MITSUBISHI MONTERO R/V4A51 AND V5A51 (4 Speed) (5 Speed) INDEX

M I T S U B I S H I M O N T EROR/V4A51 AND V5A51(4 Speed)( 5 S p e ed)INDEXQUICK EXTERNAL IDENTIFICATION .IDENTIFICATION CODE STAMPING LOCATION .4 SPEED COMPONENT APPLICATION CHART .5 SPEED COMPONENT APPLICATION CHART .ELECTRONIC COMPONENT DESCRIPTION .SOLENOID CONNECTOR IDENTIFICATION AND RESISTANCE CHART .4 SPEED WIRE SCHEMATIC .4 SPEED CONNECTOR IDENTIFICATION .5 SPEED WIRE SCHEMATIC .5 SPEED CONNECTOR IDENTIFICATION .DIAGNOSTIC TROUBLE CODE DESCRIPTION .AIR CHECKS .LINE PRESSURE TEST SPECS, PRESSURE TAP LOCATIONS, FLUID SPECIFICATION .TRANSMISSION DISASSEMBLY .COMPONENT REBUILD SECTIONTRANSMISSION CASE ASSEMBLY .EXTENSION HOUSING OR 4WD ADAPTER HOUSING .2WD SPEEDOMETER GEAR ASSEMBLY .OIL PUMP ASSEMBLY .OVERDRIVE AND REVERSE CLUTCH HOUSING ASSEMBLY .PLANETARY GEAR TRAIN AND LOW SPRAG ASSEMBLY .REVERSE SUN GEAR AND HUB ASSEMBLY .CENTER SUPPORT ASSEMBLY .REDUCTION ANNULUS AND UNDERDRIVE CLUTCH HOUSING ASSEMBLY .2ND BRAKE CLUTCH PISTON AND RETAINER ASSEMBLY .REDUCTION SERVO ASSEMBLY .DIRECT CLUTCH HOUSING ASSEMBLY .4 SPEED OUTPUT SHAFT SUPPORT .5 SPEED OUTPUT SHAFT SUPPORT AND DIRECT SPRAG ASSEMBLY .DIRECT SPRAG FREEWHEEL DIRECTION .LOW SPRAG FREEWHEEL DIRECTION .REDUCTION CARRIER AND OUTPUT SHAFT ASSEMBLY .VALVE BODY ASSEMBLY .CHECK BALL LOCATIONS .TRANSMISSION ASSEMBLY (4 SPEED) .TRANSMISSION ASSEMBLY (5 SPEED) .REDUCTION BAND ADJUSTMENT .TORQUE SPECIFICATIONS .THRUST BEARING IDENTIFICATION .SPECIAL SERVICE TOOLS .AUTOMATIC TRANSMISSION SERVICE GROUP18635 S.W. 107 AVENUEMIAMI, FLORIDA 33157(305) 670-4161Copyright ATSG 8182848586889197100112124125126

INTRODUCTIONR/V4A51 AND V5A511st PrintingNovember, 2008R/V4A51 R 2WD, V 4WDThis is a four speed, Rear Wheel Drive transmission, with fully electronic controls for the upshifts anddownshifts, with 4th gear being overdrive. The individual gear ratios are achieved through two planetary gearsets connected one behind the other. The components of the planetary gear sets are driven or held by means offive multiple plate clutch packs, and a low sprag.To minimize fuel consumption, the torque converter clutch is applied by the PCM, depending on throttleposition and vehicle speed. These units are currently found in Mitsubishi Montero 1999-2002 models,equipped with 3.0L and 3.5L engines.V5A51 V 4WDThis is a five speed, Rear Wheel Drive transmission, with fully electronic controls for the upshifts anddownshifts, with 5th gear being overdrive. The individual gear ratios are achieved through 3 planetary gear setsconnected one behind the other. The components of the planetary gear sets are driven or held by means of sixmultiple plate clutch packs, 1 band, and two sprags.To minimize fuel consumption, the torque converter clutch is applied by the PCM, depending on throttleposition and vehicle speed. These units are currently found in Mitsubishi Montero 2001-Up models, equippedwith 3.5L and 3.8L engines.We wish to thank Mitsubishi Motor Company for the information and illustrationsthat have made this booklet possible. A special thanks also to Bob Nuttall forinformation 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 orby 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 havebeen carefully compiled from industry sources known for theirreliability, but ATSG does not guarantee its accuracy.WAYNE COLONNACopyright ATSG 2008JIM DIALTECHNICAL CONSULTANTPRESIDENTDALE ENGLANDED KRUSEFIELD SERVICE CONSULTANTTECHNICAL CONSULTANTPETER LUBANGREGORY LIPNICKTECHNICAL CONSULTANTTECHNICAL CONSULTANTJON GLATSTEINDAVID CHALKERTECHNICAL CONSULTANTTECHNICAL CONSULTANTRICHARD GRAHAMROLAND ALVAREZTECHNICAL CONSULTANTTECHNICAL CONSULTANTGERALD CAMPBELLGREG CATANZAROTECHNICAL CONSULTANTTECHNICAL CONSULTANTAUTOMATIC TRANSMISSION SERVICE GROUP18635 S.W. 107 AVENUEMIAMI, FLORIDA 33157(305) 670-41611

