Mitsubishi F5M41 Manual
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Mitsubishi F5M41 Manual

Mitsubishi F5M41 Manual

Manual transmission
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See also: Workshop Manual
F5M41, F5M42, W5M42
GENERAL INFORMATION
SEALANTS AND ADHESIVES
SNAP RINGS, SPACERS AND THRUST PLATE
ADJUSTMENT
3. TRANSMISSION <F5M41>
4. TRANSMISSION <F5M42, W5M42>
6. INPUT SHAFT <F5M42, W5M42>
8. OUTPUT SHAFT <F5M42, W5M42>
9. REVERSE IDLER GEAR <F5M42, W5M42>
15. DIFFERENTIAL <F5M41, F5M42>,
FRONT DIFFERENTIAL <W5M42>
17. TRANSFER <W5M42>
E
Mitsubishi Motors Corporation
MANUAL
CONTENTS
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Jun. 2000
PWEE9508-G
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22B-0-1
22B-0-3
22B-1-1
22B-1-1
22B-1-2d
22B-1-2d
22B-1-2e
22B-1-3
22B-1-4
22B-1-9
22B-2-1
22B-3-1
22B-4-1
22B-5-1
22B-6-1
22B-7-1
22B-8-1
22B-9-1
22B-10-1
22B-11-1
22B-12-1
22B-13-1
22B-14-1
22B-15-1
22B-16-1
22B-17-1
Revised

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Summary of Contents for Mitsubishi F5M41

  • Page 1 22B-4-1 ......5. INPUT SHAFT <F5M41> 22B-5-1 ......... . .
  • Page 2 22B-0-2 NOTES...

  • Page 3: General Information

    22B-0-3 MANUAL TRANSMISSION (E - W) - General Information GENERAL INFORMATION F5M41 <Types with single synchronizer ring for 2nd gear> 14 13 TFM0809 1. Reverse gear meshing noise pre- 8. Clutch housing vention device 9. Release bearing retainer <Models with reverse brake>...
  • Page 4 22B-0-4 MANUAL TRANSMISSION (E - W) - General Information F5M41 <Types with double synchronizer ring for 2nd gear> 1. Reverse gear meshing noise pre- 8. Clutch housing vention device 9. Release bearing retainer 2. 5th-reverse speed synchronizer hub 10. Input shaft 3.
  • Page 5 12. 1st-2nd speed synchronizer hub 5. Transmission case 13. 2nd speed gear 6. Clutch housing 14. 5th speed gear 7. Release bearing retainer 15. 5th-reverse speed synchronizer hub 8. Input shaft 16. Reverse gear Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 6 12. 1st-2nd speed synchronizer hub 5. Transmission case 13. 2nd speed gear 6. Clutch housing 14. 5th speed gear 7. Release bearing retainer 15. 5th-reverse speed synchronizer hub 8. Input shaft 16. Reverse gear Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 7 15. 1st-2nd speed synchronizer hub 6. Clutch housing 16. 2nd speed gear 7. Release bearing retainer 17. 5th speed gear 8. Input shaft 18. 5th-reverse speed synchronizer hub 9. Output shaft 19. Reverse gear 10. Viscous coupling Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...

