Disassembly
Mitsubishi 5-Speed Manual Transmission:
Transmission Case
Transfer Case Adapter 4X4 Model
Transfer Case Adapter 4X2 Model
Disassembly
1. Remove the transmission as described in the Removal and Installation portion of this Section. Service and Repair Make sure the transmission is in Neutral.
2. Remove the nuts retaining the clutch housing to the transmission and remove the housing. If not removed, remove the clutch slave cylinder from the input shaft.
3. Remove the backup lamp switch and neutral sensing switch from the transmission.
4. If required, drain the fluid from the transmission by removing the drain plug from the pan.
5. Remove the bolts retaining the pan to the case and remove the pan. Remove and discard the gasket. Remove all traces of the gasket from the mating surfaces of the pan and case.
6. Remove the bolts retaining the control housing to the transfer case adapter arid remow. the control housing (with reverse lockout assembly attached). Remove and discard the rubber seal. Clean the mating surfaces of the adapter and control housing.
7. Remove the detent spring and ball from the adapter.
8. Remove the two shift gate roll pin access plugs (one on the side, one on the bottom) with a 6mm allen-head wrench.
9. Using a punch, drive the roll pins from the shift gates through the access holes.
10. From the right side of the adapter, remove the bolt, spring and neutral return plunger. Note that the plunger has a slot in the center for the detent ball.
11. From the left side of the adapter, remove the bolt, spring and neutral return plunger.
12. Lift the gate selector lever out of the shift gales. Move the lever to the rear of the adapter as far as it will go. This will allow clearance to remove the adapter from case.
13. Remove the bolts retaining the transfer case adapter to the transmission case. Note that three different bolt lengths (35mm, 55mm and 11Omm) are used to retain the case to the adapter. Mark the bolt holes accordingly. Note the location of this wire harness clip for reassembly.
14. Remove the adapter from the case. Make sure the shift gates do not bind in the adapter during removal. Rotate the gates on the rails as required. Remove and discard the gasket. Clean all traces of gasket material from the mating surfaces of the transmission case and adapter (4X4 models) or extension housing (4X2 models).
NOTE: On 4x2 models, if it is necessary to remove rear seal from extension housing, extension housing must be installed to transmission case. Remove extension housing rear seal Remover T74P-77248-A or equivalent.
15. Identify each shift rail and gate. Remove the gates from the rails.
16. From inside the case, drive out the roll pins retaining the 1-2 and 3-4 shift forks to the rails. Remove the 1-2 shift fork.
17. Drive out the overdrive-reverse shift fork roll pin.
NOTE: The roll pin in the switch actuator does not need to be removed for transmission disassembly.
18. Remove the set screw on the top of the case and remove the poppet spring and steel ball. Remove the two bolts on the side of the case. Remove the two poppet springs and two steel balls.
19. Remove the overdrive-reverse shift rail and the 3-4 shift rail from the case. Remove the overdrive-reverse shift fork. When the two shift rails are removed, the interlock pins can be removed from the case.
NOTE: The 1-2 shift rail can not be removed at this time.
20. Remove the oil seal sleeve from the output shaft using a puller such as T77J-7025-H.
NOTE Do not reuse oil seal sleeve. Once removed, replace only with a new sleeve.
21. Remove the snap ring, speedometer drive gear and steel ball (on 4x2 models).
22. Unstake the locknuts on the mainshaft and counter shaft using Mainshaft Locknut Staking Tool, T77J-7025-F or equivalent.
23. Double engage the transmission in two gears to lock up the transmission. This is done by engaging two of the synchronizers. This is necessary to remove the locknuts.
24. Remove the countershaft locknut with a 3Omm socket. Discard the locknut.
25. Remove the mainshaft locknut with Mainshaft Locknut Wrench, T77J-7025-C or equivalent. Discard the locknut.
26. Pull the rear bearing off the mainshaft using Tube, T77J-7025-B, Forcing Screw, T84T-7025-B, Puller, T77J-7025-H and Puller Ring, T77J-7025-J (or their equivalents). Remove and discard the bearing.
