Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
January, 2012
INTRODUCTION
We wish to thank Mitsubishi Motor Company for the information and illustrations
that have made this booklet possible. A special thanks also to Bob Nuttall for
information and suggestions that have made this a very accurate booklet.
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.
WAYNE COLONNA
DALE ENGLAND
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
PETER LUBAN
JIM DIAL
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
GERALD CAMPBELL
ED KRUSE
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
JON GLATSTEIN
GREGORY LIPNICK
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
GREG CATANZARO
DAVID CHALKER
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
MITSUBISHI
HYUNDAI & KIA
INDEX
IDENTIFICATION CODE STAMPING LOCATION ..........................................................................................................
GENERAL DESCRIPTION AND OPERATION ..................................................................................................................
VEHICLE APPLICATION CHART ......................................................................................................................................
INTERNAL COMPONENT LOCATIONS ............................................................................................................................
COMPONENT AND SOLENOID APPLICATION CHARTS, (Mitsubishi, Pre-06 Kia and Pre-07 Hyundai Only)...........
COMPONENT AND SOLENOID APPLICATION CHARTS, (2006-Up Kia and 2007-Up Hyundai Only) .......................
SOLENOID LOCATIONS .....................................................................................................................................................
SOLENOID OPERATION AND FUNCTION ......................................................................................................................
TRANSAXLE FLUID TEMPERATURE SENSOR .............................................................................................................
INTERNAL WIRE HARNESS ..............................................................................................................................................
CASE CONNECTOR PIN ID & RESISTANCE CHART, (Mitsubishi, Pre-06 Kia and Pre-07 Hyundai Only) .................
WIRE SCHEMATIC (Mitsubishi Only) ...............................................................................................................................
CASE CONNECTOR PIN ID & RESISTANCE CHART, (2006-Up Kia and 2007-Up Hyundai Only) ..............................
WIRE SCHEMATIC (Hyundai Only) ..................................................................................................................................
WIRE SCHEMATIC (Kia Only) ...........................................................................................................................................
TRANSAXLE RANGE SWITCH (Mitsubishi Only) ...........................................................................................................
CONNECTOR VIEWS (Mitsubishi Only) ...........................................................................................................................
TRANSAXLE RANGE SWITCH (Hyundai Only) ..............................................................................................................
CONNECTOR VIEWS (Hyundai Only) ...............................................................................................................................
TRANSAXLE RANGE SWITCH (Kia Only) .......................................................................................................................
CONNECTOR VIEWS (Kia Only) ........................................................................................................................................
INPUT AND OUTPUT SPEED SENSORS ..........................................................................................................................
PCM AND PCM LOCATIONS ..............................................................................................................................................
DIAGNOSTIC TROUBLE CODES (Mitsubishi Only) ........................................................................................................
DIAGNOSTIC TROUBLE CODES (Hyundai and Kia Only) ..............................................................................................
FLUID PASSAGE IDENTIFICATION ................................................................................................................................
PRESSURE TAP LOCATIONS .............................................................................................................................................
AIR CHECK LOCATIONS ....................................................................................................................................................
LINE PRESSURE SPECIFICATIONS ................................................................................................................................
TRANSAXLE DISASSEMBLY .............................................................................................................................................
COMPONENT REBUILD
TRANSAXLE CASE ASSEMBLY ...............................................................................................................................
REDUCTION (OWC-2) SPRAG ASSEMBLY ............................................................................................................
REAR COVER ASSEMBLY .........................................................................................................................................
REDUCTION BAND SERVO ......................................................................................................................................
REVERSE/OVERDRIVE CLUTCH HOUSING ASSEMBLY ..................................................................................
OVERDRIVE CLUTCH HUB ASSEMBLY ...............................................................................................................
PLANETARY GEAR TRAIN ASSEMBLY ..................................................................................................................
UNDERDRIVE CLUTCH HOUSING ASSEMBLY ...................................................................................................
DIFFERENTIAL (RING GEAR) ASSEMBLY ..........................................................................................................
DIRECT PLANETARY CARRIER ASSEMBLY ........................................................................................................
DIRECT CLUTCH HOUSING ASSEMBLY ...............................................................................................................
SECOND CLUTCH RETAINER ASSEMBLY ............................................................................................................
OIL PUMP ASSEMBLY ...............................................................................................................................................
VALVE BODY ASSEMBLY (Mitsubishi, Pre-06 Kia and Pre-07 Hyundai Only) .....................................................