  • Page 8: Specifications

    EA6A, EA6W 4D68 F5M42-1-F6N4 29/36 3.722 EA2A 4G63-MPI F5M42-1-F7N 30/36 3.722 EA2A 4G63-MPI F5M42-1-R6N2 29/36 4.058 EA1A 4G93 F5M42-1-R6N3 29/36 4.058 EA2A 4G63-CARB F5M42-2-F6N2 29/36 3.722 EA5A 6A13 F5M42-2-V6N 29/36 4.312 EA4A 6A12 Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 9 F5M41-1-F8A5 31/36 3.714 CJ4A, CK4A 4G92 F5M41-1-R8A1 31/36 4.052 CJ1A, CK1A 4G13 F5M41-1-R8A1 31/36 4.052 CJ2A, CK2A 4G15 F5M42-1-R6N6 29/36 4.052 EA1A 4G93 F5M42-2-R6N7 29/36 3.722 EA2A 4G63 F5M42-2-R6N8 29/36 3.722 EA6A 4D68 Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 10 F5M42-2-F6N7 29/36 3.722 EA5A 6A13 F5M42-2-R6N8 29/36 4.058 EA6A 4D56 F5M42-2-R5A2 28/36 4.058 N84W 4G64 MMAL F5M41-1-F8A5 31/36 3.722 CJ2A, CK2A 4G15 F5M42-1-F8A7 31/36 3.722 CJ5A, CK5A 4G93 F5M42-2-R5A2 28/36 4.058 N84W 4G64 Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 11 4G92 F5M42-1-R6N6 29/36 4.058 EA1A 4G93 F5M42-1-R6N7 29/36 4.058 EA2A 4G63 F5M42-1-F6N9 29/36 3.722 EA2A, EA2W 4G63 F5M42-2-F6N7 29/36 3.722 EA5A 6A13 F5M42-2-R5A2 28/36 4.058 N84W 4G64 MMAL F5M42-2-R5A2 28/36 4.058 N84W 4G64 Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 12 EA2A 4G63 F5M42-1-F6N7 29/36 3.722 EA5A 6A13 F5M42-2-R6N8 29/36 4.058 EA6A 4D68 F5M42-2-R5A2 28/36 4.058 N84W 4G64 MMAL F5M41-1-F8A5 31/36 3.714 CJ2A 4G15 F5M42-1-F8A7 31/36 3.722 CJ5A 4G93 F5M42-2-R5A2 31/36 4.058 N84W 4G64 Mitsubishi Motors Corporation Jun. 2000 PWEE9508-G Revised...

  • Page 13: Gear Ratio Table

    Allowable range Limit Input shaft front bearing end play mm - 0.01 - 0.12 Input shaft rear bearing end play <F5M41> mm - 0.01 - 0.09 Input shaft rear bearing end play <F5M42, W5M42> mm - 0.01 - 0.12 Input shaft 5th speed gear end play <F5M42, W5M42> mm - 0.01 - 0.09...

  • Page 14: Sealants And Adhesives

    Differential drive gear bolt <F5M41, F5M42> 3M STUD Locking No. 4170 or equivalent Front differential drive gear bolt <W5M42> Center differential drive gear bolt <W5M42> Front bearing retainer bolt (countersink head bolt) <F5M41> TRANSFER Item Specified sealant Air breather 3M SUPER WEATHERSTRIP No.
  • Page 15 Drive shaft oil seal lip area Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher Control shaft oil seal lip area Input shaft oil seal lip area MITSUBISHI genuine grease part No. 0101011 or equivalent Select lever shoe TRANSFER Items...
  • Page 16 Brown MD706539 Snap ring 2.31 Black (2) MD747149 (For adjustment of input shaft rear bearing end 2.35 None MD746561 play ..F5M41) (For adjustment of output shaft rear bearing end 2.39 Blue MD746562 play ..F5M42, W5M42) 2.43 Brown MD746563 2.47 Green MD746564 2.51...
  • Page 17 22B-1-5 MANUAL TRANSMISSION (E - W) - Specifications Part name Thickness mm Identification Part No. symbol Snap ring: F5M41 2.31 Black (2) MD748800 (For adjustment of output shaft rear bearing end 2.35 None MD748801 play) 2.39 Blue MD748802 2.43 Brown MD748803 2.47...
  • Page 18 22B-1-6 MANUAL TRANSMISSION (E - W) - Specifications Part name Thickness mm Identification Part No. symbol Spacer: F5M41 0.77 MD754476 (For adjustment of differential case end play) 0.86 MD720938 0.95 MD720941 1.04 MD720944 1.13 MD700270 1.22 MD700271 1.31 MD706574 1.40...
  • Page 19 MD720937 0.86 MD720938 0.89 MD720939 0.92 MD720940 0.95 MD720941 0.98 MD720942 1.01 MD720943 1.04 MD720944 1.07 MD720945 1.10 MD710454 1.13 MD700270 1.16 MD710455 1.19 MD710456 1.22 MD700271 1.25 MD710457 1.28 MD710458 1.31 MD706574 Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 20 MD710455 1.19 MD710456 1.22 MD700271 1.25 MD710457 1.28 MD710458 1.31 MD706574 Spacer: F5M41, F5M42 0.75 - 0.82 MA180862 (For adjustment of differential case backlash) 0.83 - 0.92 MA180861 0.93 - 1.00 MA180860 1.01 - 1.08 MA180875 1.09 - 1.16 MA180876 Spacer: W5M42 0.75 - 0.82...

