fluid MITSUBISHI 380 2005 Owner's Guide

MAINTENANCE SERVICE
GENERAL00-47
6. Securely insert the dipstick.
NOTE: The transmission fluid should always be replaced
under the following conditions:
.
When troubleshooting the transaxle.
When overhauling the transaxle.
When the transmission fluid is noticeably dirty or burnt
(driving under severe conditions).
TRANSMISSION FLUID CHANGE
Refer to GROUP 23A, Automatic Transmission - On-vehicle
Service P.23A-296.
12. ENGINE COOLANT (CHANGE)M1001003100357
Check the cooling system parts such as the radiator, heater
and oil cooler hoses, thermostat and their connections for leak-
age and damage.
.
CHANGING COOLANT
1. Set the temperature control knob to the "HOT" position.
2. Run the engine until the engine coolant warms, and then
stop the engine.
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
3. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.

MAINTENANCE SERVICE
GENERAL00-49
14.Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
Do not overfill the radiator condenser tank assembly.
15.Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
13. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT)
M1001009700034
Inspect the surface of radiator hoses and heater hoses for heat
and mechanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indicate deterio-
ration of the rubber.
14. DISC BRAKE PADS, ROTORS (INSPECT FOR
WEAR)
M1001003200291
Check for fluid contamination and wear. Replace the complete
set of pads if any one pad is defective.
Thickness of lining
Minimum limit: 2.0 mm
The pads for the right and left wheels should be replaced
at the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.
15. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS)
M1001003400314
Inspection of brake hoses should be included in all brake ser-
vice operations.
The hoses should be checked for:
1. Incorrect length, severe surface cracking, stretching,
scuffing or worn spots (If the fabric casing of the hoses is
exposed by cracks or abrasion in the rubber hose cover, the
hoses should be replaced. Eventual deterioration of the
hose and possible bursting failure may occur).
2. Incorrect installation, twisting or interference with wheel, tyre
or chassis.

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-13
4. Measure the wheel bearing rotation starting torque by using
the special tools MB990326 and MB990685.
Limit: 1.4 N
m (12 in-lb)
5. If the rotation starting torque is not within the limit when the
nut is tightened to 226
29 Nm (167 21 ft-lb), replace the
front wheel bearing assembly. If there is any signs of binding
or tight spots when the wheel bearing turns, replace it.
6. Measure to determine whether the wheel bearing axial play
is within the specified limit or not.
Limit: 0.05 mm (0.002 inch)
7. If the play exceeds the limit when the nut is tightened to 226
29 Nm (167 21 ft-lb), replace the front wheel hub
assembly.
DRIVE SHAFT ASSEMBLY
REMOVAL AND INSTALLATIONM1261003500429
For vehicles with ABS, do not strike the ABS rotors installed to the BJ outer race of drive shaft
against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be
damaged.
For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
Pre-installation Operation
Front Under Cover, Side Under Cover Removal
Transmission Fluid Draining (Refer to GROUP
23A, On-vehicle Service
Transmission Fluid
Change P.23A-292).
Front Exhaust Pipe Removal <3.8L-RH side>
(Refer to GROUP 15, Exhaust Pipe and Muffler
P.15-14).Post-installation Operation
Front Exhaust Pipe Installation <3.8L-RH side>
(Refer to GROUP 15, Exhaust Pipe and Muffler
P.15-14).
Check the ball joint dust cover for cracks or
damage by pushing it with your finger.
Transmission Fluid Filling (Refer to GROUP
23A, On-vehicle Service
Transmission Fluid
Change P.23A-292).
Front Under Cover, Side Under Cover
Installation

