) REMOVAL

caution

Take care as the accumulator piston (Direct clutch, B3) may eject.

Apply compressed air into the oil passage as shown in the illustration and remove the 2 accumulator pistons and the 2 accumulator springs from the transmission case.

SIZE: Accumulator springs

Piston
Free
(mm)
Outer
(mm)
Color

Direct clutch
62.0
15.9
White

B3
70.5
19.7
Purple

caution

Be careful not to damage the accumulator piston.

Using a screwdriver, remove the 2 snap rings from the 2 accumulator pistons.
3.Remove the 2 springs from the 2 accumulator pistons.

SIZE: Spring

Piston
Free
(mm)
Outer
(mm)
Color

direct clutch
14.16
11.3
-

B3
24.77
16.3
Purple

caution

Be careful not to damage the accumulator piston.

Using a screwdriver, remove the 4 O-rings from the 2 accumulator pistons.

SIZE: O-ring

Piston
Inner diameter
(mm)
Thickness
(mm)

Direct clutch
20.00
2.62

28.73
2.62

B3
23.55
2.62

34.29
2.62

21. ACCUMULATOR PISTON (REVERSE CLUTCH) REMOVAL

caution

Take care as the accumulator piston (Reverse clutch) may eject.

Apply compressed air into the oil passage as shown in the illustration and remove the accumulator piston and the 2 accumulator springs from the transmission case.

SIZE: Accumulator springs

Piston
Free
(mm)
Outer
(mm)
Color

Reverse clutch
44.0
14.0
Yellow

73.35
19.9
Red

caution

Be careful not to damage the accumulator piston.

Using a screwdriver, remove the 2 O-rings from the accumulator piston.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

26.75
2.62

34.29
2.62

22. ACCUMULATOR VALVE (B1) REMOVAL

Remove the accumulator valve and the 2 springs from the transmission case.

SIZE: Spring

Piston
Free
(mm)
Outer
(mm)
Color

Accumulator
48.76
16.6
Light
green

30.40
11.4
Pink

23. PARKING LOCK PAWL BRACKET REMOVAL

Remove the 3 bolts to remove the parking lock pawl bracket.
SIZE: Bolt
M6 x 1.0 x 14 mm

24. PARKING LOCK ROD SUB-ASSY REMOVAL

Disconnect the parking lock rod sub-assy from the manual valve lever sub-assy.

25. PARKING LOCK PAWL REMOVAL

caution

Be careful not to apply too much force to the torsion spring.

Pull out the parking lock pawl shaft and the torsion spring.
2.Using a screwdriver, remove the snap ring from the parking lock pawl shaft.
3.Remove the parking lock pawl.

26. MANUAL VALVE LEVER SHAFT REMOVAL

caution

Be careful not to damage the manual valve lever sub-assy.

Using a hammer and a screwdriver, cut off the spacer to remove it.

2.Using a hammer and a pin punch, drive out the spring pin.

3.Pull the manual valve lever shaft out through the transmission case, and remove the manual valve lever sub-assy.

27. OIL SEAL REMOVAL

caution

Be careful not to damage the transmission case.

Using a screwdriver, remove the 2 oil seals.

28. OIL PUMP ASSY REMOVAL

1.Remove the 10 bolts from the transmission case.
SIZE: Bolt
M8 x 1.25 x 40 mm

caution

Be careful not to drop the oil pump assy from the transmission case.

Using the special tool Oil pump puller (MD998212), remove the oil pump assy.

3.Remove the O-ring from the oil pump assy.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

218.40
3.50

4.Remove the thrust needle roller bearing and the thrust bearing race No. 1 from the oil pump assy.

29. FORWARD CLUTCH ASSY & DIRECT CLUTCH ASSY REMOVAL

caution

Be careful not to drop the forward clutch assy & direct clutch assy.
Be careful not to drop the one-way clutch No. 3.

Remove the forward clutch assy & direct clutch assy with the one-way clutch No. 3.

2.Remove the thrust bearing race and the thrust needle roller bearing from the forward clutch assy & direct clutch assy.

3.Remove the clutch hub thrust washer, one-way clutch No. 2 and the clutch drum thrust washer No. 2 from the forward clutch assy & direct clutch assy.

30. BRAKE DISC SET NO. 3 (B3) REMOVAL

1.Using a screwdriver, remove the snap ring from the transmission case.

2.Remove the flange, 4 discs, 4 plates and cushion plate.

note

Check the number of disc. (Refer to TRANSMISSION INSPECTION-INSPECT BRAKE DISK SET No. 3 (B3)

)

31. BRAKE PISTON RETURN SPRING SUB-ASSY NO. 3 & SECOND BRAKE PISTON & SECOND BRAKE CYLINDER REMOVAL

1.Remove the hole snap ring from the transmission case.

2.Remove the brake piston return spring sub-assy No. 3 & second brake piston & second brake cylinder with the one-way clutch No. 1, planetary carrier thrust washer No. 1 and the one-way clutch inner sub-assy.

