V4A51 Disassembly Section

BACK
M I T S U B I S H I M O N T ERO
R/V4A51 AND V5A51
(4 Speed) ( 5 S p ee d)
INDEX
QUICK EXTERNAL IDENTIFICATION ....................................................................................................................... 3
IDENTIFICATION CODE STAMPING LOCATION .................................................................................................... 4
4 SPEED COMPONENT APPLICATION CHART ........................................................................................................ 5
5 SPEED COMPONENT APPLICATION CHART ........................................................................................................ 6
ELECTRONIC COMPONENT DESCRIPTION ............................................................................................................. 7
SOLENOID CONNECTOR IDENTIFICATION AND RESISTANCE CHART ........................................................... 8
4 SPEED WIRE SCHEMATIC ........................................................................................................................................ 14
4 SPEED CONNECTOR IDENTIFICATION ................................................................................................................. 15
5 SPEED WIRE SCHEMATIC ........................................................................................................................................ 16
5 SPEED CONNECTOR IDENTIFICATION ................................................................................................................. 17
DIAGNOSTIC TROUBLE CODE DESCRIPTION ........................................................................................................ 19
AIR CHECKS .................................................................................................................................................................... 20
LINE PRESSURE TEST SPECS, PRESSURE TAP LOCATIONS, FLUID SPECIFICATION ................................. 21
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TRANSMISSION DISASSEMBLY .................................................................................................................................. 24

COMPONENT REBUILD SECTION
TRANSMISSION CASE ASSEMBLY ..................................................................................................................... 45
EXTENSION HOUSING OR 4WD ADAPTER HOUSING ................................................................................... 48
2WD SPEEDOMETER GEAR ASSEMBLY .......................................................................................................... 49
OIL PUMP ASSEMBLY ........................................................................................................................................... 51
OVERDRIVE AND REVERSE CLUTCH HOUSING ASSEMBLY ...................................................................... 55
PLANETARY GEAR TRAIN AND LOW SPRAG ASSEMBLY ............................................................................. 62
REVERSE SUN GEAR AND HUB ASSEMBLY .................................................................................................... 66
CENTER SUPPORT ASSEMBLY ........................................................................................................................... 66
REDUCTION ANNULUS AND UNDERDRIVE CLUTCH HOUSING ASSEMBLY .......................................... 70
2ND BRAKE CLUTCH PISTON AND RETAINER ASSEMBLY ......................................................................... 75
REDUCTION SERVO ASSEMBLY ......................................................................................................................... 76
DIRECT CLUTCH HOUSING ASSEMBLY ........................................................................................................... 78
4 SPEED OUTPUT SHAFT SUPPORT .................................................................................................................. 81
5 SPEED OUTPUT SHAFT SUPPORT AND DIRECT SPRAG ASSEMBLY ..................................................... 82
DIRECT SPRAG FREEWHEEL DIRECTION ...................................................................................................... 84
LOW SPRAG FREEWHEEL DIRECTION ............................................................................................................ 85
REDUCTION CARRIER AND OUTPUT SHAFT ASSEMBLY ............................................................................ 86
VALVE BODY ASSEMBLY ...................................................................................................................................... 88
CHECK BALL LOCATIONS .................................................................................................................................... 91
TRANSMISSION ASSEMBLY (4 SPEED) ..................................................................................................................... 97
TRANSMISSION ASSEMBLY (5 SPEED) ..................................................................................................................... 100
REDUCTION BAND ADJUSTMENT ............................................................................................................................. 112
TORQUE SPECIFICATIONS .......................................................................................................................................... 124
THRUST BEARING IDENTIFICATION ....................................................................................................................... 125
SPECIAL SERVICE TOOLS ........................................................................................................................................... 126
AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
Copyright © ATSG 2008
INTRODUCTION 1st Printing
November, 2008
R/V4A51 AND V5A51

R/V4A51 R=2WD, V=4WD

This is a four speed, Rear Wheel Drive transmission, with fully electronic controls for the upshifts and
downshifts, with 4th gear being overdrive. The individual gear ratios are achieved through two planetary gear
sets connected one behind the other. The components of the planetary gear sets are driven or held by means of
five multiple plate clutch packs, and a low sprag.
To minimize fuel consumption, the torque converter clutch is applied by the PCM, depending on throttle
position and vehicle speed. These units are currently found in Mitsubishi Montero 1999-2002 models,
equipped with 3.0L and 3.5L engines.
V5A51 V=4WD
This is a five speed, Rear Wheel Drive transmission, with fully electronic controls for the upshifts and
downshifts, with 5th gear being overdrive. The individual gear ratios are achieved through 3 planetary gear sets
connected one behind the other. The components of the planetary gear sets are driven or held by means of six
multiple plate clutch packs, 1 band, and two sprags.
To minimize fuel consumption, the torque converter clutch is applied by the PCM, depending on throttle
position and vehicle speed. These units are currently found in Mitsubishi Montero 2001-Up models, equipped
with 3.5L and 3.8L engines.
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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 has 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.
The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
WAYNE COLONNA Copyright © ATSG 2008 JIM DIAL

PRESIDENT TECHNICAL CONSULTANT
DALE ENGLAND ED KRUSE

FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT
PETER LUBAN GREGORY LIPNICK
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JON GLATSTEIN DAVID CHALKER
RICHARD GRAHAM ROLAND ALVAREZ
GERALD CAMPBELL GREG CATANZARO
AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
Te chnic a l S ervic e Inform a tion
PREFACE

"QUICK" EXTERNAL IDENTIFICATION

The information contained within this manual is
designed as both a teaching aid and self learning guide
for automotive technicians, who aspire to broaden 4 Speed NO BAND
their working knowledge of automatic transmissions. ANCHOR PLUG
A basic understanding of hydraulics and electronics is
also a prerequisite to mastering this transmission.
This manual will cover both the 4 speed unit
(R/V4A51), and the 5 speed unit (V5A51), in both the
"R" 2WD and "V" 4WD versions. Currently, there
are no 2WD 5 speed units available, only the 4 speed.
Mitsubishi Miracle
This transmission, in our opinion, is one of the most
well engineered transmissions we have seen. It first
appeared in the 1999 Montero, as a four speed unit,
but was engineered with the space left inside to make
it a five speed, by simply adding additional
components and changing the strategy in the PCM, to
accomodate an added solenoid and 2 added valve
trains in the valve body. This occured in 2001. They
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added a reduction planetary system, reduction band,

direct clutch pack and direct sprag. The added
solenoid is used to apply the added reduction band.
The added direct clutch is applied using the existing
L/R solenoid, along with an added switch valve in the
valve body, much like the 41TE. The power-flow for
1st thru 3rd gears, and reverse, all go through the
reduction planetary gear set, which changes all of the 5 Speed HAS BAND
gear ratios in the five speed transmission with the ANCHOR PLUG
exception of overdrive.
The manual shift indicators are the same in both the 4
and 5 speed units, and are as follows, P,R,N,D,3,2,L.
This makes it very difficult to identify the
transmissions apart when laying on the floor, since the
cases are the same in preparation for the added
internal parts. There is however an easy way to
identify it externally, as shown in Figure 1. The 5
speed will have a band anchor plug for the added
reduction band, and the 4 speed unit will not. Also the
accumulators on the outside for the direct clutch and
the reduction band will be empty.
Component applications and gear ratios for the 4
speed unit are shown in Figure 3, and component
applications and gear ratios for the 5 speed unit are
shown in Figure 4.
Copyright © 2008 ATSG

Figure 1
A U T O MATIC T R A N SMIS SIO N S E RVIC E G R O U P 3


IDENTIFICATION CODE STAMPING LOCATION
10
V5 BL
A5 74
1 30
7A
B
6
0
0
6
0
0
V 5 A 51 7AB
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Model Code
Drive Axle
R = Rear 2WD Trans Capacity
V = Rear 4WD 41 = Light Duty
Transmission Type 42 = Standard Duty
Forward Speeds A = Automatic 51 = Heavy Duty
M = Manual
4 = Four Speeds
5 = Five Speeds
VEHICLE AND TRANSMISSION APPLICATION CHART
4 Speed 2WD Models 4 Speed 4WD Models
Year Model Engine Transmission Year Model Engine Transmission
1999 Montero 3.0L SOHC R4A51-5-DDA 99-00 Montero 3.5L SOHC V4A51-5-CIA
1999 Montero 3.0L SOHC R4A51-5-DDA1 99-01 Montero 3.0L SOHC V4A51-5-DA
1999 Montero 3.0L SOHC R4A51-5-DEA 99-01 Montero 3.0L SOHC V4A51-5-DIA
1999 Montero 3.0L SOHC R4A51-5-DEA1 00-01 Montero 3.0L SOHC V4A51-5-DIB
1999 Montero 3.5L SOHC R4A51-5-CCA 00-01 Montero 3.5L SOHC V4A51-5-CIB
1999 Montero 3.5L SOHC R4A51-5-CCA1 01-02 Montero 3.0L SOHC V4A51-5-DIB1
00-01 Montero 3.0L SOHC R4A51-5-DFA 02-04 Montero 3.5L SOHC V4A51-5-CIB1
00-01 Montero 3.0L SOHC R4A51-5-DFA1
00-01 Montero 3.5L SOHC R4A51-5-CEA 5 Speed 4WD Models
00-01 Montero 3.5L SOHC R4A51-5-CEA1 Year Model Engine Transmission
01-03 Montero 3.0L SOHC R4A51-5-DFB 2001 Montero 3.5L SOHC V4A51-7-ACA1
01-04 Montero 3.5L SOHC R4A51-5-CEB 2001 Montero 3.5L SOHC V4A51-7-AA
2002 Montero 3.5L SOHC V4A51-7-ACB1
2002 Montero 3.5L SOHC V4A51-7-AB
03-05 Montero 3.8L SOHC V4A51-7-HCB