AUTOMATIC TRANSMISSION23A-2
SPECIAL TOOLS . . . . . . . . . . . . . . . .23A-286
ON-VEHICLE SERVICE. . . . . . . . . . .23A-289
A/T CONTROL COMPONENT LAYOUT . . 23A-289
ESSENTIAL SERVICE . . . . . . . . . . . . . . . . 23A-291
TRANSMISSION FLUID CHECK . . . . . . . . 23A-291
TRANSMISSION FLUID CHANGE . . . . . . . 23A-292
OIL COOLER FLOW CHECK . . . . . . . . . . . 23A-294
TRANSMISSION RANGE SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-294
TRANSMISSION RANGE SWITCH AND
CONTROL CABLE ADJUSTMENT. . . . . . . 23A-294
AUTOMATIC TRANSMISSION CONTROL
COMPONENT CHECK . . . . . . . . . . . . . . . . 23A-295
CRANKSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-295
TRANSMISSION FLUID TEMPERATURE
SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 23A-296
TRANSMISSION RANGE SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-296
STOPLIGHT SWITCH CHECK . . . . . . . . . . 23A-296
A/T CONTROL RELAY CHECK . . . . . . . . . 23A-296
SOLENOID VALVE CHECK . . . . . . . . . . . . 23A-298SELECTOR LEVER OPERATION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-299
TRANSMISSION CONTROL CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 23A-299
TRANSMISSION CONTROL* . . . . . . .23A-300
REMOVAL AND INSTALLATION . . . . . . . . 23A-300
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-301
DISASSEMBLY AND ASSEMBLY . . . . . . . 23A-302
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-303
TRANSMISSION ASSEMBLY . . . . . .23A-304
REMOVAL AND INSTALLATION . . . . . . . . 23A-304
TRANSMISSION FLUID COOLER,
HOSE AND PIPE . . . . . . . . . . . . . . . .23A-312
REMOVAL AND INSTALLATION . . . . . . . . 23A-312
SPECIFICATIONS . . . . . . . . . . . . . . .23A-313
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 23A-313
SERVICE SPECIFICATIONS . . . . . . . . . . . 23A-313
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 23A-314

GENERAL DESCRIPTION
AUTOMATIC TRANSMISSION23A-3
GENERAL DESCRIPTIONM1231000100366
ITEM SPECIFICATION
Transmission modelF5A5A-4-C5Z
Engine model 6G75-S4-MP
Torque converter Type 3-element, 1-stage, 2-phase type
Lock-up Provided
Stall torque ratio 1.71
Transmission type5 forward speeds, 1 reverse speed, fully automatic
Transmission gear
ratio1st 3.789
2nd 2.162
3rd 1.421
4th 1.000
5th 0.686
Reverse 3.117
Final reduction ratio (Differential gear ratio) 3.325
Clutch Multi-disc type 4 sets
Brake Multi-disc type 2 sets, band type 1 set
Manual control system P-R-N-D (4 position) + Sport mode (up, down)
Shift pattern control Electronic control
Hydraulic control during shifting Electronic control (Each clutch hydraulically independently
controlled)
Torque converter clutch control Electronic control
Transmission fluid Specified lubricants MITSUBISHI ELC4-SP III
Quantity (litres) 8.4

AUTOMATIC TRANSMISSION DIAGNOSIS
AUTOMATIC TRANSMISSION23A-12
AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSTIC TROUBLESHOOTING FLOWM1231013500353
INTRODUCTION TO A/T DIAGNOSISM1231012300226
The automatic transmission can exhibit any of the
following symptoms: noise or vibration is generated,
Transmission fluid leaks, the vehicle does not move
forward or backward. The causes of these symptoms
could come from: Incorrect mounting, the Transmis-
sion fluid may be low, or a component of the
transmission may be faulty. The following items are suspected as causes for the
INVECS-II troubles: malfunction of the A/T-ECU, the
sensors, the switches, the harness or connectors.