27. Remove the spacer and lock ball from the mainshaft.
NOTE: 4x4 model shown, 4x2 model similar.
28. Remove the counter-overdrive gear and ball bearing from the countershaft by installing the jaws of Puller, T77F-4220-B1 (or equivalent) behind the gear. While removing the gear, remove the 1-2 shift rail from the case.
29. Remove the 1-2 and 3-4 shift forks from the case.
30. Remove the overdrive gear, needle bearing, spacer and synchronizer ring from the mainshaft.
31. Remove the overdrive-reverse synchronizer sleeve from the synchronizer hub on the mainshaft.
NOTE: Do not lose the three keys and two springs in the hub. A spring is located on each side of the hub.
32. Pull the overdrive-reverse synchronizer hub and overdrive gear bearing sleeve from the mainshaft using Bearing Puller, T77J-7025-H, Puller Ring, T77J-7025-J, Tube, T75L-7025-B and Forcing Screw, T84T-7025-B or their equivalents.
33. Slide the reverse gear, synchronizer ring and needle bearing assembly off the mainshaft.
34. Slide the counter-reverse gear and distance spacer off the countershaft.
35. Remove the cotter pin and nut from the reverse idler shaft. Remove the thrust washer, reverse idler gear and two sets of needle bearings from the shaft.
36. Remove the 6mm allen-head bolts that attach the mainshaft rear bearing retainer to the case and remove the retainer. Remove and discard the gasket. Clean any traces of gasket material from the mating surfaces of the case and retainer.
37. Remove the 6mm allen-head bolts that retain the reverse idler gearshaft assembly to the case.
38. Pull the reverse-idler gearshaft assembly out of the case using Slide Hammer, T5OT-100-A and Reverse Idler Gearshaft Remover, T85T-7140-A or equivalent.
39. Use a "double nut" procedure to remove the four studs that retain the input shaft front bearing retainer to the case. Remove the bolts that attach the retainer to the case.
40. Remove the input shaft front bearing retainer from the case. Remove and discard the gasket. Clean all traces of gasket material from the mating surfaces of the case and retainer.
41. Remove the selective shim from inside the input shaft front bearing retainer.
DO NOT DISCARD THE SELECTIVE SHIM.
42. Remove the small selective snap ring that retains the input shaft to the bearing.
DO NOT DISCARD THE SELECTIVE SNAP RING.
43. Remove the large snap ring that retains the input shaft bearing to the case.
44. Remove the bearing from the input shaft and case using Tube, T75L-7025-B, Bearing Collets, T75L-7025-D, Bearing Collet Sleeve, T75L-7025-G and Forcing Screw, T84T-7025-B. Remove and discard the bearing.
45. Rotate the input shaft so the flats on the shaft face the countershaft, providing clearance to remove the input shaft. Remove the input shaft. The output shaft (mainshaft) may have to be pulled to the rear of the case. Remove the small caged needle bearing from the inside of the input gear.
46. Remove the snap ring from the mainshaft (output shaft) outer bearing race.
47. Remove the outer mainshaft bearing race, ball bearing and bearing sleeve from the case using Tube, T75L-7025-B, Mainshaft Bearing Collet Remover TB5T-7065-A, Bearing Collet Sleeve, T77F-7025-C and Forcing Screw, T84T-7025-B. Discard the outer bearing race and ball bearing.
NOTE: The inner race of the front bearing will remain on the mainshaft.
48. Remove the countershaft front spacer and bearing race.
49. Remove the countershaft from the case. The mainshaft assembly may have to be moved slightly to the side to allow clearance for countershaft removal. If the countershaft bearings require servicing, refer to Countershaft-Disassembly and Assembly in this section.
50. Remove the mainshaft assembly from the case. if the mainshaft assembly requires servicing, refer to Mainshaft-Disassembly and Assembly in this Section.