torque MITSUBISHI 380 2005 Service Manual

SPECIAL TOOLS
REAR AXLE27-4
SPECIAL TOOLSM1271000600525
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECKM1271000900474
1. Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc.
2. Check the bearing's end play. Place a dial gauge against the
hub surface; then move the hub in the axial direction and
check whether or not there is end play.
Limit: 0.05 mm (0.002 inch)
3. If the play exceeds the limit, replace the rear hub assembly.
4. After having finished the inspection, install the brake disc,
caliper assembly and tighten the caliper assembly mounting
bolts to the specified torque.
Tightening torque: 60
5 Nm (45 3 ft-lb) TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MB990767
Front hub and flange
yoke HolderMB990767-01 Hub fixing
MB991618
Hub bolt removerGeneral service tool Hub bolt removal
MB991897
Ball joint removerMB991113-1,
MB990635-01 or general
service toolBall joint disconnection
NOTE: Steering linkage
puller(MB990635 or
MB991113)is also used
to disconnect knuckle
and toe control arm ball
joint.

ON-VEHICLE SERVICE
REAR AXLE27-5
REAR HUB ROTARY-SLIDING RESISTANCE
CHECK
M1271001100266
1. Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc.
2. Turn the hub a few times to seat the bearing.
3. Wind a rope around the hub bolt and turn the hub by pulling
at a 90 degree angle with a spring balance. Measure to
determine whether or not the rotary-sliding resistance of the
rear hub is within the limit value.
Limit: 24 N (5.4 pounds)
4. If the rotary
sliding resistance exceeds the limit value,
replace the rear hub assembly.
5. After having finished the inspection, install the brake disc,
caliper assembly and tighten the caliper assembly mounting
bolts to the specified torque.
Tightening torque: 60
5 Nm (45 3 ft-lb)
HUB BOLT REPLACEMENTM1271001000270
Required Special Tools:
MB990767: Front Hub and Flange Yoke Holder
MB991618: Hub Bolt Remover
1. Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc.
2. Use special tool MB991618 to remove the hub bolts.
3. Install the plain washer to the new hub bolt, and install the
bolt with a nut while holding the hub with special tool
MB990767.
4. Install the brake disc, caliper assembly and tighten the
caliper assembly mounting bolts to the specified torque.
Tightening torque: 60
5 Nm (45 3 ft-lb)

23A-1
GROUP 23A
AUTOMATIC
TRANSMISSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .23A-3
AUTOMATIC TRANSMISSION
DIAGNOSIS . . . . . . . . . . . . . . . . . . . .23A-12
DIAGNOSTIC TROUBLESHOOTING FLOW23A-12
INTRODUCTION TO A/T DIAGNOSIS . . . . 23A-12
A/T DIAGNOSTIC TROUBLESHOOTING
STRATEGY . . . . . . . . . . . . . . . . . . . . . . . . . 23A-13
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 23A-13
HOW TO INITIALIZE A/T LEARNING
VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-17
FAIL-SAFE/BACKUP FUNCTION. . . . . . . . 23A-18
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 23A-19
TORQUE CONVERTER STALL TEST . . . . 23A-25
HYDRAULIC PRESSURE TESTS . . . . . . . 23A-26
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . 23A-32LINE PRESSURE ADJUSTMENT . . . . . . . . 23A-33
DIAGNOSTIC TROUBLE CODE CHART . . 23A-34
SYMPTOM CHART . . . . . . . . . . . . . . . . . . . 23A-35
DIAGNOSTIC TROUBLE CODE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 23A-36
SYMPTOM PROCEDURES . . . . . . . . . . . . 23A-218
DATA LIST REFERENCE TABLE . . . . . . . . 23A-271
ACTUATOR TEST REFERENCE TABLE . . 23A-276
A/T-ECU TERMINAL VOLTAGE REFERENCE
CHART FOR TRANSMISSION OPERATION23A-278
A/T-ECU TERMINAL RESISTANCE AND
CONTINUITY INSPECTION CHART . . . . . 23A-284
INSPECTION PROCEDURE USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 23A-285
Continued on next page
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