VALVE BODY ASSEMBLY (2006-Up Kia and 2007-Up Hyundai Only) ..................................................................
TRANSAXLE FINAL ASSEMBLY .......................................................................................................................................
LOW SPRAG (OWC-1) FREEWHEEL DIRECTION .........................................................................................................
REDUCTION (OWC-2) SPRAG FREEWHEEL DIRECTION ..........................................................................................
REDUCTION BRAKE BAND ADJUSTMENT ....................................................................................................................
BOLT CHART (Except Valve body) (See Valve Body Section For VB Bolts) ........................................................................
SPECIAL TOOLS ...................................................................................................................................................................
THRUST BEARING AND WASHER IDENTIFICATION AND LOCATIONS ..................................................................
TORQUE SPECIFICATIONS ...............................................................................................................................................
FLUID AND END-PLAY SPECIFICATIONS .....................................................................................................................
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
21
22
25
28
29
31
32
33
35
38
39
40
41
64
65
68
69
71
79
80
84
90
94
100
105
106
110
119
128
130
144
147
165
166
170
172
172
F5
A5
1K
2E
5B
1
A T F
"Mitsubishi"
F 5 A 51 K 2 E 5 B 1
Manufacturing Plant
Drive Axle
Forward Speeds
"Stamping In Case"
4 = Four Speeds
5 = Five Speeds
Transmission Type
A = Automatic
M = Manual
U
01 6KG
31 D2
38
A T F
Trans Capacity
42 = Standard Duty
51 = Heavy Duty
"Hyundai/Kia"
U 5 K BD
1
1
2
3
4
5
6
0 0 0 0 0 1
5
Figure 1
GENERAL OPERATION
Mitsubishi, Pre-07 Hyundai, Pre-2006 Kia Operation
The Mitsubishi version uses the basic 4 speed valve
body with an added solenoid to control the reduction
band, so it now has six solenoids instead of five. The
Low/Reverse solenoid is now a double duty solenoid
and is used to also apply the added direct clutch pack,
based on position of the switch valve in valve body.
The valve body has an added control valve for the
reduction band and an added Fail-safe "C" valve.
The component and the solenoid application charts for
Mitsubishi, Pre-07 Hyundai and Pre-06 Kia models are
found in Figure 4.
2007-Up Hyundia, 2006-Up Kia Operation
The later Hyundai and Kia version uses the same six
solenoid valve body as the earlier models except, it has
an additional solenoid, (Total of 7), used strictly to
control line pressure. The Low/Reverse solenoid is still
a double duty solenoid and is used to apply the added
direct clutch pack, based on the position of the switch
valve in the valve body.
However, the 2007-Up Hyundai and 2006-Up Kia
internal component and solenoid applications are
different than the earlier version. The component and
solenoid application charts for the 2007-Up Hyundai
and 2006-Up Kia are found in Figure 5.
Figure 2
LOW REVERSE
CLUTCH
UNDERDRIVE
CLUTCH
LOW (OWC-1)
SPRAG
OVERDRIVE
CLUTCH
DIRECT
CLUTCH
REDUCTION
(OWC-2) SPRAG
REDUCTION
BRAKE BAND
Figure 3
ON
ON
ON
ON
ON
ON
Sprag
TCC
Sprag
Gear Ratio
Mitsubishi
ON
ON
ON
3.117
ON
ON
ON HOLD HOLD
ON
HOLD
ON
HOLD
ON*
Dr-5th
Reduct
ON
ON
ON
ON
ON
Low
(OWC-1) (OWC-2)
ON**
ON**
ON
ON
3.789
2.162
1.421
1.000
0.686
Final Drive
Ratio 3.325
FLUID REQUIREMENTS
Mitsubishi Diamond SP III
"MITSUBISHI, pre-2007 hyundai, pre-2006 kia ONLY"
SOLENOID APPLICATION CHART
Gear
U.D.
2nd
O.D.
TCC L/R-Dir. RED.
Range
Sol
Sol
Sol
Sol
Sol***
Sol
Park
ON
Reverse ON
Neutral ON
Dr-1st OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
Dr-2nd OFF
Dr-3rd OFF
Dr-4th OFF
Dr-5th ON
OFF
ON
ON
OFF
OFF
OFF
OFF
ON**
OFF
ON**
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF*
OFF
OFF
ON
ON
OFF
OFF
ON
OFF
OFF
ON
Figure 4