Figure 2
4 A U T O MATIC T R A N SMIS SIO N S E RVIC E G R O U P

R4A51/V4A51 COMPONENT APPLICATION CHART

INPUT
TORQUE SPEED REVERSE
CONVERTER SENSOR CLUTCH
CLUTCH LOW/REVERSE
BRAKE
OVERDRIVE UNDERDRIVE
CLUTCH OUTPUT
SECOND CLUTCH
SPEED
BRAKE SENSOR
LOW
SPRAG
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R4A51/V4A51 COMPONENT APPLICATION CHART
Selector Lever Under Over Low/Rev 2nd

Drive Reverse Drive Brake Brake Low Gear
Position/Gear Clutch Sprag Ratio
Clutch Clutch Clutch Clutch
Park ON
Reverse ON ON 2.720
Neutral ON
"D" 1st ON ON HOLD 2.842
"D" 2nd ON ON 1.495
"D" 3rd ON ON 1.000
"D" 4th ON ON .731
"3" 1st ON ON HOLD 2.842

"3" 2nd ON ON 1.495
"3" 3rd ON ON 1.000
"2" 1st ON ON HOLD 2.842

"2" 2nd ON ON 1.495
"L" 1st ON ON HOLD 2.842

Figure 3


V5A51 COMPONENT APPLICATION CHART

TORQUE
CONVERTER
CLUTCH
INPUT OUTPUT
SPEED SPEED
OVERDRIVE 2-4 BRAKE SENSOR
SENSOR
CLUTCH CLUTCH REDUCTION
REVERSE LOW/REVERSE UNDERDRIVE BRAKE BAND
CLUTCH CLUTCH CLUTCH
DIRECT
LOW CLUTCH DIRECT
SPRAG
SPRAG
V5A51 COMPONENT APPLICATION CHART

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Under 2nd Over Low/Rev Reduct.

Selector Lever Drive Brake Drive Reverse Low Direct Brake Direct Gear
Brake
Position/Gear Clutch Clutch Clutch Clutch Sprag Clutch Band Sprag Ratio
Clutch
Park ON ON
Reverse ON ON ON 3.865
Neutral ON ON
"D" 1st ON ON* HOLD ON HOLD 3.789
"D" 2nd ON ON ON HOLD 2.057
"D" 3rd ON ON ON HOLD 1.421
"D" 4th ON ON ON 1.000
"D" 5th ON ON ON .731
"3" 1st ON ON HOLD ON HOLD 3.789

"3" 2nd ON ON ON HOLD 2.057
"3" 3rd ON ON ON HOLD 1.421
"2" 1st ON ON HOLD ON HOLD 3.789

"2" 2nd ON ON ON HOLD 2.057
"L" 1st ON ON HOLD ON HOLD 3.789
* Operates only when stopped in "D" 1st gear (Approximately 10 KMH {6.2 MPH} or less).
The 5 speed units from late 2001 thru current, are equipped with a "Sport Tronic" feature. This is a selector lever with two
operation gates, a Main gate and a Manual gate as shown on page 10. All manual positions below the "D" position must be
achieved in the Manual gate with Plus or Minus indicators.

Figure 4
ELECTRONIC COMPONENTS

Solenoid Locations And Identification

All solenoids operate in exactly the same manner and the low/reverse solenoid in addition to applying the
are interchangeable. The transmission control relay low/reverse clutch, must also apply the added direct
supplies battery voltage to each solenoid through clutch, with the help of an added "switch" valve in the
terminals 9 and 10 in the transmission case connector. five speed valve body, much like the 41TE unit. There
Each solenoid closes when energized (On) and opens was also a regulator valve for the reduction band
to exhaust when de-energized (Off). The PCM added to the valve body.
provides the ground to energize each solenoid. The The valve body worm tracks are the same in both
ground time is displayed in percent. The PCM valve bodies, so extra care must be used when there
energizes or de-energizes each solenoid based on are replacement parts necessary. The 4 and 5 speed
input from various sensors such as TPS, ISS, OSS, spacer plates and valve body gaskets are the same.
VSS, TFT and PNP etc. As each solenoid is energized A quick reference resistance chart has been provided
or de-energized, it controls hydraulic pressure in the for you in Figure 6, to check each solenoid, and again
transmission to apply and release control elements. they are all the same, even though Mitsubishi
The four and five speed solenoid names and recommends tagging them as they are removed so that
locations are illustrated in Figure 5. The reduction they go back in the same bore. Solenoid air checks are
band solenoid was added to the five speed unit and found in Figure 7.
Electrical Components
Continued on Page 9
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4 AND 5 SPEED SOLENOID LOCATION AND IDENTIFICATION
4 SPEED 5 SPEED
LOW/REVERSE
LOW/REVERSE AND DIRECT
SOLENOID SOLENOID
REDUCTION
BAND
SOLENOID
00
00
6
6
777
777
-2
-2
2ND BRAKE 2ND BRAKE

SOLENOID SOLENOID
UNDERDRIVE UNDERDRIVE
SOLENOID SOLENOID
OVERDRIVE OVERDRIVE
SOLENOID SOLENOID
TCC TCC
SOLENOID SOLENOID
-2 TFT -2 TFT
0X
0X
18
18
SENSOR SENSOR

Figure 5


SOLENOID AND ATF TEMPERATURE SENSOR RESISTANCE CHART
View Looking Into View Looking Into

Front Of 4 Speed Front Of 5 Speed
Harness Connector Harness Connector
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10
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7 8 9 10
TERMINAL COMPONENT PART

NUMBERS CHECKED NUMBER RESISTANCE
Terminals 7 and 10 TCC Solenoid MD758981 2.7-3.4 Ohms @ 68°F
Terminals 6 and 10 L/R Solenoid MD758981 2.7-3.4 Ohms @ 68°F
Terminals 5 and 9 OD Solenoid MD758981 2.7-3.4 Ohms @ 68°F
Terminals 4 and 9 2nd Brake Solenoid MD758981 2.7-3.4 Ohms @ 68°F
Terminals 3 and 9 UD Solenoid MD758981 2.7-3.4 Ohms @ 68°F
Terminals 8 and 10 Reduction Solenoid MD758981 2.7-3.4 Ohms @ 68°F
0°C (32°F) = 16.7 - 20.5 k ohms

20°C (68°F) = 7.3 - 8.9 k ohms
Terminals 1 and 2 ATF Temp. Sensor 40°C (104°F) = 3.4 - 4.2 k ohms
60°C (140°F) = 1.9 - 2.2 k ohms
80°C (176°F) = 1.0 - 1.2 k ohms
100°C (212°F) = 0.57 - 0.69 k ohms
Transmission Fluid Specification = Diamond SP III

Figure 6

SOLENOID AIR TESTING

Pressure
Out To
Component
Line Controled
Pressure Exhaust
Feed
MADE I
N U.S.A
NO AIR
AIR OUT MADE I
N U.S.A
NO AIR AIR OUT

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Solenoid De-Energized (Off) Solenoid Energized (On)

Figure 7
ELECTRONIC COMPONENTS (CONT'D)

Transmission Fluid Temperature Sensor
The Transmission Fluid Temp (TFT) Sensor is The TFT sensor can be checked through terminals 1
located inside the transmission on the valve body, as and 2 of the transmission case connector, as shown in
shown in Figure 5. The PCM applies a 5 volt signal to Figure 6. Notice there is also an "O" ring seal on the
the TFT sensor output terminal (terminal 1). The TFT sensor, as shown in Figure 8.
ground terminal (terminal 2) is grounded back to the Electronic Components
PCM. The TFT sensor output voltage rises when the Continued on Page 11
resistance increases, and drops when the resistance
decreases. Resistance of the TFT sensor decreases as
the fluid temperature increases, as shown in the chart TFT
in Figure 6. SENSOR
If the TFT sensor output voltage is 2.6 volts or more,
even after driving for 10 minutes, it is judged that
there is an open circuit in the TFT sensor circuit and
diagnostic trouble code 15 will be stored.
If the TFT sensor output detects the voltage that
corresponds to 200°C (392°F) for more than one
second, it is judged that there is a short in the TFT "O" RING
sensor circuit and diagnostic trouble code 16 will be SEAL
stored.