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

GENERAL DESCRIPTION
AUTOMATIC TRANSMISSION23A-4
TRANSMISSION
The transmission is made up of the torque converter and gear train. A 3-element, 1-stage, 2-phase torque
converter with built-in torque converter clutch is used. The gear train is made up of four sets of multi-disc
clutches, two sets of multi-plate brakes, one band type brake, two set of one-way clutches and three sets of
planetary gears. The planetary gears are made up of sun gears, carriers, pinion gears and annulus gears.
.
TRANSMISSION CONFIGURATION DRAWING
.
COMPONENTS AND FUNCTIONS
COMPONENT FUNCTION
Underdrive clutch UD connects the input shaft to the underdrive sun gear.
Reverse clutch REV connects the input shaft to the reverse sun gear.
Overdrive clutch OD connects the input shaft to the overdrive planetary carrier.
Direct clutch DIR connects the direct sun gear and direct planetary carrier.
Low-reverse brake LR holds the low-reverse annulus gear and the overdrive planetary
carrier.
Second brake 2ND holds the reverse sun gear.
Reduction brake RED locks the direct sun gear.
One-way clutch(DIR) OWC-D restricts the rotation direction of the direct sun gear.
One-way clutch(LR) OWC-LR restricts the rotation direction of the low-reverse annulus gear.

GENERAL DESCRIPTION
AUTOMATIC TRANSMISSION23A-6
SECTIONAL VIEW
1. OVERDRIVE CLUTCH
2. REVERSE CLUTCH
3. OVERDRIVE PLANETARY CARRIER
4. OUTPUT PLANETARY CARRIER
5. SECOND BRAKE
6. LOW-REVERSE BRAKE
7. ONE-WAY CLUTCH
8. TRANSFER DRIVE GEAR
9. TRANSMISSION CASE
10. UNDERDRIVE CLUTCH
11. OIL PUMP
12. TORQUE CONVERTER HOUSING13. TORQUE CONVERTER CLUTCH
14. TORQUE CONVERTER
15. INPUT SHAFT
16. DIFFERENTIAL
17. REAR COVER
18. OUTPUT SHAFT
19. DIRECT CLUTCH
20. REDUCTION BRAKE BAND
21. DIRECT PLANETARY CARRIER
22. TRANSFER DRIVEN GEAR
23. OUTPUT GEAR
24. DIFFERENTIAL DRIVE GEAR

GENERAL DESCRIPTION
AUTOMATIC TRANSMISSION23A-11
TORQUE CONVERTER CLUTCH CONTROL.
5TH GEAR RANGE
.
4TH GEAR RANGE

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.

AUTOMATIC TRANSMISSION DIAGNOSIS
AUTOMATIC TRANSMISSION23A-27
3. Connect the special tools (3.0 MPa (427 psi) oil pressure
gauge [MD998330] and adapters [MD998332, MD998900])
to each pressure discharge port.
NOTE: .
2ND: Second brake pressure port
UD: Underdrive clutch pressure port
LR: Low-reverse brake pressure port
DR: Torque converter release pressure port
DA: Torque converter apply pressure port
RV: Reverse clutch pressure port
OD: Overdrive clutch pressure port
DIR: Direct clutch pressure port
RED: Reduction clutch pressure port
4. Restart the engine.
5. Check that there are no leaks around the special tool port
adapters.
6. Measure the hydraulic pressure at each port under the
conditions given in the standard hydraulic pressure table,
and check that the measured values are within the standard
value ranges.
7. If the pressure is not within the standard value, stop the
engine and refer to the hydraulic pressure test diagnosis
table.
8. Remove the O-ring from the port plug and replace it.
9. Remove the special tool, and install the plugs to the
hydraulic pressure ports.
10.Start the engine and check that there are no leaks around
the plugs.