Technical Service InformationPREFACEThe information contained within this manual isdesigned as both a teaching aid and self learning guidefor automotive technicians, who aspire to broadentheir working knowledge of automatic transmissions.A basic understanding of hydraulics and electronics isalso 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, thereare no 2WD 5 speed units available, only the 4 speed.Mitsubishi MiracleThis transmission, in our opinion, is one of the mostwell engineered transmissions we have seen. It firstappeared in the 1999 Montero, as a four speed unit,but was engineered with the space left inside to makeit a five speed, by simply adding additionalcomponents and changing the strategy in the PCM, toaccomodate an added solenoid and 2 added valvetrains in the valve body. This occured in 2001. Theyadded a reduction planetary system, reduction band,direct clutch pack and direct sprag. The addedsolenoid is used to apply the added reduction band.The added direct clutch is applied using the existingL/R solenoid, along with an added switch valve in thevalve body, much like the 41TE. The power-flow for1st thru 3rd gears, and reverse, all go through thereduction planetary gear set, which changes all of thegear ratios in the five speed transmission with theexception of overdrive.The manual shift indicators are the same in both the 4and 5 speed units, and are as follows, P,R,N,D,3,2,L.This makes it very difficult to identify thetransmissions apart when laying on the floor, since thecases are the same in preparation for the addedinternal parts. There is however an easy way toidentify it externally, as shown in Figure 1. The 5speed will have a band anchor plug for the addedreduction band, and the 4 speed unit will not. Also theaccumulators on the outside for the direct clutch andthe reduction band will be empty.Component applications and gear ratios for the 4speed unit are shown in Figure 3, and componentapplications and gear ratios for the 5 speed unit areshown in Figure 4."QUICK" EXTERNAL IDENTIFICATION4 Speed5 SpeedNO BANDANCHOR PLUGHAS BANDANCHOR PLUGCopyright 2008 ATSGFigure 1AUTOMATIC TRANSMISSION SERVICE GROUP3

Technical Service InformationIDENTIFICATION CODE STAMPING LOCATION10B7A1 30A5 74V5 BL006006V 5 A 51 7ABModel CodeTrans CapacityDrive AxleR Rear 2WDV Rear 4WDTransmission TypeA AutomaticM ManualForward Speeds4 Four Speeds5 Five Speeds41 Light Duty42 Standard Duty51 Heavy DutyVEHICLE AND TRANSMISSION APPLICATION CHART4 Speed 2WD Models4 Speed 4WD ModelsYear Model Engine Transmission Year Model Engine Transmission1999 Montero1999 Montero1999 Montero3.0L SOHC3.0L SOHC3.0L SOHCR4A51-5-DDAR4A51-5-DDA1R4A51-5-DEA1999 Montero1999 Montero3.0L SOHC3.5L SOHCR4A51-5-DEA1R4A51-5-CCA1999 Montero00-01 Montero3.5L SOHC3.0L SOHCR4A51-5-CCA1R4A51-5-DFA00-01 Montero00-01 Montero3.0L SOHC3.5L SOHCR4A51-5-DFA1R4A51-5-CEA00-01 Montero01-03 Montero3.5L SOHC3.0L SOHCR4A51-5-CEA1R4A51-5-DFB01-04 Montero3.5L SOHCR4A51-5-CEB99-00 Montero3.5L SOHCV4A51-5-CIA99-01 Montero99-01 Montero00-01 Montero3.0L SOHC3.0L SOHC3.0L SOHCV4A51-5-DAV4A51-5-DIAV4A51-5-DIB00-01 Montero3.5L SOHCV4A51-5-CIB01-02 Montero02-04 Montero3.0L SOHC3.5L SOHCV4A51-5-DIB1V4A51-5-CIB15 Speed 4WD ModelsYear Model Engine Transmission2001 Montero3.5L SOHC2001 Montero3.5L SOHCV4A51-7-ACA1V4A51-7-AA2002 Montero2002 Montero3.5L SOHC3.5L SOHCV4A51-7-ACB1V4A51-7-AB03-05 Montero3.8L SOHCV4A51-7-HCBCopyright 2008 ATSGFigure 24AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service InformationR4A51/V4A51 COMPONENT APPLICATION CHSECONDBRAKEOUTPUTSPEEDSENSORLOWSPRAGR4A51/V4A51 COMPONENT APPLICATION CHARTOver Low/Rev 2ndSelector Lever UnderReverse Drive Brake BrakeDrivePosition/GearClutchClutch Clutch ClutchClutchParkReverseNeutral"D" 1st"D" 2nd"D" 3rd"D" 4th"3" 1st"3" 2nd"3" ONONON"2" 1st"2" 2ndON"L" 00ONONHOLD1.495ONON2.842HOLD2.842Copyright 2008 ATSGFigure 3AUTOMATIC TRANSMISSION SERVICE GROUP5