Figure 8


R4A51/V4A51 4 SPEED MODELS
P
R 3 4 5
H
N
2 6 P
D R
3 1 7 C
N
D
2
3
L 0 X1000 r/min 8 2
L
Instrument Panel Standard Shift Gate

(Combination Meter)
Figure 9
V5A51 5 SPEED MODELS

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"STANDARD" MODELS "SPORT TRONIC" MODELS
6 7 6 7
5 8 5 8
P P
4 R 4 R
N N
3 D 3 D
3 5
2 2
2 4
3
1 L
1 2
X1000 r/min X1000 r/min 1
0 0
P P
R R +
N
N
D
D
3
2 Main Manual
L Gate Gate

Figure 10

Manual Shift Gate (4 Speed Models) Trouble Code Diagnosis

A 7 position (P, R, N, D, 3, 2, L) manual selector lever The powertrain control module (PCM) monitors the
is used in all vehicles with the 4 speed transmission. input/output signals, some signals all of the time and
The Manual Selector Lever assembly and indicators others only under specified conditions.
in the instrument panel are illustrated in Figure 9. When an irregular signal is initially detected, the
Each indicator represents the gear that is selected with PCM decides that a malfunction has occured and will
the manual selector lever. store a code in memory. Diagnostic trouble codes are
Mitsubishi refers to the instrument panel as a kept in memory by direct battery feed. The codes are
"Combination Meter" in their wire schematics and retained in memory even if the ignition switch is off.
text. Diagnostic trouble codes will, however, be erased
when a battery terminal, or the PCM connector is
"Standard" Shift Gate (5 Speed Models) disconnected. They can also be erased using a scan
A 7 position (P, R, N, D, 3, 2, L) manual selector lever tool.
is used in some 2001 vehicles equipped with the 5
speed transmission. The Manual Selector Lever Check "N" Range Light
assembly and indicators in the instrument panel are The "N" range light flashes at a frequency of
illustrated in Figure 10. Each indicator represents the approximately 1 Hz (once per second), if there is an
gear that is selected with the manual selector lever. abnormality detected in any of the following;
Mitsubishi refers to the instrument panel as a Input Shaft Speed Sensor
"Combination Meter" in their wire schematics and Output Shaft Speed Sensor
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text. Any of the Solenoids

A/T Control Relay System
Caution: The "N" range light will flash at
"Sport Tronic" Shift Gate (5 Speed Models) approximately 2 Hz (twice per second), on 1999 to
A 4 position (P, R, N, D) Sport Tronic selector lever is 2000 models, if the transmission fluid temperature is
used in some 2001 vehicles equipped with the 5 speed too high. Stop the vehicle and wait until the "N" light
transmission. The Manual Selector Lever assembly quits flashing. 2001-Up models have an "ATF-
and indicators in the instrument panel are illustrated TEMP" light on the instrument panel
in Figure 10. Each indicator represents the gear that is
selected with the manual selector lever. The 5 speed SCANNER FOR CODE RETRIEVAL, OR "N" RANGE
units from late 2001 thru current, are equipped with a INDICATOR LIGHT ON INSTRUMENT CLUSTER
"Sport Tronic" feature. This is a selector lever with
two operation gates, a Main gate and a Manual gate, "N" Range Indicator Light Method:
and is shown in Figure 10. All manual positions Turn ignition off. Using jumper wire, ground terminal 1 of the
Data Link Connector as shown below. Turn ignition on. Read
below the "D" position must be selected using the DTC's by observing flash pattern of "N" range indicator light
Manual gate with the Plus or Minus indicators. located in the instrument cluster. First series of flashes
Please refer to Figure 10. indicates first digit of DTC. Second series of flashes indicates
Mitsubishi refers to the instrument panel as a second digit of DTC.
Example: 2 flashes followed by a pause, and then 6 flashes
"Combination Meter" in their wire schematics and indicates DTC 26. Refer to trouble code description.
text.
OBD-II Connector located on

drivers side under dash.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

Figure 11


Transmission Range Selector Switch

All models use a Transmission Range Selector The electrical connector is hard wired to, and part of
Switch, commonly referred to in the past as "Inhibitor the transmission range selector switch, as shown in
Switch", which is externally mounted on the Figure 12. Connector terminal identification is
transmission case, as shown in Figure 13. The detent shown in Figure 14 and 15.
positions vary and may have four or seven positions,
depending on model. We are covering 2 different
transmissions in this manual, and there are 2 different Continued on Page 13
range switch electrical schematics which we will
identify for you, one at a time. This will make the
diagnostic process much easier. Pay close attention to
the wire schematics provided, as some models are
equipped with a "Sport Tronic" feature, or a manual
mode, that allows a "Slap Stick" for the Up and Down
shift control.
Notice in the connector check charts (Figure 14 and
15), that there is one terminal that is common for all
ranges. This is the voltage supply terminal into the
switch. When the ignition is in the "ON" position,
there needs to be battery voltage at this terminal. If
B
2
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there is not, this needs to be repaired first. If voltage is

present, it should exit the assigned terminal per the
range selected.
Figure 12
INPUT SOLENOID AND TFT SENSOR

SPEED ELECTRICAL CONNECTOR
SENSOR
RANGE SELECTOR
SWITCH ELECTRICAL
CONNECTOR
B
2
TRANSMISSION
RANGE SELECTOR
SWITCH

Figure 13

R/V4A51 and V5A51 1999 - Some 2001 R/V4A51 and V5A51 Some 2001-Up
Park/Neutral Position Switch Transmission Range Switch
On the above models Mitsubishi calls it a On the above models Mitsubishi calls it a
Park/Neutral Position Switch, and they have seven Transmission Range Switch, and they have four
detent positions (P R N D 3 2 L), as shown in Figure detent positions (P R N D), as shown in Figure 15.
14. Although the charts in Figure 14 are used to check Although the charts in Figure 15 are used to check the
the integrity of the switch's range selection, using an integrity of the switch's range selection, using an
ohmmeter, the best method is to check the switch in ohmmeter, the best method is to check the switch in
the vehicle with a voltmeter. the vehicle with a voltmeter.
By looking at the chart in Figure 14, it can be seen By looking at the chart in Figure 15, it can be seen
that terminal 7 is the common terminal for all range that terminal 7 is the common terminal for all range
selections. This is the voltage supply into the switch. selections. This is the voltage supply into the switch.
Terminals 9 and 10 are used for starting purposes Terminals 9 and 10 are used for starting purposes
only. With the ignition switch "ON" there must be only. With the ignition switch "ON" there must be
battery voltage at terminal 7. If there is not, this must battery voltage at terminal 7. If there is not, this must
be repaired first and is usually a fuse. If voltage is be repaired first and is usually a fuse. If voltage is
present, it should exit the assigned terminal for each present, it should exit the assigned terminal for each
range selection. range selection.
The PNP switch can also be checked for shorts. With The TRS switch can also be checked for shorts. With
the ignition switch "OFF", using an ohmmeter at the the ignition switch "OFF", using an ohmmeter at the
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same terminals shown in the Figure 14 chart, the same terminals shown in the Figure 15 chart, the
reading should be less than 2 ohms resistance. reading should be less than 2 ohms resistance.
A complete wiring schematic from transmission to A complete wiring schematic from transmission to
the PCM is shown in Figure 16 and PCM connector the PCM is shown in Figure 18 and PCM connector
identification is shown in Figure 17. identification is shown in Figure 19.
"R/V4A51 AND V5A51 "R/V4A51 AND V5A51

1999 - Some 2001 Some 2001-Up
1 2 3 4 5 1 2 3 4 5
6 7 8 9 10 6 7 8 9 10
View Looking Into Transaxle View Looking Into Transaxle

PRNDL Switch Connector B-01 PRNDL Switch Connector C-04
Position/ B-02 Connector Terminal Position/ C-04 Connector Terminal
Range 9 10 7 1 8 2 3 4 5 6 Range 9 10 7 1 8 2 3
P P
R R
N N
D D
3
2
L
Copyright © 2008 ATSG Copyright © 2008 ATSG
Figure 14 Figure 15


**100
TRANSMISSION TO PCM WIRE SCHEMATIC
HOT AT ALL TIMES 2000 MONTERO 4 SPEED
Fuse Dedicated
Link 6 Fuse 5
C-90
Conn **101
40A 10A HOT IN RUN
Black/Green
66 PCM Fuse 10
10A
White White/Green White/Green
1 Trans 4 50
Control Red/Green
Black C-91 C-92
2 Relay 3 Red/Blue
Conn Conn
BEHIND RIGHT
C-97 KICK PANEL
89
Red/Green
Conn
88 3 Input
White
97 103 2 Speed
Black
1 Sensor
Red/Blue 76
Red/Blue
Automatic Transmission B-02 Red/Green
3 Output
Conn 104
Black
2 Speed
Red/Green
Yellow Black
Low/Reverse
C-92 1 Sensor
Solenoid Green
Conn
Brown
6 B-01
Conn 7
129 Black/Yellow P
P 101 1
Red/Blue Red R
R 108 8
2 N
Black/White
N 121
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Yellow Red/Blue PCM

10 3 D
Yellow
TCC Control D 102
4 3
Solenoid Blue
Blue
7 Yellow
107 3 109
Yellow/Black 2
2 122 5
Red Yellow/Red L
L 110 6
Underdrive
Blue/Black
Solenoid White Black 10
3 120 Blue/Black
9
P
Red
Starting R
Overdrive
Solenoid Charging
Orange Blue
5 130 System N
D
Red Red/Blue Red/Green
2nd Brake
9 3
Solenoid Green BlackRed 2
4 106 Behind 126 Reverse 1
Right Side Lamps
Transmission Fluid Park/Neutral
Temp. Sensor Of Dash Position Switch
Red Black
1 124
PCM
Black Black
2 50 Red/Green
1
Green/Blue
C-90 2
Conn
Black
Pattern Select
Switch
Black/Yellow
Black/White
Yellow/Black
Green/Blue
Yellow/Red
Yellow
Red
Blue
PCM Located behind