  • Page 21: Torque Specifications

    Select lever mounting nut Front differential drive gear mounting bolt <W5M42> Center differential flange mounting screw <W5M42> Center differential drive gear mounting bolt <W5M42> Differential drive gear mounting bolt <F5M41, F5M42> Back-up lamp switch Front bearing retainer mounting bolt Poppet spring Restrict ball <F5M41>...

  • Page 22: Special Tools

    Installation of differential case taper roller bearing outer race MB990937 Installer adapter Installation of center differential taper roller bearing <W5M42> MB990938 Handle Use with Installer adapter MD998325 Differential oil seal Installation of differential oil seal installer <F5M41, F5M42> Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 23 Installation of input shaft front bearing (30) <F5M42, W5M42> MD998817 Installer adapter Installation of input shaft front bearing (34) <F5M41>, output shaft rear bearing <F5M42, W5M42> MD998818 Installer adapter Installation of input shaft rear bearing, roller (38) bearing inner race, reverse gear, needle roller bearing, reverse gear bearing sleeve <F5M42,...
  • Page 24 Installation of 5th speed gear sleeve, 2nd (42) speed gear sleeve <F5M41> MD998822 Installer adapter Installation of 1st speed gear sleeve,1st-2nd (46) speed synchronizer hub <F5M41>, 2nd speed gear sleeve and 3rd speed gear <F5M42, W5M42> MD998823 Installer adapter Installation of differential case taper roller (48) bearing inner race <F5M42, W5M42>...
  • Page 25 MB990933 Installer adapter Installation of transfer cover oil seal MD998304 Oil seal installer Installation of transfer extension housing oil seal MD998800 Oil seal installer Installation of transfer cover oil seal Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...

  • Page 26: Transmission

    22B-3-1 MANUAL TRANSMISSION (E - W) - Transmission <F5M41> 3. TRANSMISSION <F5M41> DISASSEMBLY AND REASSEMBLY 18 Nm 32 Nm 3.9 Nm 69 Nm 69 Nm TFM0718 Disassembly steps 1. Roll stopper bracket 2. Insulator washer 3. Shift cable bracket 4. Insulator washer "MA 5.
  • Page 27 22B-3-2 MANUAL TRANSMISSION (E - W) - Transmission <F5M41> Lubricate all internal parts with gear oil dur- ing reassembly. 30 Nm 18 Nm 44 Nm 48 Nm 18 Nm TFM0719 Disassembly steps 13. Interlock plate bolt AC" "GA 21. Reverse idler gear shaft 14.
  • Page 28 22B-3-3 MANUAL TRANSMISSION (E - W) - Transmission <F5M41> Lubricate all internal parts with gear oil dur- ing reassembly. 18 Nm TFM0720 Disassembly steps "DA 29. Spring pin AD" "CA 38. Reverse interlock rail 30. 1st-2nd speed shift rail AD" "CA 39. Steel ball 31.
  • Page 29 22B-3-4 MANUAL TRANSMISSION (E - W) - Transmission <F5M41> DISASSEMBLY SERVICE POINTS AA" SEALING CAP REMOVAL Sealing cap AB" TRANSMISSION CASE REMOVAL Expand the snap ring to remove it from the snap ring groove of the ball bearing. NOTE Expansion of the snap ring causes the snap ring groove to get out of position because of the output shaft’s own weight.
  • Page 30 (T - 0.05 mm) to (T - 0.17 mm) REASSEMBLY SERVICE POINTS Detent "AA OUTPUT SHAFT / INPUT SHAFT INSTALLATION <F5M41 with reverse brake> While placing the reverse brake cone detent in the illustrated position, install the input and output shafts together. "BA FRONT BEARING RETAINER INSTALLATION Apply a sealant to the front bearing retainer mounting bolts (countersunk bolts only).
  • Page 31 22B-3-6 MANUAL TRANSMISSION (E - W) - Transmission <F5M41> "CA REVERSE INTERLOCK RAIL / STEEL BALL / 3rd-4th 5TH SPEED SHIFT RAIL / REVERSE SHIFT LUG 3rd-4th speed / SNAP RING / 5TH SPEED SHIFT FORK / speed shift 3RD-4TH SPEED SHIFT FORK / 3RD-4TH SPEED...
  • Page 32 "HA TRANSMISSION CASE INSTALLATION (1) Apply a 1.5 mm bead of sealant to the illustrated positions of the transmission case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
  • Page 33 "KA CONTROL HOUSING INSTALLATION Apply a 1.5 mm bead of sealant to the illustrated position of the transmission case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
  • Page 34 "MASELECT LEVER INSTALLATION Control shaft Apply grease to the control shaft sliding portion of the select lever shoe. Select Specified grease: lever MITSUBISHI genuine grease part No. 0101011 or shoe equivalent INSPECTION BACK-UP LAMP SWITCH Check for continuity between terminals. Switch condition...