3.Remove the one-way clutch inner race sub-assy and the planetary carrier thrust washer No. 1
4.Remove the one-way clutch No. 1 from the brake piston return spring sub-assy No. 3 & second brake piston & second brake cylinder.

32. FR PLANETARY GEAR ASSY REMOVAL

Remove the FR planetary gear assy and the planetary carrier thrust washer No. 2.

33. FR PLANETARY GEAR & FR PLANETARY GEAR FLANGE & MIDDLE PLANETARY RING GEAR REMOVAL

1.Remove the FR planetary gear & FR planetary gear flange & middle planetary ring gear.
2.Remove the thrust bearing race No. 3 and the thrust needle roller bearing from the FR planetary gear & FR planetary gear flange & middle planetary ring gear.

34. BRAKE DISC SET NO. 1 (B1) REMOVAL

Remove the flange, 4 discs and 4 plates.

note

Check the number of disc. (Refer to TRANSMISSION INSPECTION-INSPECT BRAKE DISK SET No. 1 (B1)

)

35. MIDDLE PLANETARY GEAR ASSY AND PLANETARY SUN GEAR REMOVAL

1.Remove the middle planetary gear assy and planetary sun gear.
2.Remove the thrust needle roller bearing and the thrust bearing race No. 4 from the middle planetary gear assy.

36. BRAKE PISTON & BRAKE CYLINDER (NO. 1) REMOVAL

1.Set the special tool Adapter (MB992320) on the flange.

2.Using the special tools and a screwdriver, remove the hole snap ring from the transmission case.

Base (MB992317)
Cylinder (MB992318)
Center bolt (MB992319)
Flange bolt (MB992322)

3.Remove the brake piston return spring sub-assy and the brake piston No. 1 & brake cylinder No. 1.

37. BRAKE DISC SET NO. 2 (B2) REMOVAL

1.Set the special tool Adapter (MB992321) on the brake piston return spring sub-assy.

2.Using the special tools and a screwdriver, remove the hole snap ring from the transmission case.

Base (MB992317)
Cylinder (MB992318)
Center bolt (MB992319)
Flange bolt (MB992322)

3.Remove the flange.

4.Remove the 4 discs, 3 plates and flange.

note

Check the number of disc. (Refer to TRANSMISSION INSPECTION-INSPECT BRAKE DISK SET No. 2 (B2)

)

5.Remove the brake piston return spring sub-assy No. 2.

38. BRAKE PISTON NO. 2 & BRAKE CYLINDER NO. 2 REMOVAL

Remove the brake piston No. 2 and brake cylinder No. 2 from the transmission case.

39. PLATE STOPPER SPRING REMOVAL

Remove the plate stopper spring from the transmission case.

40. INTERMEDIATE SHAFT REMOVAL

1.Remove the hole snap ring from the transmission case.

2.Remove the intermediate shaft with the one-way clutch inner race, one-way clutch No. 3, RR planetary gear flange sub-assy & RR planetary gear, thrust bearing race No. 7, thrust needle roller bearing and thrust bearing race No. 8 from the transmission case.
3.

Remove the one-way clutch inner race, one-way clutch No. 3, RR planetary gear flange sub-assy & RR planetary gear, thrust bearing race No. 7, thrust needle roller bearing and the thrust bearing race No. 8 from the intermediate shaft.

41. BRAKE DISC SET NO. 4 (B4) REMOVAL

Remove the 2 flanges, 8 discs and 7 plates.

note

Check the number of disc. (Refer to TRANSMISSION INSPECTION-INSPECT BRAKE DISK SET No. 4 (B4)

)

42. RR PLANETARY GEAR ASSY REMOVAL

Remove the RR planetary gear assy with the thrust bearing race No. 9, thrust needle roller with race bearing and thrust needle roller bearing.

43. LOW/REVERSE BRAKE RETURN SPRING SUB-ASSY REMOVAL

1.Set the special tools as shown in the illustration, and compress the spring.

Spring compressor body (MD998903)
Retainer (MD998924)

caution

Be careful not to expand the shaft snap ring too much.

Using special tools, remove the shaft snap ring.

3.Remove the low/reverse brake return spring sub-assy.

44. INNER BRAKE PISTON (NO. 4) REMOVAL

1.While pushing the inner brake piston No. 4 by hand, apply compressed air (392 kPa) into the oil passage as shown in the illustration and remove the inner brake piston No. 4 from the transmission case.

note

When applying compressed air, shut a oil passage of the transmission case as shown in the illustration.

2.Remove the inner brake piston No. 4, brake reaction sleeve and reverse brake piston.

3.Remove the 2 O-rings from the inner brake piston No. 4.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

67.35
2.62

116.40
2.62

4.Remove the 2 O-rings from the brake reaction sleeve.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

79.10
2.62

128.00
2.62

5.Remove the O-ring from the low/reverse brake piston.

SIZE: O-ring

Inner diameter (mm)
Thickness (mm)

131.60
2.62