D IND
N IND
HOLD
2 IND
3 IND
R IND
P IND
L IND
Right Side of Dash

Instrument Panel
PRND32L Indicator Lamps
(Combination Meter)
**100 = ENGINE COMPARTMENT RELAY BOX (LEFT INNER FENDER PANEL)

**101 = JUNCTION BLOCK (BEHIND LEFT SIDE OF DASH)
Figure 16

PCM CONNECTOR TERMINAL IDENTIFICATION

FOR 4 SPEED TRANSMISSION (R/V4A51)
PCM Located Behind

FUSE BLOCK Right Side Of Dash
Transmission
LOCATION Control Relay
Located Behind
Right Kick Panel
PCM CONNECTOR C-90 PCM CONNECTOR C-91 PCM CONNECTOR C-92

41 42 43 44 45 46 71 72 73 74 75 76 77
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101 102 103 104 105 106 107
47 48 49 50 51 52 53 54 55 56 57 78 79 80 81 82 83 84 85 86 87 88 89 108 109 110 111 112 113 114 115 116 117 118 119 120
58 59 60 61 62 63 64 65 66 90 91 92 93 94 95 96 97 98 121 122 123 124 125 126 127 128 129 130
All PCM Connector Views are from the wire side of connector.
View Looking Into

Front Of 4 Speed View Looking Into Neutral Switch
Harness Connector Front Of 4 Speed Harness Connector
(B-02 Connector) Harness Connector (B-01 Connector)
(B-01 Connector)
1 2 3 4 5 6
1 2 3 4 5
6 7 8 9 10
P
7 8 9 10 R
N
B23
2
D
View Looking Into
Front A/T Relay 1 2
3
Harness Connector 3 4 2
(C-97 Connector) L
Figure 17


TRANSMISSION TO PCM WIRE SCHEMATIC **100 **101

2003 MONTERO 5 SPEED HOT AT ALL TIMES HOT IN RUN
Fuse 18 Fuse 8
Automatic Transmission C-03 Red/Blue
20A 10A
Conn White/Violet
Yellow
Blue/Yellow
Low/Reverse Red/Blue
and Direct Brown Blue/Black
3 Trans BEHIND
6 127 PCM White/Violet Control
RIGHT
SIDE
4 DASH
Relay
Yellow Black Blue/Yellow
Reduction 128 2 1
Band Gray
D-13
Blue/Green
8 129 Conn
Shift Switch Asm.
Pink
Yellow Red/Blue 68 8 DN
Blue/Yellow
TCC Control
10 3
Solenoid Yellow/Black
Blue
7 Yellow/Red
130 77 7 UP
Blue/Yellow
Red Red/Black
Underdrive
85 4 SPORT
Solenoid Yellow
White
3 Red
137 5 AUTO
Yellow
1
Red Blue/Yellow
Overdrive
Solenoid Blue/Yellow
Orange
5
Blue
138 3 Input
Lt. Green
64 2 Speed
Blue/Yellow
Black
Red Red/Blue 1 Sensor
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2nd Brake
9 PCM
Solenoid Green Red/Yellow Blue/Yellow
4 136 3 Output
D-136 Black/Yellow
73 2 Speed
Transmission Fluid Conn Black
Sensor
88 1
Temp. Sensor
Red Green/Red
1 119 C-04
Conn 7
Black Black
2 96 BlackBlue P
D-135 66 1
Conn Red/Green R
67 8
Yellow/Green N
Red
75 2
135 Yellow D
76 3
Yellow/Blue
142 10
Violet
122 Behind 9 P
Right Side D-134
Yellow/Black Conn R
125 Starting
Of Dash Charging N
Orange
134 System
D
Pink
121 PCM Range
D-136 Switch
Conn
Red/Green Reverse
Lamps
Yellow/Green
Yellow/Black
Black/Blue
Red/Green
Yellow/Blue
Yellow
Orange
Pink
Violet
PCM Located Behind

Red
Right Side Of Dash

ATF TMP
D IND
N IND
4 IND
5 IND
2 IND
3 IND
1 IND
R IND
P IND
Instrument Panel
PRND Indicator Lamps
(Combination Meter)
**100 = ENGINE COMPARTMENT RELAY BOX (LEFT SIDE OF ENGINE COMPARTMENT)

**101 = JUNCTION BLOCK (BEHIND LEFT SIDE OF DASH)
Figure 18

PCM CONNECTOR TERMINAL IDENTIFICATION

FOR 5 SPEED TRANSMISSION (V5A51)
PCM And Transmission

FUSE BLOCK
Control Relay
LOCATION Located Behind
Right Side Of Dash
PCM CONNECTOR D-134 PCM CONNECTOR D-135 PCM CONNECTOR D-136
61 62 63 64 91 92 93 94 95 121 122 123 124

65 66 67 68 69 70 71 72 73 96 97 98 99 100 101 102 103 104 125 126 127 128 129 130 131 132 133
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74 75 76 77 78 79 80 81 82 105 106 107 108 109 110 111 112 134 135 136 137 138 139 140 141
83 74 85 86 87 88 89 113 114 115 116 117 118 119 120 142 143 144 145 146
All PCM Connector Views are from the wire side of connector.
View Looking Into Range Switch

Front Of 5 Speed View Looking Into Harness Connector
Harness Connector Front Of 5 Speed (C-04 Connector)
(C-03 Connector) Harness Connector
(C-04 Connector)
1 2 3 4 5 6
1 2 3 4 5
6 7 8 9 10
P
R
7 8 9 10 N
23
B
2
D
View Looking Into
Front A/T Relay 1 2
Harness Connector 3 4
(D-13 Connector)
Figure 19

INPUT SPEED SENSOR CIRCUIT OPERATION

INPUT SPEED SENSOR

When the key is turned on, you should see battery
PCM Terminal Numbers Vary
voltage at input speed sensor terminal 3. A coil built
Ground
Signal
Power
Between 4 and 5 Speed Units.
(Refer to Wire Schematics Figure 16 and 18) into the input shaft speed sensor generates a 0 - 5 volt
pulse signal at both ends of this coil when the input
Black/Orange
shaft rotates. The pulse signal frequency increases
White
Black
3 2 1
with a rise in input shaft speed. Both ends of the coil
are connected to the PCM, via the input shaft speed
sensor connector (terminals 1 and 2), as shown in
Figure 20. The PCM detects the input shaft speed by
1 2 3 the signal input from terminal 2. The input shaft
speed sensor generates the pulse signal as the teeth on
the reverse clutch housing pass the magnetic tip of the
sensor.
CONDITIONS TO SET DTC

If no output pulse is detected from the input shaft
speed sensor for one second or more, while driving in
3rd or 4th gear at a speed of 30 km/h (19 mph) or
more, there is an open or short in the input shaft speed
sensor circuit, and a DTC is set. When a DTC is
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output four times, transmission is locked into 3rd or

2nd gear as a failsafe measure, and the "N" range light
Copyright © 2008 ATSG flashes once per second.
Figure 20
OUTPUT SPEED SENSOR CIRCUIT OPERATION
When the key is turned on, you should see battery
OUTPUT SPEED SENSOR
voltage at output speed sensor terminal 3. A coil built
into the output shaft speed sensor generates a 0-5 volt
pulse signal at both ends of this coil when the output
shaft rotates. The pulse signal frequency increases
3 with a rise in output shaft speed. Both ends of the coil
2 are connected to the PCM, via the output shaft speed
sensor connector (terminals 1 and 2), as shown in
1
Figure 21. The PCM detects the output shaft speed by
the signal input from terminal 2. The output shaft
1
Ground
speed sensor generates the pulse signal as the teeth on
2
Black
Green/Yellow
Signal the output shaft pass the magnetic tip of the sensor.
Power
Black/Orange
3
CONDITIONS TO SET DTC

If the output from the output speed sensor is
continuously 50% lower than vehicle speed for one
second or more, while driving in 3rd or 4th gear at a
speed of 30 km/h (19 mph) or more, there is an open or
PCM Terminal Numbers Vary short in the output speed sensor circuit, and a DTC is
Between 4 and 5 Speed Units. set. When a DTC is output four times, the
(Refer to Wire Schematics Figure 16 and 18)
transmission is locked into 3rd or 2nd gear as a
failsafe measure, and the "N" range light flashes once
Copyright © 2008 ATSG per second.
Figure 21

DIAGNOSTIC TROUBLE CODES

CODE OBD II COMPONENT DESCRIPTION
11 Throttle Position Sensor Short Circuit
12 Throttle Position Sensor Open Circuit
14 Throttle Position Sensor Out Of Adjustment
15 P0713 Transmission Fluid Temperature System Open Circuit
16 P0712 Transmission Fluid Temperature System Short Circuit
21 Crankshaft Position Sensor System Open Circuit
22 P0715 Input Shaft Speed Sensor System Open/Short Circuit
23 P0720 Output Shaft Speed Sensor System Open/Short Circuit
26 Stoplight Switch System Short Circuit
27 P0705 Transmission Range Switch System Open Circuit
28 ---- Transmission Range Switch System Short Circuit
29 P0500 Vehicle Speed Sensor System Open/Short Circuit
31 P0753 Low/Reverse-Direct Solenoid System Open/Short Circuit
32 P0758 Underdrive Solenoid System Open/Short Circuit
33 P0763 2nd Brake Solenoid System Open/Short Circuit
34 P0768 Overdrive Solenoid System Open/Short Circuit
*35 P0773 Reduction Band Solenoid System Open/Short Circuit
36 P0743 Torque Converter Clutch Solenoid System Open/Short Circuit
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41 P0731 1st Gear Incorrect Ratio Mechanical Solenoid Failure