  • Page 35: Transmission

    11. Connector bracket <For GDI engine except DA2A> 12. Clutch fluid line blacket <DA2A only> 13. Oil temperature sensor harness <For GDI engine only> 14. Oil temperature sensor <For GDI engine only> 15. Gasket <For GDI engine only> Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 36 21. Reverse idler gear shaft bolt 22. Gasket 23. Reverse idler gear AA" "GA 24. Sealing cap AB" "FA 25. Transmission case "EA 26. Outer race "DA 27. Spacer 28. Magnet holder 29. Magnet Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 37 AC" "BA 37. 5th-reverse speed shift rail AC" "BA 38. 5th-reverse speed shift fork 39. Front bearing retainer AD" "AA 40. Input shaft AD" "AA 41. Output shaft 42. Differential 43. Clutch housing Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 38 5th-reverse with the shift fork. speed shift rail 3rd-4th speed shift rail AD" INPUT SHAFT / OUTPUT SHAFT REMOVAL Input shaft Remove the input and output shafts together. Output shaft Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 39 (2) Install the 3rd-4th speed shift rail and fork and the 5th-reverse speed shift rail and fork. 3rd-4th speed shift rail 3rd-4th speed shift fork 5th-reverse speed shift rail 5th-reverse speed shift fork Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 40 "FA TRANSMISSION CASE INSTALLATION (1) Apply a 1.5 mm bead of sealant to the illustrated position of the transmission case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
  • Page 41 "HA UNDER COVER INSTALLATION Apply a 1.5 mm bead of sealant to the illustrated position of the transmission case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
  • Page 42 Control shaft Apply grease to the control shaft sliding portion of the select lever shoe. Specified grease: Select lever shoe MITSUBISHI genuine grease part No. 0101011 or equivalent INSPECTION BACK-UP LAMP SWITCH (1) Check for continuity between terminals. Switch condition...

  • Page 43: Input Shaft

    22B-5-1 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 5. INPUT SHAFT <F5M41> DISASSEMBLY AND REASSEMBLY <Models with reverse brake> Apply gear oil to all moving parts before installation. TFM0834 Disassembly steps "MA 1. Snap ring 15. 4th speed gear AA"...
  • Page 44 22B-5-2 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> DISASSEMBLY AND REASSEMBLY <Except models with reverse brake> Apply gear oil to all moving parts before installation. Disassembly steps "MA 1. Snap ring 14. Synchronizer ring AA" "LA 2. Ball bearing "DA 15.
  • Page 45 22B-5-2a MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> DISASSEMBLY SERVICE POINTS MD998801 AA" BALL BEARING REMOVAL AB" REVERSE BRAKE SLEEVE REMOVAL MD998801 Mount a special tool on the 5th speed gear and remove the reverse brake sleeve. AC" 5TH-REVERSE SPEED SYNCHRONIZER HUB...
  • Page 46 22B-5-2b MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> Intentionally blank Mitsubishi Motors Corporation July 1999 PWEE9508-F Added...
  • Page 47 22B-5-3 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> AF" BALL BEARING REMOVAL MD998801 REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION 3.5 mm Oil seal Drive in the oil seal all the way up to the illustrated dimension. "BA BALL BEARING INSTALLATION...
  • Page 48 22B-5-4 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> "EA 3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION Install the 3rd-4th speed synchronizer hub in such a way that it will be oriented in the direction shown. Rear of trans- mission Identification mark...
  • Page 49 22B-5-5 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> "HA 5TH SPEED GEAR SLEEVE INSTALLATION MD998812 MD998813 MD998820 MD998801 "IA 5TH-REVERSE SPEED SYNCHRONIZER HUB INSTALLATION Install the 5th-reverse speed synchronizer hub in such a way that it will be oriented in the direction shown.
  • Page 50 22B-5-6 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> "KA REVERSE BRAKE SLEEVE INSTALLATION MD998812 MD998818 MD998801 "LA BALL BEARING INSTALLATION MD998812 MD998818 MD998801 "MASNAP RING INSTALLATION Select and install a snap ring so that the input shaft rear bearing end play will have the standard value.
  • Page 51 22B-5-7 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> SYNCHRONIZER RING (1) Check to ensure that the clutch gear tooth surfaces are not damaged and broken. (2) Check to ensure that the cone inside diameter is not damaged or worn and that the threads are not crushed.