AUTOMATIC TRANSMISSION DIAGNOSIS
AUTOMATIC TRANSMISSION23A-13
A/T DIAGNOSTIC TROUBLESHOOTING STRATEGYM1231007600339
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will find most A/T mal-
functions.
1. Gather as much information as possible about the
complaint from the customer.
2. Verify that the condition described by the
customer exists.
3. Check the vehicle for any A/T Diagnostic Trouble
Codes (DTCs).
4. If you can not verify the condition and there are no
DTCs, the malfunction is intermittent. For
information on how to cope with intermittent
malfunctions, refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points
How
to Cope with Intermittent Malfunction P.00-14.
5. If you can verify the condition but there are no
DTCs, or the system can not communicate with
diagnostic tool, refer to the Symptom Chart
P.23A-35.6. If there is a DTC, record the number of the code,
then erase the code from memory using
diagnostic tool.
7. Reconfirm the symptom with a Road Test.
8. If a DTC is set again, go to the Inspection Chart
for Diagnostic Trouble Codes.
9. If a DTC is not set again, the malfunction is
intermittent. For information on how to cope with
intermittent malfunctions, refer to GROUP 00,
How to Use Troubleshooting/Inspection Service
Points
How to Cope with Intermittent
Malfunction P.00-14.
10.After repairs are completed, conduct a Road Test
duplicating the complaint conditions to confirm the
malfunction has been eliminated.
DIAGNOSTIC FUNCTIONM1231022500135
CHECK "N" RANGE LIGHT
The "N" range light flashes once per second if there is an
abnormality in any of the items in the table below which are
related to the A/T system. Check for diagnostic trouble codes if
the "N" range light is flashing once per second.
NOTE: The "N" indicator lamp warning function does not
operate with the selector lever in the "P" (PARK), "R"
(REVERSE) or "N" (NEUTRAL) position.
"N" range light flashing items
Input shaft speed sensor
Output shaft speed sensor
Each solenoid valve
Gear incorrect ratio
A/T control relay system
If the "N" range light is flashing rapidly (twice per second),
the transmission fluid temperature is too high. (It flashes
when the fluid is approximately 125
C or more and goes
off when the fluid is approximately 115
C or less)
ON-BOARD DIAGNOSTICS
The automatic transmission -electronic control unit
(A/T-ECU) monitors its input/output signals (some
signals all the time and others under specified condi-
tions). When an irregular signal is initially monitored,
the A/T-ECU decides that a malfunction has
occurred and records the occurrence as a diagnostic
trouble code. The diagnostic results can be read with diagnostic tool. Diagnostic trouble codes are kept in
memory by direct battery feed. The codes are
retained in memory even if the ignition switch is in
the "LOCK" (OFF) position. DTCs are not erased
even after the battery terminals and the A/T-ECU
connector are disconnected. In addition, the diagnos-
tic trouble code can also be erased by diagnostic
tool.

AUTOMATIC TRANSMISSION DIAGNOSIS
AUTOMATIC TRANSMISSION23A-19
ROAD TESTM1231007800407
Check using the following procedures.
STEP CONDITION
BEFORE
TEST/OPERATIONTEST/OPERATION STANDARD INSPECTION
ITEMINSPECTION
PROCEDURE
PA G E
1 Ignition switch:
(LOCK) OFFIgnition switch
(1) ONData list No.8
(1) Control Relay
Voltage [V]A/T Control
relay
output
voltageA/T Control
relay system
(P.23A-207).
2 Ignition switch:
ON
Engine: Stopped
Transmission
range: PTransmission range
(1) P, (2) R, (3) N, (4)
DData list No.34
(1) P, (2) R, (3) N, (4)
DTransmissi
on range
switchTransmission
range switch
system
(P.23A-97,
P.23A-119).
Transmission range
(1) D (1st gear)
(2) Select the sport
mode (1st gear)
(3) Upshift and hold
the selector lever in
that position (2nd
gear)
(4) Downshift and
hold the selector
lever in that position
(1st gear)Data list No.27
(1) OFF, (2) ON, (3)
ON, (4) ON
Data list No.28
(1) OFF, (2) OFF, (3)
ON, (4) OFF
Data list No.29
(1) OFF, (2) OFF, (3)
OFF, (4) ONSelect
switch and
Shift switchShift switch
assembly
system
(P.23A-252).
Brake pedal
(1) Depressed
(2) ReleasedData list No.19
(1) ON
(2) OFFSto pl amp
switchSt o pla mp
switch system
(P.23A-89).
3 Ignition switch:
ST
Engine: StoppedCranking test with
lever in P or N rangeCranking should be
possibleCranking Engine does
not crank
(P.23A-218).
4 Engine warming
upDrive for 15 minutes
or more so that the
transmission fluid
temperature
becomes 70
90CData list No.7
Gradually rises to 70
90CTransmissi
on fluid
temperatur
e sensorTransmission
fluid
temperature
sensor system
(P.23A-36,
P.23A-47).
5 Engine: Idling
Transmission
range: NBrake pedal (Retest)
(1) Depressed
(2) ReleasedData list No.19
(1) ON
(2) OFFSto pl amp
switchSt o pla mp
switch system
(P.23A-89).
Transmission range
(1) N
D
(2) N
RShould be no
abnormal shift
shocks
Time delay when
engaging should be
within 2 secondsMalfunction
when
startingEngine stalls
when moving
selector lever
from N to D or
N to R
(P.23A-227).