42 P0732 2nd Gear Incorrect Ratio Low Line Pressure
43 P0733 3rd Gear Incorrect Ratio Low Fluid Level
44 P0734 4th Gear Incorrect Ratio Sealing Ring Failure
Piston Seal Failure
*45 P0735 5th Gear Incorrect Ratio Valve Body Malfunction
46 P0736 Reverse Gear Incorrect Ratio
52 P0741 Torque Converter Clutch Solenoid System, Performance Defective System
53 P0742 Torque Converter Clutch Solenoid System Clutch Stuck On
54 P1751 Transmission Control Relay System Open/Short Circuit
56 ---- "N" Range Light System Open Circuit
* = 5 Speed Only
SCANNER FOR CODE RETRIEVAL, OR "N" RANGE

INDICATOR LIGHT ON INSTRUMENT CLUSTER P
OBD-II Connector located on
"N" Range Indicator Light Method:
Turn ignition off. Using jumper wire, ground terminal 1 of the Data
R
drivers side under dash. Link Connector as shown at left. Turn ignition on. Read DTC's by N
observing flash pattern of "N" range indicator light located in
1 2 3 4 5 6 7 8 instrument cluster. First series of flashes indicates first digit of DTC. D
9 10 11 12 13 14 15 16
Second series of flashes indicates second digit of DTC.
Example: 2 flashes followed by a pause, and then 3 flashes 3
View Looking Into
indicates DTC 23, as show below.
2
Diagnostic Connector
1.5 s 0.5 s
L
0.5 s
LIGHT
"ON"
LIGHT
"OFF"
Figure 22

ELECTRONIC CONTROLS (CONT'D)

Innovative Electronic Control System style. If the PCM determines from the driving
Sometime during the 2001 model year, after the five patterns that the driver is one who enjoys a relaxed,
speed was introduced, Mitsubishi introduced unhurried style, it adjusts timing to execute upshifts at
advanced software package for the Montero referred a lower engine speed to provide a smooth quiet ride.
to as "Inovative Electronic Control System" On the other hand if the PCM determines the driver to
(INVECS-II). The new INVECS-II system uses prefer a sporty ride, it adjusts timing to shift up at a
adaptive learning that provides a high level of comfort higher engine speed to provide a more powerful
and matches all driving conditions as well as the response.
individual driver's driving style. The shift patterns If the PCM determines that the driver tends to apply
found satisfying by the typical driver for all ranges of the brakes often on a descending road, it adjusts
driving, are stored in the PCM's memory. The PCM timing to downshift sooner, so that engine braking is
uses this data to analyze road conditions and the more effectively applied. Conversely, if the PCM
drivers style of operation, and then outputs the determines that the driver does not brake much while
optimal shift patterns stored in its memory to best driving downhill, it delays downshifting to minimize
match the conditions. the effect of engine braking.
Using adaptive shift control, the PCM learns the This new "Adaptive Learning" software obviously
driving habits and preferences of each individual changed the PCM, and also changed the number of
driver, by processing driving data on engine output, terminals in the PCM and related connectors, as
tire load, foot brake operation, etc. It then uses this shown in Figure 17 and 19.
data to adjust the shift timing to best suit the drivers
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AIR CHECKS
Low/Reverse
Clutch
Underdrive
Clutch
Overdrive
Clutch
Direct
Clutch
Reverse
Clutch
2nd Brake
Clutch Reduction
Bamd
Figure 23

LINE PRESSURE SPECIFICATIONS
R4A51/V4A51 4 SPEED PRESSURE CHART (PSI)

Low 2nd Torque
Selector Gear Engine Underdrive Reverse Overdrive Reverse Brake Converter
Position RPM Clutch Clutch Clutch Clutch Clutch Clutch
"UC" "RC" "OC" "LB" "2B" "TR"
P 2500 38-52 *32-52
R Reverse 2500 185-256 185-256 *73-106
N 2500 38-52 *32-52
D 1st Gear 2500 142-152 142-152 *94-123
D 2nd Gear 2500 142-152 142-152 *94-123
D 3rd Gear 2500 113-131 113-131 *94-123
D 4th Gear 2500 113-131 113-131 *94-123
* When the TCC pressure is measured, the engine speed should be 1500 RPM or less.
V5A51 5 SPEED PRESSURE CHART (PSI)

Low 2nd Reduction Torque
Selector Gear Engine Underdrive Reverse Overdrive Direct Reverse Brake Brake Converter
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Position RPM Clutch Clutch Clutch Clutch Clutch Clutch Band Clutch
"UC" "RC" "OC" "DC" "LB" "2B" "RB" "TR"
P 2500 38-52 38-52 *32-52
R Reverse 2500 185-256 185-256 185-256 *73-106
N 2500 38-52 38-52 *32-52
D 1st Gear 2500 142-152 142-152 142-152 *73-106
D 2nd Gear 2500 142-152 142-152 142-152 *73-106
D 3rd Gear 2500 113-131 113-131 113-128 *65-104
D 4th Gear 2500 113-131 113-131 113-128 *65-104
D 5th Gear 2500 113-131 113-128 113-128 *65-104
* When the TCC pressure is measured, the engine speed should be 1500 RPM or less.
NOTE: Pressure tap locations are shown on Page 22.

Requires Special Tool Adapters MB998332 and MB998900.
Refer to Page 23 if line pressure adjustment is necessary.
Caution:
(1) Transmission fluid temperature should be between
70-80°C (158-176°F) during the test.
(2) Replace all port plug "O" rings with new ones after
line pressure test and torque to 11 N•m (97 in.lb.).
(3) Start the engine and ensure that there are no leaks
around the plugs after the test.
(4) Refill with the proper transmission fluid as
necessary.
Transmission Fluid Specification = Diamond SP III

Figure 24


PRESSURE TAP LOCATIONS

RC
Reverse Clutch
4 AND 5 SPEED
RC
TR
TCC Release
TR
TA
TCC Apply
TA
23
B2
OC 2B LB UC
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OC 2B LB UC
Overdrive 2nd Brake Low/Reverse Underdrive
Clutch Clutch Clutch Clutch
5 SPEED ONLY
RB
Reduction
Band
DC
Direct
Clutch
RB DC

Figure 25
ADJUSTING LINE PRESSURE

Adjustment Procedure
1. Drain the transmission fluid.
Note: Pressure test must be performed before
attempting any adjustments.
2. Remove the transmission oil pan.
3. Turn the adjusting screw shown in Figure 26 to
adjust line pressure to the nominal value. The
pressure increases when the screw is turned
counter-clockwise.
Note: Adjust to the middle of the nominal
range when transmission is in "D" position.
Nominal line pressure is 142-152 PSI.
Each complete turn of the adjusting screw
changes pressure 5.1 PSI.
4. Install the transmission pan and transmission
fluid.
5. Repeat the line pressure test, and re-adjust the
line pressure as necessary.
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302
0X
18
336
372
302 MANUAL VALVE SLIDER

336 MANUAL VALVE
Line Pressure Adjusting Screw

Figure 26

TRANSMISSION DISASSEMBLY

SAFETY PRECAUTIONS
Service information provided in this manual by SPECIAL NOTE:
ATSG is intended for use by professional, qualified This manual will cover both 4 speed and 5 speed
technicians. Attempting repairs or service without versions of the 5A51 unit in the Montero. Most of
the appropriate training, tools and equipment could the illustrations will be of the 5 speed unit, however,
cause injury to you or others. we will show the differences when they are
The service procedures we recommend and necessary.
describe in this manual are effective methods of EXTERNAL COMPONENTS
performing service and repair on this unit. Some of 1. The transmission should be steam cleaned on
the procedures require the use of special tools that the outside, to remove any dirt or debris before
are designed for specific purposes. disassembly begins.
This manual contains CAUTIONS that you must 2. This transmission can be disassembled very
observe carefully in order to reduce the risk of injury easily on a work bench without the benifit of
to yourself or others. This manual also contains a holding fixture for rotation.
NOTES that must be carefully followed in order to 3. Remove torque converter from transmission, as
avoid improper service that may damage the vehicle, shown in Figure 27, and place on a container
tools and/or equipment. to drain.
Caution: Use extreme care when removing
the torque converter, to avoid personal injury
and/or damage to the converter, as it is heavy.
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Continued on Page 25
TORQUE
CONVERTER
B
2

Figure 27

EXTERNAL COMPONENTS (CONT'D) OUTPUT SPEED

4. Remove the output speed sensor from the case, SENSOR
as shown in Figure 28, remove and discard the
speed sensor "O" ring.
5. Remove fluid level indicator from the tube, as
shown in Figure 29.
Note: Fluid level indicators vary in design by
year and model. RB DC
6. Remove the input speed sensor from the case,

speed sensor "O" ring.
7. Remove the external manual control lever nut,
washer, and manual control lever, as shown in
Figure 29.
8. Remove the transmission range switch from
case, as shown in Figure 29. Copyright © 2008 ATSG
Figure 28
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A T F
FLUID LEVEL
INDICATOR
ADJUST AT HOT
RANGE
HOT
SWITCH
B
2
MANUAL
LEVER
INPUT SPEED
SENSOR

Figure 29


EXTERNAL COMPONENTS (CONT'D)

9. Remove the 4WD adapter housing, as shown in 11. Remove the parking gear snap ring from the
Figure 30, or the 2WD extension housing. Both output shaft, as shown in Figure 31.
are similar in their removal, and bolt locations 12. Remove the parking gear using a puller that is
and lengths are the same on both versions. capable of 2200 pounds.
Note: Exploded views of both versions are Note: There are two versions of the parking
shown in Figure 32 and 33. gear. One that uses a "heat shrink" process
10. Set the adapter housing, or extension housing for installation and one that does not.
aside for component rebuild. Two ID grooves is the normal type and three
ID grooves is the shrink fit type.
13. Some parking gears may be removed without
using a puller.
575
572
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ID GROOVES
FACE
571 REARWARD
570
574
572 4WD ADAPTER HOUSING.

