Mitsubishi V5A51 User manual

GENERAL INFORMATION 23E-0-3................................................
1. SPECIFICATIONS 23E-1-1...................................................
TRANSMISSION MODEL TABLE 23E-1-1....................................
GENERAL SPECIFICATIONS 23E-1-2.......................................
SERVICE SPECIFICATIONS 23E-1-3........................................
VALVE BODY SPRING IDENTIFICATION 23E-1-4.............................
TORQUE SPECIFICATIONS 23E-1-5.........................................
SNAP RING, THRUST RACE, SPACER AND PRESSURE PLATE
FOR ADJUSTMENT 23E-1-7................................................
SEALANTS 23E-1-12.......................................................
LUBRICANTS 23E-1-13.....................................................
2. SPECIAL TOOLS 23E-2-1....................................................
3. TRANSMISSION AND TRANSFER 23E-3-1.....................................
4. TRANSFER CASE ADAPTER 23E-4-1.........................................
5. TRANSMISSION 23E-5-1.....................................................
6. REVERSE AND OVERDRIVE CLUTCH 23E-6-1.................................
7. SECOND BRAKE 23E-7-1....................................................
8. LOW/REVERSE ANNULUS GEAR 23E-8-1.....................................
9. CENTER SUPPORT 23E-9-1..................................................
10. UNDERDRIVE CLUTCH 23E-10-1..............................................
11. VALVE BODY 23E-11-1.......................................................
12. DIRECT ANNULUS GEAR 23E-12-1............................................
13. DIRECT CLUTCH 23E-13-1....................................................
14. OUTPUT SHAFT SUPPORT 23E-14-1..........................................
15. TRANSFER 23E-15-1.........................................................
16. TRANSFER CASE PLATE 23E-16-1............................................
17. INPUT GEAR 23E-17-1........................................................
18. COUNTER GEAR 23E-18-1....................................................
19. REAR OUTPUT SHAFT 23E-19-1..............................................
20. FRONT OUTPUT SHAFT 23E-20-1.............................................
21. TRANSFER DRIVE SHAFT 23E-21-1...........................................
22. SHIFT RAIL DRIVE GEAR 23E-22-1............................................
23. 2-4WD SHIFT RAIL AND H-L SHIFT RAIL 23E-23-1..............................
23E-0-1
AUTOMATIC
TRANSMISSION
V5A51
CONTENTS
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

23E-0-2
NOTES
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - General Information 23E-0-3
GENERAL INFORMATION
This transmission is the newly developed 5-speed automatic transmission that merges advanced electronic
technology and mechanical technology.
(1) A hydraulic balance mechanism is incorporated for the transmission clutch, allowing speed changes
at ultra-high speeds to be handled.
(2) The weight has been reduced by using precision sheet metal pressing of the clutch retainer, etc.,
and using aluminum die cast for the oil pump housing, etc.
SECTIONAL VIEW <TRANSMISSION>
12345678910111213 15
16
17
14
18
19
1. Torque converter clutch
2. Torque converter
3. Oil pump
4. Overdrive clutch
5. Reverse clutch
6. Overdrive planetary carrier
7. Second brake
8. Output planetary carrier
9. Low/reverse brake
10. One-way clutch
11. Center support
12. Underdrive clutch
13. Output shaft support
14. Parking gear
15. Output shaft
16. One-way clutch
17. Direct clutch
18. Valve body
19. Input shaft
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - General Information
23E-0-4
SECTIONAL VIEW <TRANSFER>
1 2 3 4 5 6 7 8 9 10
11
12
1. Transfer input gear
2. H-L clutch
3. Low speed gear
4. 2-4WD clutch sleeve
5. Drive sprocket
6. Chain
7. Viscous coupling
8. Center differential planetary carrier
9. Transfer drive shaft
10. Rear output shaft
11. Front output shaft
12. Counter shaft gear
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - General Information 23E-0-5
HYDRAULIC CONTROL SYSTEM
12 3 4 5
6
78
910
11
12
13 14 15
16 17 18 19 20
21
22 23
24
25
26 27
28 29
30
31 32
1. Reverse clutch
2. Low/reverse brake
3. Second brake
4. Underdrive clutch
5. Overdrive clutch
6. Torque converter clutch
7. Fail-safe valve A
8. Fail-safe valve B
9. Torque converter clutch control valve
10. Switching valve
