Mitsubishi Montero (2002-2004). Manual - part 540

DIRECT CLUTCH

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-91

DIRECT CLUTCH

DISASSEMBLY AND ASSEMBLY

M1233009700026

<V5A51>

AKX00392

4

5

6

1

2

3

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11

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6

1

2

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7

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10

APPLY AUTOMATIC
TRANSMISSION FLUID
TO ALL MOVING PARTS
BEFORE INSTALLATION.

AB

5

DIRECT CLUTCH

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-92

Required Special Tools:

• MB991630: Spring Compressor

• MD998924: Spring Compressor Retainer

DISASSEMBLY SERVICE POINT

.

<<A>> SNAP RING REMOVAL
1. Set special tools MB991630 and MD998924 as shown in the 

illustration.

2. Compress the return spring, and remove the snap ring. 

ASSEMBLY SERVICE POINTS

.

>>A<< D-RING INSTALLATION
1. Apply ATF to the D-ring.
2. Install the D-ring in the direct clutch piston and spring 

retainer groove. Make sure that the D-ring is not twisted or 
damaged when installing.

.

>>B<< SNAP RING INSTALLATION
1. Set special tools MB991630 and MD998924 as shown in the 

illustration.

2. Compress the return spring, and install the snap ring. 

.

DISASSEMBLY STEPS

>>D<<

1.

SNAP RING

>>C<<

2.

REACTION PLATE

>>C<<

3.

CLUTCH DISC

>>C<<

4.

CLUTCH PLATE

<<A>>

>>B<<

5.

SNAP RING

6.

SPRING RETAINER

>>A<<

7.

D-RING

8.

RETURN SPRING

9.

DIRECT CLUTCH PISTON

>>A<<

10. D-RING

>>A<<

11. D-RING
12. DIRECT CLUTCH RETAINER

DISASSEMBLY STEPS 

AKX00393

MD998924

MB991630

SNAP RING

AB

AKX00393

MD998924

MB991630

SNAP RING

AB

DIRECT CLUTCH

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-93

>>C<< CLUTCH PLATE/CLUTCH DISC/REACTION PLATE 
INSTALLATION
1. Alternately assemble the clutch plate and clutch disc in the 

reverse clutch retainer. Align and assemble both clutch 
plates (where there are no teeth) (A in the illustration) with 
the reverse clutch retainer hole (B in the illustration).

2. Install the reaction plate so that it is oriented as shown in the 

illustration. Assemble in the same manner as the clutch 
plate so that the section with no teeth (A in the illustration) 
matches the retainer hole (B in the illustration).

.

>>D<< SNAP RING INSTALLATION
1. Install the snap ring in the direct clutch retainer groove.
2. Press the entire periphery of the reaction plate with a force 

of 49 N (11 pound), and confirm that the clearance (direct 
clutch end play) between the snap ring and reaction plate is 
the standard value. If the clearance is not at the standard 
value, select the snap ring and adjust so that the clearance 
is within the standard value.

standard value: 1.0 

− 1.2 mm (0.037 − 0.047 inch)

AKX00394

B

A

AB

AKX00395

CLUTCH PLATES ROUNDED EDGE

REACTION PLATE

 R 
STAMP

CLUTCH DISCS

AB

AKX00396

SNAP RING

AB

AKX00397

SNAP RING

REACTION
PLATE

STANDARD 
VALUE

AB

OUTPUTSHAFT SUPPORT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-94

OUTPUTSHAFT SUPPORT

DISASSEMBLY AND ASSEMBLY

M1233029000018

<V5A51>

ASSEMBLY SERVICE POINT

.

>>A<< ONE-WAY CLUTCH INSTALLATION
Install the one-way clutch in such a way that it will be oriented 
in the direction shown.

AKX00398

APPLY AUTOMATIC
TRANSMISSION FLUID
TO ALL MOVING PARTS
BEFORE INSTALLATION.

1

2

3

4

AB

DISASSEMBLY STEPS

1.

SNAP RING

>>A<<

2.

ONE-WAY CLUTCH

3.

SEAL RING

4.

OUTPUT SHAFT SUPPORT

DISASSEMBLY STEPS 

AKX00399

OUTPUT SHAFT
SUPOORT

ONE-WAY
CLUTCH

IDENTIFICATION
GROOVE

AB