574 35MM (1.378") ADAPTER HOUSING BOLT (8 REQUIRED). 570 PARKING GEAR.
575 90MM (3.543") ADAPTER HOUSING BOLT (3 REQUIRED). 571 PARKING GEAR RETAINING SNAP RING.
Figure 30 Figure 31

4WD ADAPTER HOUSING, V4A51 AND V5A51 MODELS, EXPLODED VIEW
77
78
70 ALIGNMENT DOWEL PIN.

71 PARKING PAWL.
72 PARKING PAWL SPRING.
70 73 PARKING PAWL PIVOT PIN.
74 PARKING ROD ROLLER SUPPORT.
75 PARKING ROD ROLLER SUPPORT SHAFT (2 REQUIRED).
72 76 SEALING CUP PLUG (2 REQUIRED).
77 REAR OIL SEAL.
71 78 4WD ADAPTER HOUSING.
73
75
74 76
75
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76

Figure 32
2WD EXTENSION HOUSING, R4A51 MODELS, EXPLODED VIEW

70 ALIGNMENT DOWEL PIN.
71 PARKING PAWL.
77 72 PARKING PAWL SPRING.
73 PARKING PAWL PIVOT PIN.
74 PARKING ROD ROLLER SUPPORT.
79 75 PARKING ROD ROLLER SUPPORT SHAFT (2).
76 SEALING CUP PLUG (2 REQUIRED).
77 REAR OIL SEAL.
79 2WD EXTENSION HOUSING.
80 DRIVEN SPEEDOMETER GEAR.
81 "O" RING SEAL.
82 EXTENSION TO ADAPTER "O" RING SEAL.
83 SPEEDOMETER ADAPTER HOUSING.
70 86 84 SPEEDOMETER RETAINING CLIP.
85 RETAINING BOLT.
86 ROLLED PIN.
80
72
81
23- 2 5
-22
29
71 82 85
- 31
20
83 26- 2 8
73
75 84
74 76
75
76
Figure 33


INTERNAL COMPONENTS
1. Remove the twenty oil pan bolts and remove 2. Remove the two oil filter retaining bolts and
the oil pan, as shown in Figure 34 remove and discard the oil filter, as shown in
Figure 34.
OIL PAN
OIL PAN BOLTS

(20 REQUIRED)
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RETAINING
BOLT
13MM LENGTH
M O A
N P
R K 6
>
5
2
8
8
6
3
6
-
G
F
3
0
<
OIL
FILTER
"O" RING
00
6
77 2
7
-
10
V5 BL
A5 74
1 30
7A
0X
B
18
6
0
0
6
0
0

Figure 34

INTERNAL COMPONENTS (CONT'D)

3. Remove solenoid and TFT sensor connectors
and fold the wiring harness over the pan rail, as
shown in Figure 35.
4. Remove the inside detent spring bolt and the
detent spring, as shown in Figure 35.
5. Remove the TFT sensor retaining bolt and the
TFT sensor, as shown in Figure 35.
Note: Some models the retaining bolt screws
into the valve body, and other models the bolt
goes through the valve body and screws into
the case.
6. Remove and discard the TFT sensor "O" ring
seal, as shown in Figure 35.
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RETAINING
BOLT
10MM LENGTH
DETENT
SPRING
RETAINING
BOLT
25MM LENGTH
DISCONNECTED
TFT WIRE HARNESS
SENSOR
"O" RING
SEAL
00
6
77 2
7
-
10
V5 BL
A5 74
1 30
7A
0X
B
18
6
0
0
6
0
0

Figure 35



8. Remove the valve body assembly, as shown in
7. Remove the 20 valve body bolts retaining the Figure 36, and set aside for component rebuild.
valve body onto the case. Note: Alignment dowels may stick in case.
Note: The twenty valve body retaining bolts 9. Remove and discard the "O" ring seals in the
are the plated bolts. You may have only 19, case. 1 for 4 speed units, 3 for 5 speed units.
as we have already removed TFT sensor. Refer to Figure 36.
36 VALVE BODY TO CASE "O" RING SEALS.

(3 REQUIRED IN 5 SPEED, 1 REQUIRED IN 4 SPEED)
368 VALVE BODY TO CASE HOLLOW ALIGNMENT DOWELS.
00
6
77 2
7
-
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0X
18
36
36
36
5 SPEED
ONLY
368
368
10
V5 BL
A5 74
1 30
7A
B
6
0
0
6
0
0

Figure 36


10. Remove the oil screen, low/reverse seal and
2nd brake seal from the transmission case, as
shown in Figure 38.
Note: Discard all three, as they come in the
Trans-Tec® overhaul kit.
11. Remove the external snap ring from pass-thru
connector as shown in Figure 37.
SNAP
Note: The wire harness is one piece and does RING
not disconnect externally.
12. Remove the complete wiring harness through
the inside of the case, as shown in Figure 38.
Figure 37
"O" RING
SEAL WIRE
HARNESS
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LOW/REVERSE ASSEMBLY
CLUTCH SEAL
SNAP
OIL
2ND BRAKE RING
SCREEN
CLUTCH SEAL
10
V5 BL
A5 74
1
7A03
B
6
0
0
6
0
0

Figure 38


ACCUMULATOR PISTON AND SPRING LOCATIONS EXPLODED VIEW

24
21
18
16 36
15 25
22
19
17
5 SPEED
ONLY
26
23
20
ProCarManuals.com
10
V5 BL
A5 74
1 30
7A
B
6
0
0
6
0
0
15
15 ACCUMULATOR PISTON SCARF-CUT SEAL (ALL, 6 REQUIRED)
35
16 OVERDRIVE CLUTCH ACCUMULATOR PISTON
17 OVERDRIVE CLUTCH ACCUMULATOR OUTER SPRING 15
18 2ND BRAKE CLUTCH ACCUMULATOR PISTON
19 2ND BRAKE CLUTCH ACCUMULATOR OUTER SPRING 31 34
20 2ND BRAKE CLUTCH ACCUMULATOR INNER SPRING 29
21 LOW/REVERSE CLUTCH ACCUMULATOR PISTON 33
22 LOW/REVERSE CLUTCH ACCUMULATOR OUTER SPRING 30 32
23 LOW/REVERSE CLUTCH ACCUMULATOR INNER SPRING
24 UNDERDRIVE CLUTCH ACCUMULATOR PISTON 29
25 UNDERDRIVE CLUTCH ACCUMULATOR OUTER SPRING 28
26 UNDERDRIVE CLUTCH ACCUMULATOR INNER SPRING 27
27 DIRECT CLUTCH ACCUMULATOR COVER SNAP RING
28 DIRECT CLUTCH ACCUMULATOR COVER
29 ACCUMULATOR COVER "O" RING SEAL (2 REQUIRED)
30 DIRECT CLUTCH ACCUMULATOR SPRING
31 DIRECT CLUTCH ACCUMULATOR PISTON
32 REDUCTION BAND ACCUMULATOR COVER SNAP RING
33 REDUCTION BAND ACCUMULATOR COVER
34 REDUCTION BAND ACCUMULATOR SPRING
35 REDUCTION BAND ACCUMULATOR PISTON
36 VALVE BODY TO CASE "O" RING SEAL
(3 REQUIRED IN 5 SPEED, 1 REQUIRED IN 4 SPEED)
Figure 39

INTERNAL COMPONENTS (CONT'D) 18. On 5 speed units, remove the reduction band
13. Remove the 4 accumulator pistons from case, servo cover, as shown in Figure 40, remove
under the valve body, as shown in Figure 39. and discard the "O" ring seal.
Note: Accumulator pistons are all the same 19. Remove the reduction band servo piston and
for 4 and 5 speed transmissions. spring, as shown in Figure 41, remove and
14. Remove the accumulator springs from case, as discard the scarf-cut piston seal.
shown in Figure 39.
Note: Best procedure is to tag the springs for Continued on Page 34
identification, as they are removed.
15. Remove the snap rings retaining the reduction
band and direct clutch accumulators, located 43
on the side of case, as shown in Figure 39.
16. Remove the accumulator covers from the case,
as shown in Figure 39.
17. Remove the accumulator springs and pistons, 44
Note: These 2 pistons are the same as under
the valve body, but tag the springs for ID.
ProCarManuals.com
40 45
10
41
46
42 10
10
V5 B L
A5 74
1 30
V5 BL 7A
A5 74 B
1 30
7A
B
43 REDUCTION BAND SERVO PISTON RETAINING SNAP RING

