Tools and consumables
- Basic hand tools: metric socket & wrench set (including deep sockets), extensions, breaker bar.
- Torque wrench (range covering 5–200+ Nm).
- Snap‑ring/circlip pliers (internal & external).
- Hydraulic press (or heavy-duty arbor press) with adapters.
- Bearing puller / slide hammer.
- Drift punches, pin punches, brass/nylon drift set, hammer (soft-faced).
- Dial indicator with magnetic base.
- Micrometer / calipers.
- Feeler gauges.
- Seal drivers and bearing drivers.
- Gear puller for ring gear (if needed).
- Cleaning solvent, lint‑free rags, parts trays.
- Transmission assembly lube.
- New transmission fluid, ATF catch pan.
- New parts: planetary gear set (carrier, planet gears, pins), sun gear, ring gear (if damaged), all bearings and races, thrust washers, bushings, snap rings, seals, O‑rings, filter and pan gasket, torque converter hub seal (if removed).
- Safety: jack stands, engine support or transmission jack, gloves, eye protection.

Safety precautions
- Work on a flat level surface. Chock wheels. Disconnect negative battery terminal.
- Use proper lifting gear: transmission jack under the transmission; support engine if removing mount.
- Relieve fluid pressure and drain ATF into a clean container before disconnecting lines.
- Wear safety glasses and gloves; avoid loose clothing.
- Clean environment: contamination (dirt/metal shavings) will ruin trans; keep parts covered.
- Never use compressed air to clean parts (forces debris into seals); use solvent & brushes.
- Use correct press adapters and support pieces to avoid cracking housings or distorting gears.

Step‑by‑step planetary gear repair (automatic transmission)
Note: these are generic steps for a Delica L300 automatic transmission planetary pack. Follow a factory manual for torque values and specific sequences.

1) Vehicle prep and removal
- Park, chock, disconnect battery.
- Raise vehicle, support on jack stands.
- Drain ATF: remove pan, drain into catch.
- Remove drive shafts/prop shaft, electrical connectors, gear selector linkage, cooler lines (cap/plug lines), exhaust or crossmember obstructing transmission, starter, and any brackets.
- Support transmission with a trans jack, remove transmission mount bolts and bellhousing bolts, separate trans from engine, lower transmission.

2) Access the planetary assembly
- Secure transmission on bench.
- Remove torque converter from input shaft if required (mark orientation).
- Remove bolts for tail housing and oil pan if still attached.
- Remove valve body and solenoids (label/photograph connections).
- Remove the valve body bolts in specified pattern, set aside.
- Remove front pump/cover. This exposes the planetary assembly.

3) Disassemble planetary carrier
- Identify carrier assemblies (low/reverse, direct, etc.). Note orientation and stack order as you disassemble — photograph and tag parts.
- Remove snap rings/circlips that retain the carrier or ring gear. Use internal/external snap‑ring pliers as appropriate; work slowly to avoid losing clips.
- Use a press or puller to separate the carrier halves if it’s a two‑piece design.
- Remove planet gears by driving out the pins or rolling the cage off — support the cage and press out fixed pins carefully. Keep planet gear rollers and thrust washers organized.
- Remove sun gear (may be threaded in or pressed). Use gear puller or press if required.
- Remove ring gear (may be bolted or pressed). Use a gear puller or drift out bolts.

4) Inspect and measure
- Inspect gear teeth for pitting, scoring, broken teeth. If any damage, replace the gear(s).
- Inspect bearings/races for pitting, discoloration, or play — replace bearings & races; do not reuse.
- Measure endplay/backlash: clean and reassemble temporarily to check. Use dial indicator to measure ring gear backlash relative to sun gear — compare to spec; excessive backlash indicates worn teeth or incorrect shim.
- Measure bearing bores, planet pin diameter and gear clearances with micrometer/caliper to determine wear.
- Check thrust washers and bushings for wear or scoring — replace if out of tolerance. Do not reuse thin thrust washers.