11. Cooler
12. Low-reverse brake pressure control
valve
13. Second brake pressure control valve
14. Underdrive clutch pressure control
valve
15. Overdrive clutch pressure control
valve
16. Torque converter clutch control sole-
noid valve
17. Low-reverse brake solenoid valve
18. Second brake solenoid valve
19. Underdrive clutch solenoid valve
20. Overdrive clutch solenoid valve
21. Torque converter pressure control
valve
22. Regulator valve
23. Manual valve
24. Oil filter
25. Oil pan
26. Oil pump
27. Oil strainer
28. Reduction brake
29. Direct clutch
30. Fail-safe valve C
31. Reduction brake pressure control
valve
32. Reduction brake solenoid valve
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-1
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE - MODEL 2001
Transmission models Vehicle model Engine model
EUR V5A51-7-ACA V65W, V75W 6G74
V5A51-7-SDA V68W, V78W 4M41
EXP V5A51-7-CCA1 V75W 6G74
V5A51-7-CCA2 V65W, V75W 6G74
V5A51-7-SDA1 V78W 4M41
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications
23E-1-2
GENERAL SPECIFICATIONS
Item V5A51
Torque converter Type 3-element, with torque converter clutch
Transmission Type 5-speed, fully automatic
Gear ratio 1st 3.789
2nd 2.057
3rd 1.421
4th 1.000
5th 0.731
Reverse 3.865
Transfer Type 2-speed constant mesh
Gear ratio High 1.000
Low 1.900
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-3
SERVICE SPECIFICATIONS
TRANSMISSION
Item Standard value
Direct planetary carrier mm 0.25 - 0.55
Underdrive clutch end play mm 1.6 - 1.8
Input shaft end play mm 0.25 - 0.81
Direct clutch end play mm 1.0 - 1.2
Overdrive clutch end play mm 2.0 - 2.2
Overdrive clutch return spring retainer end play mm 0 - 0.09
Second brake end play mm 1.49 - 1.95
Center support end play mm 0 - 0.16
Brake reaction plate end play mm 0 - 0.16
Reverse clutch end play mm 1.5 - 1.7
Low/reverse brake end play mm 1.65 - 2.11
TRANSFER
Item Standard value Limit
Input gear bearing end play mm 0 - 0.06 -
Countershaft gear end play mm 0 - 0.15 -
Countershaft gear bearing end play mm 0 - 0.08 -
2-4WD clutch hub end play mm 0 - 0.08 -
H-L clutch hub end play mm 0 - 0.08 -
Rear output shaft preload mm 0.12 - 0.24 -
Rear output shaft end play mm 0 - 0.12 -
Rear output shaft bearing end play mm 0 - 0.08 -
Rear output shaft annulus gear end play mm 0 - 0.08 -
Differential lock hub end play mm 0 - 0.08 -
Clearance between outer synchronizer ring and drive sprocket mm - 0.3
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications
23E-1-4
VALVE BODY SPRING IDENTIFICATION
Item Wire
diameter
mm
Outside
diameter
mm
Free
height
mm
Number of
loops
Orifice check ball spring 0.5 4.5 15.4 15
Torque converter clutch control valve spring 0.7 5.9 28.1 19
Damping valve spring 1.0 7.7 35.8 17
Torque converter pressure control valve spring 1.6 11.2 29.4 9.5
Fail-safe valve A spring 0.7 8.9 21.9 9.5
Pressure control valve spring 0.7 7.6 37.7 25
Line relief valve spring 1.0 7.0 17.3 10
Regulator valve spring 1.3 13.3 44.6 10.5
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-5
TORQUE SPECIFICATIONS
TRANSMISSION
Item Torque Nm
Output shaft support mounting bolt 23 ±3
Upper valve body mounting bolt 11 ±1
Park/neutral position switch mounting bolt 11 ±1
Anchor plug 98 ±15
Oil pan mounting bolt 11 ±1
Oil filter mounting bolt 6±1
Oil pump mounting bolt 23 ±3
Cable end bracket mounting bolt 48 ±6
Converter housing to transmission case tightening bolt 48 ±6
Output shaft speed sensor mounting bolt 11 ±1
Reduction brake piston nut 19 ±3
Separating plate mounting bolt 6±1
Solenoid support mounting bolt 6±1
Transfer to transfer case adapter tightening bolt 35 ±6
Transmission case to transfer case adapter tightening bolt 48 ±6
Input shaft speed sensor mounting bolt 11 ±1
Valve body mounting bolt 11 ±1
Detent spring mounting bolt 6±1
Manual control lever mounting nut 22 ±3
Lower valve body mounting bolt 11 ±1
Lower valve body cover mounting bolt 11 ±1
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications
23E-1-6
TRANSFER
Item Torque Nm
Dynamic damper 35 ±6
Transfer case cover tightening bolt 19 ±2
Input gear bearing retainer mounting bolt 20 ±2
Transfer case to chain cover tightening bolt 35 ±6
Rear bearing retainer mounting bolt 20 ±2
Transfer case plate to transfer case tightening bolt and nut 35 ±6
Rear cover to chain cover tightening bolt 35 ±6
Shift actuator mounting bolt 11 ±1
4LLC switch 35 ±6
2WD switch 35 ±6