40 REDUCTION BAND SERVO COVER SNAP RING 44 REDUCTION BAND SERVO APPLY PISTON ASSEMBLY
41 REDUCTION BAND SERVO COVER 45 REDUCTION BAND SERVO PISTON SCARF-CUT SEAL
42 REDUCTION BAND SERVO COVER "O" RING SEAL 46 REDUCTION BAND SERVO PISTON RETURN SPRING
Figure 40 Figure 41



20. Remove the 8 converter housing retaining bolts
and remove converter housing, as shown in
Figure 42.
21. Remove the 10 oil pump assembly retaining
bolts, as shown in Figure 43.
22. Remove and discard the oil pump retaining
bolt seals, as they come in the Trans-Tec kit.
Refer to Figure 44.
1
2 3
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3 OIL PUMP RETAINING BOLTS AND SEAL ASM. (10 REQUIRED)

Figure 43
OIL PUMP
RETAINING BOLT
OIL PUMP
BOLT SEAL
1 CONVERTER HOUSING
2 CONVERTER HOUSING RETAINING BOLTS (8 REQUIRED)
Figure 42 Figure 44


23. Break the oil pump assembly loose from case
4
using the tools shown in Figure 45.
Note: The converter housing bolts may also
be used to loosen the oil pump assembly.
24. Remove the oil pump assembly from the case,
oil pump to converter housing "O" ring seal.
25. Remove the number 1 selective thrust washer,
5
Note: Selective washer may be stuck to back
of oil pump assembly.
26. Set the oil pump assembly aside for component
rebuild section.
27. Remove and discard oil pump to case gasket,
28. Remove the number 2 thrust bearing from the
overdrive/reverse clutch housing, as shown in 6
Figure 46, just so we do not lose it during the
cleaning process.
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7
MITSUBISHI
MD998333
4 OIL PUMP TO CONVERTER HOUSING "O" RING

5 OIL PUMP ASSEMBLY
6 NUMBER 1 SELECTIVE THRUST WASHER
7 OIL PUMP TO CASE GASKET
8 NUMBER 2 THRUST BEARING
Figure 45 Figure 46



29. Remove overdrive and reverse clutch housing, 33. Remove the number 4 thrust bearing, as shown
as shown in Figure 47, by grasping and lifting in Figure 48.
straight up. Note: Thrust bearing may be stuck to back
30. Set the overdrive and reverse clutch housing of overdrive clutch hub.
aside for the component rebuild section. 34. Remove the reverse sun gear and reverse hub
31. Remove the number 3 thrust bearing, as shown assembly, as shown in Figure 48.
in Figure 48.
32. Remove the overdrive clutch hub and shaft, as
shown in Figure 48. Continued on Page 37
424
426
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404
427
502
424 THRUST BEARING NUMBER 3.

426 OVERDRIVE CLUTCH HUB.
427 THRUST BEARING NUMBER 4.
502 REVERSE SUN GEAR AND HUB ASSEMBLY.
404 OVERDRIVE AND REVERSE CLUTCH HOUSING ASSEMBLY
Figure 47 Figure 48


35. Remove 2nd brake clutch retainer snap ring, as 36. Remove 2nd brake clutch retainer, as shown in
shown in Figure 49. Figure 49.
Note: Best procedure is to tag all snap rings 37. Set the 2nd brake clutch retainer aside for the
for identification, as most are selective. component rebuild section.
38. Remove 2nd brake clutch piston return spring,
39. Remove the 2nd brake clutches, as shown in
428 Figure 49.
40. Remove the low/reverse annulus and planetary
assembly, as shown in Figure 50.
41. Remove the number 7 thrust bearing, as shown
429 in Figure 50.
Note: Thrust bearing may be stuck to back
of planetary assembly.
42. Set the low/reverse annulus and planetary aside
for component rebuild section.
433 Continued on Page 38

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C
434
510
435
437
436
509
428 2ND BRAKE CLUTCH RETAINER SNAP RING.

429 2ND BRAKE CLUTCH RETAINER.
433 2ND BRAKE CLUTCH PISTON RETURN SPRING.
434 2ND BRAKE CLUTCH PRESSURE PLATE (SELECTIVE). 509 THRUST BEARING NUMBER 7.
435 2ND BRAKE CLUTCH FLAT STEEL PLATES, .154" THICK (2 REQ). 510 LOW/REVERSE ANNULUS AND PLANETARY ASSEMBLY.
436 2ND BRAKE CLUTCH "STEPPED" APPLY PLATE.
437 2ND BRAKE CLUTCH FRICTION PLATES, (4 REQUIRED).
Figure 49 Figure 50


INTERNAL COMPONENTS (CONT'D) 44. Remove low/reverse pressure plate and one
43. Remove low/reverse pressure plate selective friction plate, as shown in Figure 51.
snap ring, as shown in Figure 51. 45. Remove low/reverse pressure plate .080" snap
Note: Best procedure is to tag all snap rings ring, as shown in Figure 51, and tag for ID.
for identification, as most are selective. 46. Remove low/reverse clutch plates, as shown in
Figure 51.
47. Remove low/reverse clutch apply plate and the
cushion spring, as shown in Figure 51.
48. Remove the center support retaining snap ring,
as shown in Figure 52, and tag for ID.
438
49. Remove center support assembly from case, as
439 shown in Figure 52.
440 as shown in Figure 52.
Note: Thrust washer may be stuck on back
of the center support.
51. Set the center support assembly aside for the
component rebuild section.
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442 441
455
443
454
444
B
514
438 LOW/REVERSE PRESSURE PLATE SNAP RING (SELECTIVE).

439 LOW/REVERSE STEPPED PRESSURE PLATE.
440 LOW/REVERSE PRESSURE PLATE SNAP RING (.080" THICK).
441 LOW/REVERSE FRICTION PLATES (6 REQUIRED).
442 LOW/REVERSE STEEL PLATES (5 REQUIRED). 454 CENTER SUPPORT ASSEMBLY.
443 LOW/REVERSE "STEPPED" APPLY PLATE (SELECTIVE). 455 CENTER SUPPORT ASSEMBLY RETAINING SNAP RING.
444 LOW/REVERSE "WAVED" CUSHION PLATE. 514 NUMBER 8 THRUST WASHER (SELECTIVE).
Figure 51 Figure 52

"4 SPEED" INTERNAL COMPONENTS (CONT'D)

After the center support has been removed, the We will begin here with the 4 speed disassembly
disassembly process changes between the 4 speed below the center support, as shown in Figure 53.
and 5 speed units. This of course is because of the The 5 speed disassembly below the center support
added reduction planetary, reduction band, direct begins on Page 42.
clutch and direct sprag, all in the rear of case.
4 SPEED BELOW CENTER SUPPORT EXPLODED VIEW

517 533
519
514 515 518
520 535
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556
536
539
537
514 NUMBER 8 THRUST WASHER (SELECTIVE REAR END-PLAY).

557 515 NUMBER 9 THRUST BEARING.
517 REDUCTION RING GEAR OUTPUT FLANGE.
554 555 518 NUMBER 10 THRUST BEARING.
519 UNDERDRIVE CLUTCH HUB.
520 NUMBER 11 THRUST BEARING.
533 COMPLETE UNDERDRIVE CLUTCH HOUSING ASSEMBLY.
536 UNDERDRIVE CLUTCH BUTT-CUT TEFLON SEAL RINGS.
537 OUTPUT SHAFT BUSHING.
539 OUTPUT SHAFT STEEL HOOK-JOINT SEAL RINGS.
554 NUMBER 13 THRUST BEARING RETAINER.
556 OUTPUT SHAFT ASSEMBLY.
557 OUTPUT SHAFT SUPPORT.
Figure 53



1. Remove the number 8 selective thrust washer, 8. Remove number 12 thrust bearing, as shown in
as shown in Figure 54. Figure 55.
2. Remove the number 9 thrust bearing, as shown Note: Thrust bearing may be stuck to back
in Figure 54. of underdrive clutch housing.
3. Remove output flange, as shown in Figure 54, 9. Set the underdrive clutch housing aside for the
by lifting straight up. component rebuild section.
4. Remove number 10 thrust bearing, as shown in
Figure 55. Continued on Page 41
5. Remove the underdrive clutch hub, as shown
in Figure 55.
6. Remove number 11 thrust bearing, as shown
in Figure 55.
of underdrive clutch hub. 518
7. Remove complete underdrive clutch housing,
519
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520
533
514
515
535
517

519 UNDERDRIVE CLUTCH HUB.
514 NUMBER 8 THRUST WASHER (SELECTIVE REAR END-PLAY). 520 NUMBER 11 THRUST BEARING.
515 NUMBER 9 THRUST BEARING. 533 COMPLETE UNDERDRIVE CLUTCH HOUSING ASSEMBLY.
517 OUTPUT FLANGE. 535 NUMBER 12 THRUST BEARING.
Figure 54 Figure 55


10. Remove output shaft from transmission case, 13. Remove the retaining bolts and remove output
as shown in Figure 56. shaft support from case, as shown in Figure 57.
11. Remove the number 13 thrust bearing and the 14. Remove and discard output shaft support to
bearing retainer, as shown in Figure 56. case gasket, as shown in Figure 57.
12. Remove the sealing rings from output shaft and
set output shaft aside for component rebuild.
556
568
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567
566
569
554
555
566 REAR TRANSMISSION SUPPORT ALIGNMENT DOWEL.