5) Replace worn parts
- Replace all bearings and races using the press and proper drivers: press straight, support adjacent surfaces. Heat housing slightly (not hot) to ease seating if manufacturer allows, but avoid overheating.
- Replace snap rings and thrust washers.
- Replace seals and O‑rings when reassembling pump/front cover and torque converter area.
- Replace planetary gear set or individual gears if any tooth damage or excessive wear.

6) Reassemble planetary pack
- Clean all parts with solvent and dry. Lightly coat bearings and gear teeth with assembly lube.
- Install sun gear, ring gear, and planet gears in original orientation. Use a press and drivers to seat gears squarely.
- Install planet pins/pivots and secure with new snap rings/clips. Ensure clips seat fully in grooves — verify with feel and visual check.
- Reassemble carrier halves and torque any bolts to spec.
- Refit thrust washers and verify axial endplay with feeler gauge/dial indicator. If endplay out of spec, change shims/thrust washers per manual.
- Measure backlash with a dial indicator: move sun gear back and forth or ring gear. Adjust shims or replace parts until backlash is within factory spec.
- Check rotational smoothness — should rotate smoothly with minimal play.

7) Reassemble transmission
- Reinstall front pump/cover with new gasket/seal. Torque fasteners to spec.
- Reinstall valve body and solenoids, using correct torque and sequence; ensure check balls and valves are in correct position.
- Reinstall pan with new filter and gasket.
- Refit torque converter (lubricate hub spline) and align into pump; ensure it fully engages.
- Refit transmission to engine, torque bellhousing bolts to spec, reconnect mounts, driveshafts, cooler lines, electrical connectors, shift linkage.
- Refill with correct type and quantity of ATF.
- Reconnect battery.

8) Test and break‑in
- Start engine, let ATF circulate, check for leaks.
- Cycle through gears with foot on brake, check for correct shifting.
- Road test under light load, monitor temperatures and behavior.
- Recheck fluid level hot, adjust as necessary.

How specific tools are used / tips
- Snap‑ring pliers: use correct size tips; compress/expand slowly and seat clip fully in groove. Keep the clip pointed down into a parts tray when removed.
- Hydraulic press: support the part on flat plates to press bearings squarely. Use appropriate adapters to press on the bearing outer race (when installing outer race) or inner race for removal. Use a receiver to allow bearing to slide out into.
- Bearing puller/gear puller: attach jaws evenly; tighten center screw slowly; use heat on housing only if necessary and safe. Protect mating surfaces.
- Dial indicator: mount magnetic base to carrier or housing, zero against a stable reference, rotate gear slowly and record peak-to-peak for backlash.
- Torque wrench: use calibrated wrench; tighten to spec in recommended sequence to avoid distortion.
- Seal drivers: drive seals squarely without tilting; use the correct diameter driver.

Common pitfalls and how to avoid them
- Reusing bearings, thrust washers, or seals — always replace wear items.
- Allowing contamination — keep work area clean, cap open passages, work on lint‑free mat.
- Losing/incorrectly orienting small parts (check balls, springs, clips) — use labeled trays and photos.
- Incorrect shim selection, causing excessive backlash or preload — measure and adjust per spec; don’t guess.
- Damaging gear teeth with improper pressing or hammering — always use correct drivers and press.
- Not checking endplay/backlash — leads to premature failure.
- Improper snap ring seating — a sprung clip can fail and destroy transmission.
- Not replacing valve body gasket/filter when servicing — can cause internal fluid starvation or contamination.
- Overfilling or underfilling ATF — use correct procedure for level at operating temperature.

Replacement parts recommended
- Full planetary gear kit (carrier, planets, pins, snap rings) if wear present.
- Bearings & races for planetary and carrier shafts.
- Thrust washers/bushings and any shims specified.
- Seals and O‑rings (front pump, torque converter hub, pan).
- Filter and pan gasket.
- Torque converter hub seal if converter removed.
- ATF of correct specification.

Final notes
- Use the Mitsubishi factory service manual for L300 for exact disassembly diagrams, part numbers, torque values, and clearance specs — critical for correct shim/backlash settings.
- If unsure about measuring backlash or bearing preload, consider replacing entire planetary assembly or a reman transmission to avoid repeated failures.

End.
rteeqp73

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