AUTOMATIC TRANSMISSION DIAGNOSIS
AUTOMATIC TRANSMISSION23A-25
TORQUE CONVERTER STALL TESTM1231005400362
This test measures the maximum engine speed when the
selector lever is in the "D" or "R" position and the torque con-
verter stalls. This tests the operation of the torque converter,
starter motor and one-way clutch operation, as well as the hold-
ing performance of the clutches and brakes in the transmission.
Do not let anyone stand in front of or behind the vehi-
cle while this test is performed.
1. Check the transmission fluid level and temperature. Check
the engine coolant temperature.
Transmission fluid level: At the "HOT" mark on the dipstick
Transmission fluid temperature: 70 80C
Engine coolant temperature: 80 100C
NOTE: Measures transmission fluid temperature with
diagnostic tool MB991958 (MUT-III sub assembly).
2. Check both rear wheels.
3. Pull the parking brake lever on, with the brake pedal fully
depressed.
4. Start the engine. 9 Transmission
range: N (on a
flat and straight
road)Monitor data list
No.22 and No.23
with the diagnostic
tool MB991958
(MUT-III sub
assembly)
(1) Move selector
lever to R range,
drive at constant
speed of 10 km/hThe ratio between
data list No.22 and
No.23 should be the
same as the gear
ratio when reversing.Does not
shiftInput shaft
speed sensor
system
(P.23A-55).
Output shaft
speed sensor
system
(P.23A-72).
Reverse gear
incorrect ratio
(P.23A-196).
STEP CONDITION
BEFORE
TEST/OPERATIONTEST/OPERATION STANDARD INSPECTION
ITEMINSPECTION
PROCEDURE
PA G E

AUTOMATIC TRANSMISSION DIAGNOSIS
AUTOMATIC TRANSMISSION23A-26
The throttle should not be fully open for any more than
five seconds.
If you repeat the stall test when the transmission fluid
temperature is greater than 80
C, move the selector
lever to the "N" position and let the engine run at
approximately 1,000 r/min for at least one minute. Wait
until the transmission fluid temperature returns to 80
C
or less.
5. Move the selector lever to the "D" position. Fully depress the
accelerator pedal and read the maximum engine speed at
this time.
Standard value: Stall speed: 2,100
2,600 r/min
6. Move the selector lever to the "R" position. Fully depress the
accelerator pedal and read the maximum engine speed.
Standard value: Stall speed: 2,100
2,600 r/min
TORQUE CONVERTER STALL TEST JUDGMENT
RESULTS
1. Stall speed is too high in both "D" and "R" range
Malfunction of the torque converter (Slippage on the splines
of the torque converter and the input shaft)
Low line pressure
Low-reverse brake slippage and malfunction of the one-way
clutch
2. Stall speed is too high in "D" range only
Underdrive clutch slippage
3. Stall speed is too high in "R" range only
Reverse clutch slippage
4. Stall speed is too low in both "D" and "R" ranges
Malfunction of the torque converter (Slippage of the
one-way clutch)
Insufficient engine output
HYDRAULIC PRESSURE TESTSM1231005500392
The transmission fluid temperature should be between 70
80C during the test.
1. Check the transmission fluid level and temperature. Check
engine coolant temperature.
Transmission fluid level: "HOT" mark on the dipstick
Transmission fluid temperature: 70 80C
Engine coolant temperature: 80 100C
2. Raise the vehicle so that the wheels are free to turn.