554 NUMBER 13 THRUST BEARING RETAINER. 567 COMPLETED REAR TRANSMISSION SUPPORT ASSEMBLY.
555 NUMBER 13 THRUST BEARING. 568 REAR SUPPORT TO CASE BOLTS (8 REQUIRED).
556 OUTPUT SHAFT ASSEMBLY (2WD SHAFT ILLUSTRATED). 569 REAR SUPPORT TO CASE GASKET.
Figure 56 Figure 57



After the center support has been removed, the We will begin here with the 5 speed disassembly
disassembly process changes between the 4 speed below the center support, as shown in Figure 58, and
and 5 speed units. This of course is because of the the 4 speed disassembly below the center support
added reduction planetary, reduction band, direct begins on Page 39.
clutch and direct sprag, all in the rear of case.
5 SPEED BELOW CENTER SUPPORT EXPLODED VIEW

534
514 NUMBER 8 THRUST WASHER (SELECTIVE REAR END-PLAY).
515 NUMBER 9 THRUST BEARING. 514 515
534 REDUCTION ANNULUS AND UNDERDRIVE CLUTCH ASSEMBLY.
536 UNDERDRIVE CLUTCH BUTT-CUT TEFLON SEAL RINGS.
537 OUTPUT SHAFT BUSHING.
538 REDUCTION PLANETARY CARRIER AND OUTPUT SHAFT.
539 OUTPUT SHAFT STEEL HOOK-JOINT SEAL RINGS.
552 COMPLETE DIRECT CLUTCH HOUSING.
565 DIRECT CLUTCH STEEL HOOK-JOINT SEALING RINGS.
567 OUTPUT SHAFT SUPPORT AND DIRECT SPRAG ASSEMBLY.
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600 REDUCTION BAND ASSEMBLY.
538
536
535 539
537
552 600 567

565
553
R

Figure 58


2. Remove the number 9 thrust bearing, as shown
in Figure 59.
3. Remove the reduction annulus and underdrive
clutch assembly, as shown in Figure 59, and
set aside for the component rebuild section.
4. Remove number 12 thrust bearing, as shown
535
in Figure 60.
5. Remove reduction planetary carrier and output
shaft, as shown in Figure 60. 536
6. Remove and discard underdrive clutch butt-cut

teflon seal rings, as shown in Figure 60.
7. Remove and discard the steel hook-joint seal 538
rings, as shown in Figure 60.
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514
515
539
534

514 NUMBER 8 THRUST WASHER (SELECTIVE REAR END-PLAY). 536 UNDERDRIVE CLUTCH BUTT-CUT TEFLON SEAL RINGS.
515 NUMBER 9 THRUST BEARING. 538 REDUCTION PLANETARY CARRIER AND OUTPUT SHAFT.
534 REDUCTION ANNULUS AND UNDERDRIVE CLUTCH ASSEMBLY. 539 OUTPUT SHAFT STEEL HOOK-JOINT SEAL RINGS.
Figure 59 Figure 60



8. Remove the complete direct clutch housing, as 12. Remove output shaft support and direct sprag
shown in Figure 61, and set the drum aside for assembly, as shown in Figure 62, and set aside
the component rebuild section. for the component rebuild section.
9. Remove number 13 thrust bearing, as shown in 13. Remove and discard output shaft support to
Figure 61. case gasket, as shown in Figure 62.
of the direct clutch housing.
10. Remove the reduction band assembly from the Disassembly Complete
case, as shown in Figure 61.
11. Remove the eight retaining bolts holding the
output shaft support, as shown in Figure 62.
568
R
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552 567
566
553
569
600
566 REAR TRANSMISSION SUPPORT ALIGNMENT DOWEL.

552 COMPLETE DIRECT CLUTCH HOUSING. 567 OUTPUT SHAFT SUPPORT AND DIRECT SPRAG ASSEMBLY.
553 NUMBER 13 THRUST BEARING. 568 REAR SUPPORT TO CASE BOLTS (8 REQUIRED).
600 REDUCTION BAND ASSEMBLY. 569 REAR SUPPORT TO CASE GASKET.
Figure 61 Figure 62
COMPONENT REBUILD

TRANSMISSION CASE ASSEMBLY

1. Disassemble the manual and parking linkage 5. Inspect all case and linkage parts thoroughly
parts by removing the two retaining pins, and for any wear and/or damage and replace as
using Figure 63 as a guide. necessary.
2. Remove and discard the two "O" ring seals on
the manual shaft, as shown in Figure 63.
3. Remove and discard the manual shaft seal from Continued on Page 46
the case, as shown in Figure 63.
4. Clean all case and linkage parts thoroughly and
dry with compressed air.
PARKING LINKAGE AND RELATED PARTS EXPLODED VIEW

56
55
52
53
54
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58
57
10
10
V5 BL
A5 7 4
1 30
7A
B
6
0
0
6
0
0
10 TRANSMISSION CASE ASSEMBLY 55 INSIDE DETENT LEVER

52 SMALL MANUAL SHAFT "O" RING 56 MANUAL SHAFT SOLID RETAINING PIN (GOES IN CASE)
53 LARGE MANUAL SHAFT "O" RING 57 INSIDE DETENT LEVER RETAINING SPRING PIN (SPLIT)
54 MANUAL SHAFT 58 PARK ROD AND ROLLER ASSEMBLY

Figure 63

V4A51 Disassembly Section

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TRANSMISSION DISASSEMBLY .................................................................................................................................. 24

AUTOMATIC TRANSMISSION SERVICE GROUP

R/V4A51 R=2WD, V=4WD

The information and part numbers contained in this booklet have

WAYNE COLONNA Copyright © ATSG 2008 JIM DIAL

DALE ENGLAND ED KRUSE

AUTOMATIC TRANSMISSION SERVICE GROUP

"QUICK" EXTERNAL IDENTIFICATION

added a reduction planetary system, reduction band,

Copyright © 2008 ATSG

A U T O MATIC T R A N SMIS SIO N S E RVIC E G R O U P 3

IDENTIFICATION CODE STAMPING LOCATION

Copyright © 2008 ATSG

R4A51/V4A51 COMPONENT APPLICATION CHART

R4A51/V4A51 COMPONENT APPLICATION CHART

Selector Lever Under Over Low/Rev 2nd

"3" 1st ON ON HOLD 2.842

"2" 1st ON ON HOLD 2.842

"L" 1st ON ON HOLD 2.842

Copyright © 2008 ATSG

A U T O MATIC T R A N SMIS SIO N S E RVIC E G R O U P 5

V5A51 COMPONENT APPLICATION CHART

V5A51 COMPONENT APPLICATION CHART

Under 2nd Over Low/Rev Reduct.

"3" 1st ON ON HOLD ON HOLD 3.789

"2" 1st ON ON HOLD ON HOLD 3.789

"L" 1st ON ON HOLD ON HOLD 3.789

Copyright © 2008 ATSG

Solenoid Locations And Identification

4 AND 5 SPEED SOLENOID LOCATION AND IDENTIFICATION

2ND BRAKE 2ND BRAKE

Copyright © 2008 ATSG

A U T O MATIC T R A N SMIS SIO N S E RVIC E G R O U P 7

SOLENOID AND ATF TEMPERATURE SENSOR RESISTANCE CHART

View Looking Into View Looking Into

TERMINAL COMPONENT PART

Terminals 6 and 10 L/R Solenoid MD758981 2.7-3.4 Ohms @ 68°F

Terminals 5 and 9 OD Solenoid MD758981 2.7-3.4 Ohms @ 68°F

Terminals 4 and 9 2nd Brake Solenoid MD758981 2.7-3.4 Ohms @ 68°F

Terminals 3 and 9 UD Solenoid MD758981 2.7-3.4 Ohms @ 68°F

Terminals 8 and 10 Reduction Solenoid MD758981 2.7-3.4 Ohms @ 68°F

0°C (32°F) = 16.7 - 20.5 k ohms

Transmission Fluid Specification = Diamond SP III

Copyright © 2008 ATSG

SOLENOID AIR TESTING

NO AIR AIR OUT

Solenoid De-Energized (Off) Solenoid Energized (On)

ELECTRONIC COMPONENTS (CONT'D)

Copyright © 2008 ATSG

A U T O MATIC T R A N SMIS SIO N S E RVIC E G R O U P 9

R4A51/V4A51 4 SPEED MODELS

Instrument Panel Standard Shift Gate

V5A51 5 SPEED MODELS

"STANDARD" MODELS "SPORT TRONIC" MODELS

Copyright © 2008 ATSG

Manual Shift Gate (4 Speed Models) Trouble Code Diagnosis

text. Any of the Solenoids

OBD-II Connector located on

TRANSMISSION TO PCM WIRE SCHEMATIC 100 101