Center differential lock switch 35 ±6
4H switch 35 ±6
2WD-4WD switch 35 ±6
Vehicle speed sensor mounting bolt 11 ±1
Front outoput sensor mounting bolt 11 ±1
Rear output sensor mounting bolt 11 ±1
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-7
SNAP RING, THRUST RACE, SPACER AND PRESSURE PLATE FOR ADJUSTMENT
TRANSMISSION
Thrust race (for adjustment of direct planetary carrier end play)
Thickness mm Identification symbol Part number
1.6
1.8
2.0
2.2
2.3
None
None
None
None
None
MR276705
MR276706
MR276707
MR276708
MR276709
Snap ring (for adjustment of underdrive clutch and overdrive clutch end play)
Thickness mm Identification symbol Part number
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
Brown
None
Blue
Brown
None
Blue
Brown
None
Blue
Brown
None
Blue
Brown
None
Blue
MD759960
MD759961
MD759962
MD758892
MD750841
MD750842
MD750843
MD750844
MD750845
MD750846
MD750847
MD750848
MD750849
MD750850
MD750851
Thrust race (for adjustment of input shaft end play)
Thickness mm Identification symbol Part number
1.4
1.6
1.8
2.0
2.2
2.4
2.6
None
None
None
None
None
None
None
MD723063
MD707267
MD723064
MD707268
MD723065
MD724358
MD754798
Snap ring (for adjustment of overdrive clutch return spring retainer end play)
Thickness mm Identification symbol Part number
1.48
1.53
1.58
1.63
Brown
Black
None
Brown
MR336158
MR336159
MR336160
MR336161
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications
23E-1-8
Pressure plate (for adjustment of second brake end play)
Thickness mm Identification symbol Part number
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
F
E
D
C
B
A
0
1
MR336390
MR336391
MR336392
MR336393
MR336394
MR336395
MR336396
MR336397
Snap ring (for adjustment of center support and brake reaction plate end play)
Thickness mm Identification symbol Part number
2.2
2.3
2.4
2.5
None
Blue
Brown
None
MD756784
MD756785
MD758552
MD758553
Snap ring (for adjustment of reverse clutch end play)
Thickness mm Identification symbol Part number
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
None
Blue
Brown
None
Blue
Brown
None
Blue
Brown
None
Blue
Brown
None
MD761088
MD761089
MD761090
MD758947
MD756690
MD756691
MD756692
MD756693
MD756694
MD756695
MD756696
MD756697
MD756698
Snap ring (for adjustment of direct clutch end play)
Thickness mm Identification symbol Part number
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
Brown
None
Blue
Brown
None
Blue
Brown
None
Blue
Brown
None
Blue
MD758946
MD753397
MD753398
MD753399
MD753400
MD753401
MD753402
MD753403
MD753404
MD753405
MD753406
MD753497
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-9
Snap ring (for adjustment of low/reverse brake end play)
Thickness mm Identification symbol Part number
1.8
2.0
2.2
2.4
2.6
2.8
3.0
E
D
C
B
A
0
1
MD759425
MD759426
MD759427
MD759428
MD759429
MD759430
MD759431
TRANSFER
Spacer (for adjustment of input gear bearing end play)
Thickness mm Identification symbol Part number
2.30
2.35
2.40
2.45
2.50
None
Red
White
Blue
Green
MD704199
MD704200
MD704201
MD704202
MD704203
Spacer (for adjustment of countershaft gear end play)
Thickness mm Identification symbol Part number
1.77
1.91
2.05
2.19
2.33
None
Blue
Brown
White
Red
MB896728
MB896729
MB896730
MB896731
MB896732
Snap ring (for adjustment of countershaft gear bearing end play)
Thickness mm Identification symbol Part number
1.48
1.62
Blue
None
MB919176
MB919177
Snap ring (for adjustment of H-L clutch hub end play)
Thickness mm Identification symbol Part number
2.18
2.25
2.32
2.39
None
None
None
None
MR410928
MR410929
MR410930
MR410931
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications
23E-1-10
Snap ring (for adjustment of differential lock hub end play)
Thickness mm Identification symbol Part number
2.56
2.63
2.70
2.77
2.84
2.91
2.98
None
Red
White
Blue
Yellow
Green
Brown
MD738386
MD738387
MD738388
MD738389
MD738390
MD738391
MD738392
Snap ring (for adjustment of 2-4WD clutch hub end play)
Thickness mm Identification symbol Part number
2.56
2.63
2.70
2.77
2.84
None
Red
White
Blue
Yellow
MD738393
MD738394
MD738395
MD738396
MD738397
Snap ring (for adjustment of rear output shaft bearing end play)
Thickness mm Identification symbol Part number
2.26
2.33
2.40
2.47
None
Red
White
Blue
MD734311
MD734312
MD734313
MD734314
Snap ring (for adjustment of rear output shaft annulus gear end play)
Thickness mm Identification symbol Part number
1.90
1.94
1.98
2.02
2.06
2.10
None
None
None
