With 2WD
DISASSEMBLY AND REASSEMBLY
Part 1:
Part 2:
Part 3:
SEALING AND ADHESION POINTS
SERVICE POINTS OF DISASSEMBLY
14. REMOVAL OF SPRING PIN
Remove the spring pin using the special tool or a pin punch.
15./16. REMOVAL OF LOCK NUTS
1. Unstake lock nuts of the input shaft and intermediate gear.
2. Shift the transmission in reverse using the control lever and select lever.
3. Install the special tool onto the input shaft.
4. Screw a bolt [10 mm (0.40 in.)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
5. Remove the lock nut, while using the bolt as a spinner handle stopper.
45./46. REMOVAL OF SPRING PINS
Remove the spring pins for 1st-2nd and 3rd-4th speed shift forks using the pin punch.
47./48. REMOVAL OF SHIFT RAILS AND FORKS
1. Shift the 1st-2nd speed shift fork to the 2nd speed.
2. Shift the 3rd-4th speed shift fork to the 4th speed.
3. Rotate the the shift controls in the direction of the arrow in numerical order. Remove the shift lugs from the control finger and interlock plate
4. Raise each of the shift rails upward and remove them from the clutch housing.
5. Remove the all shift rails and forks.
52. REMOVAL OF INTERMEDIATE GEAR ASSEMBLY
Lift up the input shaft assembly and remove the intermediate gear assembly.
INSPECTION
BACKUP LIGHT SWITCH
Operate the backup light switch to check continuity with a circuit tester. If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLY
61. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.
60. INSTALLATION OF OIL SEAL
Install the input shaft front oil seal using the special tool.
52. INSTALLATION OF INTERMEDIATE GEAR ASSEMBLY/53.INPUT SHAFT ASSEMBLY
Lifting up the input shaft assembly, install it simultaneously with the intermediate gear assembly.
47./48. INSTALLATION OF SHIFT RAILS AND FORKS
1. Set the 1st-2nd speed shift sleeve at 2nd speed.
2. Set the 3rd-4th speed shift sleeve at 4th speed.
3. Fit the shift forks of shift rail assembly to groove of sleeves.
4. Insert the shift rails into the shift rail holes of clutch housing.
5. Turn the shift rails in the directions indicated by the arrows in the order shown in the illustration and engage the shift lugs to control finger and inter lock plate.
45./46. INSTALLATION OF SPRING PINS
1. Install the spring pins using the special tool or a pin punch. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.
CAUTION: Do not reuse the spring pins.
35./37./39. SELECTION OF SPACERS
1. Place two pieces of solder measuring about 10 mm (0.4 in.) in length and 3 mm (0.12 in.) in diameter as illustrated and install the outer races of intermediate gear, output shaft and differential.
2. Install the transaxle case and tighten the bolts to specified torque.
3. Remove the transaxle case.
4. Remove the outer races and take out the crushed solder.
5. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard preload.
Standard value:
Intermediate shaft: 0.05 - 0.10 mm (0.002 - 0.004 in.)
Output shaft: 0.05 - 0.10 mm (0.002 - 0.004 in.)
Differential case: 0.05 - 0.10 mm (0.002 - 0.004 in.)
33. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.
27. INSTALLATION OF OIL GUIDE
Install the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF SEALANT TO TRANSAXLE CASE
1. Place the selected spacers on the intermediate gear and the bearing outer race of the differential. Also insert the selected spacers between the output shaft bearing outer race and the transaxle case.
2. Set so that the threaded hole in the head of the reverse idler gear shaft is in the direction shown in the illustration.
NOTE: If there is a significant deviation of the direction of the threaded hole, it will become impossible to align the threaded hole and the hole in the case after the transaxle case is installed.
3. Apply specified sealant to the clutch housing side of the transaxle case.
Specified sealant: MITSUBISHI Genuine Sealant Part No.MD997740 or equivalent
CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuity.
4. Install the transaxle case onto the clutch housing.
5. As shown in the illustration, insert a Phillips-head screwdriver [with an 8 mm (0.32 in.) shaft diameter] from the bolt hole in the case, and use it to align the threaded hole in the reverse idler gear shaft and the bolt hole in the case.
6. Install the reverse idler gear shaft bolt and tighten the bolt by fingers.
7. Tighten the all transaxle tightening bolts to specified torque.
8. Tighten the reverse idler gear shaft bolt to specified torque.
18. INSTALLATION OF 5TH SPEED SHIFT FORK/17. 5TH SPEED SYNCHRONIZER ASSEMBLY
Install the 5th speed shift fork and the 5th speed synchronizer assembly at the same time.
15./16. INSTALLATION OF LOCK NUTS
1. Install the special tool to the splined end of input shaft.
2. Screw a bolt [10 mm (0.40 in.)] in to the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
3. Shift the transmission in reverse using control lever and select lever.
4. Tighten the lock nut to specified torque, while using the bolt attached in the above step as a spinner handle stopper.
5. Loosen the lock nuts.
6. Retighten the lock nuts to the specified torque.
7. Stake the lock nut.
14. INSTALLATION OF SPRING PIN
1. Install the spring pin using the special tool or a pin punch
CAUTION: Do not reuse the spring pins.
2. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.