Assembly

Assembly in reverse order as Disassembly.

NOTE: Assembly service points as follows:





A. Maindrive gear bearing installation. (72)
Required Special Tools or equivalents:
MD998812: Installer Cap
MD998813: Installer - 100
MD998819: Installer Adapter (40).





B. Snap ring installation. (70)
Select and install the snap ring so that main drive gear bearing end play is within standard value.

Standard value: 0 - 0.06 mm (0 - 0.002 inch)

C. Spacer installation. (69)





1. Place two pieces of solder measuring about 10 mm (0.4 inch) in length and 1.6 mm (0.06 inch) in diameter on the bearing outer race as shown in the illustration.
2. Install the front retainer and tighten the nuts the specified torque.
3. Remove the front bearing retainer and remove the solder.
4. If the solders are not compressed, use larger-diameter solder to perform step 1 to 3.





5. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of appropriate thickness to bring it to the standard value.

Standard value: 0 - 0.1 mm (0 - 0.003 inch)

D. Oil seal installation. (67)
Required Special Tool:
MD998200: Oil Seal Installer or equivalent.





1. Using special tool MD998200, install the oil seal.





2. Apply Mitsubishi genuine grease Part number 0101011 or equivalent to the lip of the front bearing retainer oil seal.





E. Front bearing retainer gasket installation. (66)
Apply sealant 3M ATD Part number 8660 or equivalent to the both sides of the front bearing retainer gasket.





F. Mainshaft center bearing installation. (64)
Required Special Tools or equivalents:
MD998812: Installer Cap
MD998814: Installer - 100
MD998814: Installer - 200
MD998819: Installer Adapter (40).

G. Spacer installation. (62)





1. Press-fit the outer race and countershaft securely.





2. Assemble the select spacers and align them with a Straight edge.
3. Select a spacer which will achieve the standard value.

Standard value: 0 - 0.05 mm (0 - 0.001 inch)




H. Bolt installation. (60 & 58)
Apply sealant 3M STUD Locking Number 4170 or equivalent to the mounting bolts (countersunk bolts only).





I. Synchronizer key/synchronizer spring installation. (47 & 49)
Install two synchronizer springs. When installing the springs, check that steps of front and rear springs are positioned on the synchronizer key, but not on the same key.





J. OD-R synchronizer hub/OD-R synchronizer sleeve installation. (46 & 48)





K. Bearing sleeve installation. (44)
Required Special Tools or equivalents:
MD998812: Installer Cap
MD998814: Installer - 100
MD998814: Installer - 200
MD998818: Installer Adapter (38) or equivalents.
L. Mainshaft jam nut installation. (36)
Required Special Tool:
MD998809: Lock Nut Wrench (41) or equivalent.





1. Using special tool MD998809, tighten the mainshaft jam nut.





2. Stake the illustrated area of the jam nut.
3. Ensure that the OD gear rotates smoothly.





M. 1st-2nd speed shift rail/counter overdrive gear installation. (34 & 35)
Install the 1st-2nd speed shift rail and counter overdrive gear simulation.





N. Countershaft rear bearing installation. (33)
Required Special Tools or equivalents:
MD998812: Installer Cap
MD998816: Installer Adapter (30)
MD998809: Lock Nut Wrench (41).

O. Countershaft jam nut installation. (32)





1. Tighten the countershaft jam nut to the specified torque.





2. Stake the area as shown in illustration to prevent jam nut from loosening.
3. Ensure that the OD gear rotates smoothly.





P. Spring pin installation. (26)





Q. Spring pin installation. (25)





R. Spring installation. (23)
Insert the spring with small end on the steel ball side. Three springs are identical to each other.





S. Plug installation. (22)
Apply sealant 3M ATD Part number 8660 or equivalent to the plug.





T. Snap ring installation. (20)
Select the proper snap ring and install so that the end play between the main shaft rear bearing and snap ring meet the standard value.

Standard value: 0 - 0.13 mm (0 - 0.005 inch)





U. Extension housing gasket installation. (17)
Apply sealant 3M ATD Part number 8660 or equivalent to both sides of the extension housing gasket.





V. Extension housing installation. (16)
Install the extension housing while pushing the change shifter in the direction of the arrow and fit the control finger into the groove in the selector.





W. Neutral return plunger seal plug installation. (12)
Apply sealant 3M ATD Part number 8660 or equivalent to the seal plugs.

X. Stopper bracket installation. (8)





1. Apply sealant 3M ATD Part number 8660 or equivalent to the extension housing cover mounting surface of the bolt.





2. Apply sealant 3M ATD Part number 2353 or equivalent to the bolt threads.





Y. Speedometer gear installation. (2)
1. Apply Mitsubishi genuine grease Part number 0101011 or equivalent to the O-ring of the speedometer.
2. Match the mating marks to the number to teeth on the speedometer driven gear. Install the speedometer gear.