Transmission
DISASSEMBLY SERVICE POINTS
LOCKING NUT REMOVAL
REVERSE SHAFT REMOVAL
COUNTERSHAFT BALL BEARINGS REMOVAL
MAINSHAFT BALL BEARING / DRIVE PINION BALL BEARING REMOVAL
MAINSHAFT ASSEMBLY / DRIVE PINION REMOVAL
1. Pull out the drive pinion to the front of the case. The gear diameter is larger than the case hole diameter so that the drive pinion cannot be removed at this point.
2. Remove the mainshaft assembly from the case.
3. Remove the drive pinion.
COUNTERSHAFT REMOVAL
1. Move the snap ring from its groove toward the countershaft reverse gear.
2. Move the overdrive gear as well toward the countershaft reverse gear.
3. Raise the countershaft a little and then lift it further up at its front end to remove from the transmission case.
REASSEMBLY SERVICE POINTS
COUNTERSHAFT INSTALLATION
1. Move the snap ring and overdrive gear toward the counter- shaft reverse gear.
2. Install the countershaft in the transmission case.
3. Move the overdrive gear rearward.
4. Put the snap ring in its groove.
BALL BEARING INSTALLATION
DRIVE PINION / PILOT BEARING / MAINSHAFT ASSEMBLY INSTALLATION
1. Install the drive pinion to the transmission case, working from case inside and let it protrude from the case.
2. Fit the snap ring in the ball bearing outer race groove.
3. Insert the pilot bearing into the drive pinion rear hole.
4. Install the mainshaft assembly to the case, working from case inside and insert its front end into the pilot bearing.
5. Push in the drive pinion until the snap ring over the bearing comes into contact with the case front. When doing so, hold the mainshaft. If the front end of the mainshaft is disengaged from the pilot bearing, it can cause damage to the bearing.
BALL BEARING INSTALLATION
BALL BEARING INSTALLATION
1. Fit the snap ring to the ball bearing outer race groove.
2. Using the special tool, support the countershaft at the rear end.
3. Using the special tool, install the ball bearing.
4. Fit the snap ring to the countershaft front end groove.
5. Remove the special tool.
BALL BEARING INSTALLATION
SUB GEAR INSTALLATION
1. Install the spring so that the long end is directed toward the gear, and combine the sub gear and spacer into an assembly using the snap rings.
2. Turn the sub gear to align all of the through holes.
3. Secure the through holes with a screwdriver, etc., and install the sub gear to the transmission case.
SIDE WASHERS INSTALLATION
LOCKING NUT INSTALLATION
1. Side the 1st-2nd gear synchronizer sleeve to the first speed side and the OD-R gear synchronizer sleeve to the reverse side for double meshing. This prevents the mainshaft from turning.
2. Using the special tool, tighten the lock nut to specified torque.
3. Punch the lock nut into two grooves on the mainshaft.
OIL SEAL INSTALLATION
1. Using the special tool, drive the oil seal into the clutch housing.
2. Apply specified grease to the oil seal lip. Specified grease: Multipurpose grease SAE J310, NLGI No.2
CLUTCH HOUSING INSTALLATION
1. Apply specified sealant to the clutch housing on its surface that contacts the transmission case. Specified sealant: Mitsubishi genuine sealant Part No.MD997740 or equivalent.
2. Wind vinyl tape around the splined portion of the drive pinion to protect the oil seal against damage.
3. Install the clutch housing to the transmission case and tighten bolts to specified torque.
4. Remove the vinyl tape.
NEUTRAL RETURN PLUNGER (A) / NEUTRAL RETURN PLUNGER (B) INSTALLATION
Apply grease to the neutral return plungers (A) and (B) in the places shown in the illustration. Specified grease: Multipurpose grease SAE J310, NLGI No.2
TRANSFER CASE ADAPTER / SHIFT JAWS INSTALLATION
1. Apply specified sealant to the adapter on its surface that contacts the transmission case. Specified sealant: Mitsubishi genuine sealant Part No.MD997740 or equivalent.
2. Insert the shift rails into the shift rail holes of the transfer case adapter and install the adapter part way. If it is installed to the case completely, the shift jaws cannot be installed.
NOTE: When replacing the shift rails or the shift jaws, replace the shift rails and the shift jaws as a unit.
3. Precoated bolts are used for the attaching bolts, so when reusing the bolts, apply sealant on the threads. Specified sealant: 3M STUD Locking No.4170 or equivalent
4. Screw in adapter attaching bolts two pitches each.
5. Install the three shift jaws to respective shift rails.
6. Push the adapter into close contact with the case and tighten the six bolts to specified torque.
AIR BREATHER INSTALLATION
1. Apply specified sealant to the press-fit portion of the air breather. Specified sealant: Mitsubishi genuine sealant Part No.MD997740 or equivalent.
2. Install the air breather with a mark toward rear.
SPRING PIN INSTALLATION
1. Drive the spring pin in using the pin punch.
Caution: Do not reuse spring pin.
2. Drive the spring pin in with the slit in the spring pin parallel to the shaft center of the shift rail, so that the dimensions are as shown in the illustration.
REVERSE GEAR INSTALLATION
Confirm the direction of reverse gear installation by observing the shape of portion (A) in the illustration.
SPRING PIN INSTALLATION