  • Page 52: Input Shaft

    7. Needle roller bearing "CA 17. Snap ring AC" "GA 8. 4th speed gear sleeve AD" "BA 18. Ball bearing 9. Synchronizer ring "AA 19. Oil seal "DA 10. Synchronizer spring 20. Input shaft Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 53 Use the special tool to remove the ball bearing. MD998801 REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION 3.5 mm Oil seal Drive in the oil seal all the way up to the illustrated dimension. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 54 Rear of trans- mission Identification mark Caution MD998812 When the hub is installed, make sure that the synchronizer ring is not caught. MD998813 MD998801 MD998825 Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 55 "IA THRUST PLATE INSTALLATION Select and install a thrust plate so that the input shaft 5th speed gear end play will have the standard value. Standard value: - 0.01 - 0.09 mm Thrust plate Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 56 (2) Check the splines for damage and wear. NEEDLE ROLLER BEARING (1) Check to ensure that when the input shaft and gear are combined and made to rotate, they rotate smoothly without looseness and noise. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 57 (2) Check to ensure that the synchronizer cone surfaces are not roughened, damaged or worn. (3) Check to ensure that the gear inside diameter and front and rear surfaces are not damaged and worn. Mitsubishi Motors Corporation Jun. 2000 PWEE9508-G Revised...
  • Page 58 22B-7-1 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 7. OUTPUT SHAFT <F5M41> DISASSEMBLY AND REASSEMBLY <Types with single synchronizer ring for 2nd gear> Apply gear oil to all moving parts before installation. TFM0715 Disassembly steps "JA 1. Snap ring "DA 12.
  • Page 59 22B-7-2 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> DISASSEMBLY AND REASSEMBLY <Types with double synchronizer ring for 2nd gear> Apply gear oil to all moving parts before installation. Disassembly steps "JA 1. Snap ring 13. Outer synchronizer ring AA"...
  • Page 60 22B-7-2a MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> DISASSEMBLY SERVICE POINTS AA" BALL BEARING REMOVAL MD998801 AB" 2ND SPEED GEAR SLEEVE REMOVAL Mount a special tool on the synchronizer sleeve and remove the 2nd speed gear sleeve. MD998917 AC"...
  • Page 61 22B-7-2b MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> Intentionally blank Mitsubishi Motors Corporation July 1999 PWEE9508-F Added...
  • Page 62 22B-7-3 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> "BA SNAP RING INSTALLATION Select and install a snap ring so that the output shaft front bearing end play will have the standard value. Standard value: - 0.01 - 0.12 mm Snap ring "CA 1ST SPEED GEAR SLEEVE INSTALLATION...
  • Page 63 22B-7-4 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> "FA SYNCHRONIZER SLEEVE INSTALLATION (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown. Rear of transmission (2) When the synchronizer sleeve is installed, make sure that...
  • Page 64 22B-7-5 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> "JA SNAP RING INSTALLATION Select and install a snap ring so that the output shaft rear bearing end play will have the standard value. Standard value: - 0.01 - 0.09 mm "KA SYNCHRONIZER SPRING INSTALLATION...
  • Page 65 22B-7-6 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> (3) Press the synchronizer ring against the gear and check clearance “A”. If “A” is less than the limit, replace. Limit: 0.5 mm Synchronizer ring Gear OUTER SYNCHRONIZER RING / INNER...
  • Page 66 22B-7-7 MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> SPEED GEARS (1) Check to ensure that the helical and clutch gear tooth surfaces are not damaged or worn. (2) Check to ensure that the synchronizer cone surfaces are not roughened, damaged or worn.
  • Page 67 AF" "CA 31. 1st speed gear sleeve "KA 15. 4th speed gear "BA 32. Snap ring "JA 16. Snap ring AG" "AA 33. Roller bearing inner race AD" "IA 17. 3rd speed gear 34. Output shaft Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 68 32. Needle roller bearing "JA 16. Snap ring AF" "CA 33. 1st speed gear sleeve AD" "IA 17. 3rd speed gear "BA 34. Snap ring AG" "AA 35. Roller bearing inner race 36. Output shaft Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised...
  • Page 69 Mount a special tool on the 2nd speed gear and remove the 3rd speed gear. 3rd speed gear MD998917 AE" 2ND SPEED GEAR SLEEVE REMOVAL Mount a special tool on the 1st speed gear and remove the 2nd speed gear sleeve. Sleeve MD998917 Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 70 Standard value: - 0.01 - 0.12 mm Snap ring "CA 1ST SPEED GEAR SLEEVE INSTALLATION Use the special tools to install the 1st speed gear sleeve. MD998812 MD998814 Sleeve MD998825 Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 71 Rear of trans- mission (2) When the synchronizer sleeve is installed, make sure that Synchronizer sleeve the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve. Synchronizer hub Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 72 Standard value: - 0.01 - 0.09 mm Snap ring "KA 4TH SPEED GEAR INSTALLATION MD998812 Use the special tools to install the 4th speed gear. MD998813 MD998819 4th speed gear Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 73 Use the special tools to install the reverse gear, needle roller Reverse gear Sleeve bearing and reverse gear bearing sleeve. "OA BALL BEARING INSTALLATION MD998812 Use the special tools to install the ball bearing. MD998818 Ball bearing Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 74 (3) Press the synchronizer ring against the gear and check clearance “A”. If “A” is less than the limit, replace. Limit: 0.5 mm Synchronizer ring Gear Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 75 (2) Check to ensure that the front and rear ends of the sleeve inside surface are not damaged. SYNCHRONIZER SPRING Check to ensure that the spring is not sagging, deformed or broken. Mitsubishi Motors Corporation Jun. 2000 PWEE9508-G Revised...
  • Page 76 (2) Check to ensure that the synchronizer cone surfaces are not roughened, damaged or worn. (3) Check to ensure that the gear inside diameter and front and rear surfaces are not damaged and worn. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...