None
None
None
MR305024
MR305025
MR305026
MR305027
MR305028
MR305029
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-11
Snap ring (for adjustment of rear output shaft preload)
Thickness mm Identification symbol Part number
1.57
1.63
1.69
1.75
1.81
1.87
1.93
1.99
2.05
2.11
2.17
2.23
2.29
2.35
2.41
2.47
2.53
2.59
2.65
2.71
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
MR486340
MR486341
MR486342
MR486343
MR486344
MR486345
MR486346
MR486347
MR477935
MR477936
MR477937
MR477938
MR477939
MR477940
MR477941
MR477942
MR477943
MR477944
MR477945
MR477946
Spacer (for adjustment of rear output shaft end play)
Thickness mm Identification symbol Part number
2.57
2.63
2.69
2.75
2.81
2.87
2.93
2.99
3.05
3.11
3.17
3.23
None
None
None
None
None
None
None
None
None
None
None
None
MR477950
MR477951
MR477952
MR477953
MR477954
MR477955
MR477956
MR477957
MR477958
MR477959
MR477960
MR477961
3.29
3.35
3.41
3.47
3.53
3.59
3.65
3.71
3.77
3.83
3.89
3.95
None
None
None
None
None
None
None
None
None
None
None
None
MR477962
MR477963
MR477964
MR477965
MR477966
MR477967
MR477968
MR486348
MR486349
MR486350
MR486351
MR486352
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications
23E-1-12
SEALANTS
TRANSMISSION
Item Specified sealant
Oil pan MITSUBISHI genuine sealant part No. MR166584 or
equivalent
Transfer case adapter (transmission side) MITSUBISHI genuine sealant part No. MR166584 or
equivalent
TRANSFER
Item Specified sealant
Bearing retainer mounting bolt MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Chain cover MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Transfer case cover MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Rear cover MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Sealing cap 3MTM AAD part No. 8672 or equivalent
Transfer case plate MITSUBISHI genuine sealant part No. MD997740 or
equivalent
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation AddedPWEE8920-I EMar. 2000Mitsubishi Motors Corporation

V5A51 - Specifications 23E-1-13
FORM-IN-PLACE GASKET (FIPG)
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that
the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
Since the FIPG used in the transmission hardens as it reacts with the moisture in the atmospheric air,
it is normally used in the metallic flange areas.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have broken by lightly striking with
a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined
surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old FIPG remaining in the bolt holes.
Form-in-place gasket application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
LUBRICANTS
TRANSFER
Item Specified lubricant
Lip of transfer case oil seal MITSUBISHI genuine grease part No. 0101011 or
Lip of transfer case plate oil seal
equivalent
Lip of rear cover oil seal
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Special Tools 23E-2-1
2. SPECIAL TOOLS
TRANSMISSION
Tool Number Name Use
MB990929 Installer adapter Installation of transfer case adapter oil seal
MB990938 Handle Use with installer adapter
MD998727 Oil pan remover Removal of oil pan
MD998333 Oil pump remover Removal of oil pump
MB991693 Reduction brake
stopper
Adjustment reduction brake piston
MB991633 Reduction brake
wrench set
Adjustment reduction brake piston
MB991603 Bearing installer
stopper
Measurement of direct planetary carrier and
center support end plays
MD998304 Oil seal installer Measurement of direct planetary carrier end
play
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation

V5A51 - Special Tools
23E-2-2
Tool UseNameNumber
MB991632 Clearance dummy
plate
Measurement of brake reaction plate, second
brake and low/reverse brake end plays
MD998913 Dial gauge exten-
sion
Measurement of brake reaction plate, second
brake and low/reverse brake end plays
MD998412 Guide Installation of oil pump
MD998316 Dial gauge support Measurement of input shaft end play
MD999590 Spring compressor Removal and installation of reverse and
overdrive clutch spring retainer snap ring
MD998924 Spring compressor
retainer
Use with spring compressor
MB991629 Spring compressor Measurement of overdrive clutch and under-
drive clutch end plays
MB991789 Spring compressor Adjustment reverse clutch end play
MB991630 Spring compressor Removal and installation of center support
snap ring and direct clutch snap ring
AddedPWEE8920-I
EMar. 2000Mitsubishi Motors Corporation