Technical Service InformationV5A51 COMPONENT APPLICATION ECLUTCHOUTPUTSPEEDSENSOR2-4 BRAKECLUTCHREVERSECLUTCHREDUCTIONBRAKE BANDLOW/REVERSE UNDERDRIVECLUTCHCLUTCHDIRECTCLUTCH DIRECTSPRAGLOWSPRAGV5A51 COMPONENT APPLICATION CHARTUnder 2ndOver Low/RevSelector Lever Drive Brake DriveReverseBrakePosition/Gear Clutch Clutch ClutchClutchClutchParkReverseNeutral"D" 1st"D" 2nd"D" 3rd"D" 4th"D" 3" 1st"3" 2nd"3" 3rdON"2" 1st"2" 2ndON"L" 9* 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 twooperation gates, a Main gate and a Manual gate as shown on page 10. All manual positions below the "D" position must beachieved in the Manual gate with Plus or Minus indicators.Copyright 2008 ATSGFigure 46AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service InformationELECTRONIC COMPONENTSSolenoid Locations And IdentificationAll solenoids operate in exactly the same manner andare interchangeable. The transmission control relaysupplies battery voltage to each solenoid throughterminals 9 and 10 in the transmission case connector.Each solenoid closes when energized (On) and opensto exhaust when de-energized (Off). The PCMprovides the ground to energize each solenoid. Theground time is displayed in percent. The PCMenergizes or de-energizes each solenoid based oninput from various sensors such as TPS, ISS, OSS,VSS, TFT and PNP etc. As each solenoid is energizedor de-energized, it controls hydraulic pressure in thetransmission to apply and release control elements.The four and five speed solenoid names andlocations are illustrated in Figure 5. The reductionband solenoid was added to the five speed unit andthe low/reverse solenoid in addition to applying thelow/reverse clutch, must also apply the added directclutch, with the help of an added "switch" valve in thefive speed valve body, much like the 41TE unit. Therewas also a regulator valve for the reduction bandadded to the valve body.The valve body worm tracks are the same in bothvalve bodies, so extra care must be used when thereare replacement parts necessary. The 4 and 5 speedspacer plates and valve body gaskets are the same.A quick reference resistance chart has been providedfor you in Figure 6, to check each solenoid, and againthey are all the same, even though Mitsubishirecommends tagging them as they are removed so thatthey go back in the same bore. Solenoid air checks arefound in Figure 7.Electrical ComponentsContinued on Page 94 AND 5 SPEED SOLENOID LOCATION AND IDENTIFICATION4 SPEED5 SPEEDLOW/REVERSEAND NOIDTCCSOLENOIDTFTSENSOR0X-27772ND BRAKESOLENOIDUNDERDRIVESOLENOID180X182ND pyright 2008 ATSGFigure 5AUTOMATIC TRANSMISSION SERVICE GROUP7-2

Technical Service InformationSOLENOID AND ATF TEMPERATURE SENSOR RESISTANCE CHARTView Looking IntoFront Of 4 SpeedHarness Connector12738459View Looking IntoFront Of 5 SpeedHarness ESISTANCETerminals 7 and 10TCC SolenoidMD7589812.7-3.4 Ohms @ 68 FTerminals 6 and 10L/R SolenoidMD7589812.7-3.4 Ohms @ 68 FTerminals 5 and 9OD SolenoidMD7589812.7-3.4 Ohms @ 68 FTerminals 4 and 92nd Brake SolenoidMD7589812.7-3.4 Ohms @ 68 FTerminals 3 and 9UD SolenoidMD7589812.7-3.4 Ohms @ 68 FTerminals 8 and 10Reduction SolenoidMD7589812.7-3.4 Ohms @ 68 FTERMINALNUMBERSTerminals 1 and 20 C (32 F) 16.7 - 20.5 k ohms20 C (68 F) 7.3 - 8.9 k ohms40 C (104 F) 3.4 - 4.2 k ohms60 C (140 F) 1.9 - 2.2 k ohms80 C (176 F) 1.0 - 1.2 k ohms100 C (212 F) 0.57 - 0.69 k ohmsATF Temp. SensorTransmission Fluid Specification Diamond SP IIICopyright 2008 ATSGFigure 68AUTOMATIC TRANSMISSION SERVICE GROUP