  • Page 77: Reverse Idler Gear

    (1) Check to ensure that when the shaft and gear are combined and made to rotate, they rotate smoothly without looseness and noise. (2) Check to ensure that the cage is not deformed. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...

  • Page 78: Speedometer Gear

    MANUAL TRANSMISSION (E - W) - Speedometer Gear 10. SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Lubricate all internal parts with gear oil dur- ing reassembly. TFM0593 Disassembly steps 1. e-clip 2. Speedometer driven gear 3. O-ring 4. Sleeve Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added...

  • Page 79: Select Lever

    7. Select lever 3. Spring washer 8. Select lever bushing 4. Washer "AA 9. Dust cover 5. Select lever bushing 10. Select lever shaft REASSEMBLY SERVICE POINT Dust cover "AA DUST COVER INSTALLATION Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added...

  • Page 80: Control Housing

    10. Neutral return spring 15. Control shaft boot 11. Spacer "BA 16. Oil seal "AA 17. Needle bearing 18. Spring washer 19. Stopper bracket 20. Control housing Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 81 (1) Apply a sealant to the outside circumference of the inserting portion. Specified sealant: 3M SUPER WEATHERSTRIP No. 8001 or equivalent (2) Make sure that the projecting portion is oriented in the direction shown. Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added Mitsubishi Motors Corporation Jan. 1997...
  • Page 82 "EA SPRING PIN INSTALLATION Spring pin 45° TFM0861 "FA LOCK PIN INSTALLATION Drive in the lock pin in the direction shown in the illustration. Lock pin Control finger Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added Mitsubishi Motors Corporation Jan. 1997 PWEE9508-C Added...

