Disassembly

Mitsubishi 5-Speed Manual Transmission:

1. Remove nuts attaching clutch housing to transmission, then the housing, Fig. 1.
2. Remove clutch slave cylinder from input shaft.
3. Remove back-up lamp switch and shift indicator switch from transmission.
4. Drain fluid from transmission, if necessary.
5. Remove pan attaching bolts from transmission. Remove gasket from transmission to pan gasket surface.
6. Remove bolts attaching cover to transfer case adapter.
7. Remove detent spring and ball from adapter.
8. Remove three shift gate roll pin access plugs.
9. Using a suitable punch and hammer, drive roll pins from the shift gates.
10. Working from the right side of the adapter, remove bolt spring and neutral return plunger. Note that the plunger has a slot in the center for the detent ball.
11. Working from the left side of the adapter, remove bolt, spring and neutral return plunger.
12. Remove gate selector from shift gates. Move the lever to the rear as far as it will go. This will allow clearance to remove the adapter from case.
13. Remove bolts retaining transfer case adapter to the transmission case assembly. Bolt sizes (35mm, 55mm and 110mm) used to retain the case to the adapter assembly. Mark bolt holes accordingly for installation.
14. Remove adapter from case assembly. Ensure shift gates do not bind in the adapter during removal. Rotate gates on the rails as required. Remove and discard gasket.
15. Identify each shift rail and gate, then remove gates from the rails.
16. Working from inside the case, drive out the roll pins retaining the 1-2 and 3-4 shift forks to the rails. Drive out the overdrive-reverse shift fork roll pin.
17. Remove set screw from top of the case, then the poppet spring and steel ball. Remove two bolts on the side of the case. Remove two poppet springs and two steel balls.
18. Remove overdrive-reverse shift rail and the 3-4 shift rail from case. Remove the overdrive-reverse shift fork. When the two shift rails are removed, the interlock pins can be driven from case assembly.
19. Unstake locknuts on the mainshaft.
20. Double engage the transmission in two gears to lock the transmission.
21. Remove and discard countershaft locknut.
22. Remove mainshaft locknut.
23. Pull rear bearing from mainshaft using these following tools, remover/replacer tube tool No. T77J-7025-B, TOD forcing screw tool No. T84T-7025-B, bearing puller tool No. T77J-7025-H, puller ring tool No. T77J-7025-J or equivalent. Remove and discard bearing.
24. Remove spacer and lock ball from mainshaft.
25. Remove counter-overdrive gear and ball bearing from countershaft. While removing the gear, remove 1-2 shift rail from the case.
26. Remove 1-2 and 3-4 shift forks from the case.
27. Remove overdrive gear, needle bearing, spacer and synchronizer ring from the mainshaft.
28. Remove overdrive synchronizer sleeve from synchronizer hub on the mainshaft.
29. Pull overdrive synchronizer hub and overdrive gear bearing sleeve from mainshaft.
30. Slide reverse gear and needle bearing assembly from mainshaft.
31. Slide counter-reverse gear and spacer from the countershaft.
32. Remove cotter pin and nut from reverse idler gear shaft. Remove thrust washer, reverse idler gear and two sets of needle bearings from the shaft.
33. Remove allen head bolts attaching mainshaft rear bearing retainer to the case assembly. Remove retainer.
34. Remove allen head bolts attaching reverse idler gear shaft assembly to the case assembly.
35. Pull reverse idler gear shaft assembly from case.
36. Remove four studs attaching input shaft front bearing retainer to the case assembly. Remove bolts attaching retainer to case.
37. Remove input shaft front bearing retainer front case. Remove selective shim from inside input shaft from bearing retainer.
38. Remove small selective snap ring retaining input shaft to the bearing.
39. Remove large snap ring retaining input shaft bearing to the case.
40. Remove bearing from input shaft. Remove and discard bearing.
41. Rotate input shaft so flats on shaft face the countershaft, then remove input shaft. The 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.
42. Remove snap ring from mainshaft outer bearing race.
43. Remove outer mainshaft bearing race, ball bearing and bearing sleeve from case. Front bearing will remain on the mainshaft.
44. Remove countershaft front spacer and bearing race.
45. Remove countershaft from case. The mainshaft assembly may have to be moved slightly to the side to allow clearance for countershaft removal.
46. Remove mainshaft assembly from case assembly.