  • Page 83: Clutch Housing

    Disassembly steps 1. Clutch release bearing retainer AB" "BA 5. Outer race "EA 2. Oil seal 6. Oil guide <F5M41> "DA 3. Oil seal <F5M41, F5M42> "AA 7. Bushing* AA" "CA 4. Outer race <F5M42, W5M42> 8. Clutch housing NOTE: Referring to INSTALLATION SERVICE POINTS is required only when the clutch housing is replaced.
  • Page 84 (1) Install the outer race so that the model number stamped side will be oriented in the direction shown. Model number stamped side (2) Use the special tools to install the outer race. MB990938 MB990934 Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...
  • Page 85 Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher MD998325 "EA OIL SEAL INSTALLATION Pack grease in the oil seal lip area. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent MB990938 MB990926 Mitsubishi Motors Corporation Nov. 1995...

  • Page 86: Transmission Case

    "AA BUSHING INSTALLATION Split ends Press fit the bushing up to the illustrated position, while making sure that the split ends of the bushing do not coincide with the air purge groove. Air purge groove Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added...
  • Page 87 "CA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area. Specified oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher MD998325 Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added Mitsubishi Motors Corporation July 1999...
  • Page 88 132 Nm TFM0760 Disassembly steps "EA 1. Differential drive gear AA" "DA 2. Ball bearing <F5M41> AB" "CA 3. Taper roller bearing <F5M42, W5M42> "BA 4. Lock pin "AA 5. Pinion shaft "AA 6. Pinion "AA 7. Washer "AA 8.
  • Page 89 MANUAL TRANSMISSION (E - W) - Front Differential <W5M42> DISASSEMBLY SERVICE POINTS MD998801 AA" BALL BEARING REMOVAL <F5M41> Use the special tool to remove the ball bearing. AB" TAPER ROLLER BEARING REMOVAL <F5M42> MD998801 Use the special tool to remove the taper roller bearing.
  • Page 90 MD998812 <F5M42> Use the special tools to install the taper roller bearing. MD998819 Taper roller bearing "DA BALL BEARING INSTALLATION <F5M41> Use the special tools to install the ball bearing. MD998812 MD998819 Ball bearing "EA DIFFERENTIAL DRIVE GEAR INSTALLATION (1) Apply a sealant to the entire threaded portion of the bolt.
  • Page 91 Differential <F5M41, F5M42>, 22B-15-4 MANUAL TRANSMISSION (E - W) - Front Differential <W5M42> (2) Tighten to the specified torque in the illustrated sequence. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised...

  • Page 92: Center Differential

    "CA 7. Side gear 17. Differential case "CA 8. Lock pin "CA 9. Pinion shaft DISASSEMBLY SERVICE POINTS MD998917 AA" TAPER ROLLER BEARING REMOVAL Use the special tool to remove the taper roller bearing. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...
  • Page 93 4 pinions simultaneously in the side gear. Rotate the gears to place them in position, then install Lock pin the pinion shaft holder. Pinion shaft (3) Insert the pinion shafts. (4) Install the lock pins in the illustrated direction. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...
  • Page 94 INSTALLATION (1) Apply sealant to the entire threaded portion of the bolt. Specified sealant: 3M STUD Locking No. 4170 or equivalent (2) Tighten the bolts to the specified torque in the illustrated sequence. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...

  • Page 95: Transfer

    2. Dust seal guard "EA 3. Oil seal "DA 4. Oil seal "AA 5. O-ring "AA 6. O-ring "CA 7. Oil seal "BA 8. Oil seal "AA 9. O-ring 10. Transfer cover 11. Transfer Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...
  • Page 96 Use the special tools to install the oil seal. MB990933 "DA OIL SEAL INSTALLATION MB990891 Use the special tools to install the oil seal. MB990887 "EA OIL SEAL INSTALLATION Use the special tool to install the oil seal. MD998304 Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...
  • Page 97 22B-17-3 MANUAL TRANSMISSION (E - W) - Transfer <W5M42> "FA AIR BREATHER INSTALLATION Apply sealant to the air breather. Specified sealant: SUPER WEATHERSTRIP 8001 equivalent. Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added...
  • Page 98 NOTES...

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