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1.Remove the back-up lamp switch assembly.
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2.Remove the lock ball assembly.
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3.Remove the control cable bracket and whirring harness clamp bracket.
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4.Remove the wiring harness clamp bracket
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5.Remove the control shift lever
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6.Remove the straight screw plug with head.
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7.Remove the straight screw plug with head.
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8.Remove the lock ball assembly.
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9.Remove the straight pin.
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10.Remove the shift and select lever shaft assembly.
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11.Remove the reverse idler shaft mounting bolt and gasket.
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12.Use snap ring pliers to expand the indicated hole snap rings. The hole snap rings will
release the radial ball bearings, and the input shaft and output shaft #1 will fall under
its own weight.
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13.Remove the transmission case sub-assembly.
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14.Remove the transmission oil separator.
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15.Remove the straight screw plug with head, the shift detente ball spring seat #1,
the compression spring and ball (four places).
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16.Remove the washer based hexagon bolt.
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17.Remove the slotted spring pin (three places).
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18.Remove the gear shift fork shaft #4 and the gear shift fork shaft #3.
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19.Remove the gear shift fork assembly #3 and the reverse shift fork.
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20.After removing the gear shift fork shaft #1, remove the slotted spring pin of
the gear shift fork shaft #2 and gear shift head #2.
21.Remove the gear shift fork shaft # 2.
22.Remove the gear shift head # 2.
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23.Remove the gear shift fork assembly # 2.
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24.Remove the reverse idler gear shaft, reverse idler thrust washer, needle roller bearing
and reverse idler gear.
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25.Remove the output shaft # 2 sub-assembly.
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26.Remove the input shaft sub-assembly, output shaft # 1 sub-assembly and gear shift
fork assembly # 1.
27.Remove the differential sub-assembly.
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28.Remove the E-ring.
29.Remove the shift arm pivot.
30.Remove the gear shift head # 3 and gear shift fork shaft # 5 and
shift arm simultaneously.
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1.Set the differential assembly to the transmission case.
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2.Push and fit the tapered roller bearing outer race by hand.
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3.To fit the tapered roller bearing outer race, rotate the differential assembly by hand
about 10 times with the special tool Preload socket (MB992038).
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4.Put the transmission case on the surface table and use a height gauge to measure the dimension
"a1," which is from the mating surface of the transmission case to the end surface of the tapered
roller bearing outer race.
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5.Put the straight edge on the mating surface of the transmission case and measure the dimension
"b1" with a vernier caliper.
6.Select the shim whose dimension is the difference between "b1" and "a1."
7.Install the differential assembly to the transmission case. Tighten the transmission
case bolts to the specified torque of 29 ± 5 N·m.
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8.Using special tool Preload socket (MB992038), measure the rotational starting torque of
differential case. When it is not within the standard range, reselect the shim.
Standard value: 1.00 - 2.49 N·m
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1.Set the output shaft # 2 assembly and differential assembly to the transmission
case.
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2.Push and fit the tapered roller bearing outer race by hand.
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3.To fit the tapered roller bearing outer race, rotate the output shaft # 2 assembly
by hand about 10 times with the special tool Preload socket (MB992038).
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4.Put the transmission case on the surface table and measure the dimension "a2," which is
from the mating surface of the transmission case to the end surface of the bearing outer race,
with a height gauge.
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5.Put the straight edge on the mating surface of the transmission case and measure the dimension
"b2" with a vernier caliper.
6.Select the shim whose dimension is the difference between "b2" and "a2."
7.Install the output shaft # 2 assembly and differential assembly to the transmission
case. Tighten the transmission case bolts to the specified torque of 29 ± 5 N·m.
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8.Using special tool Preload socket (MB992038), measure the rotational starting torque on
the differential shaft. From this rotational starting torque, subtract the value measured in
the adjustment of the bearing preload on the differential side. When this is not within the
standard range, reselect the shim.
Standard value: 4.14 - 5.87 N·m
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1.Install the differential sub-assembly in the transmission case.
2.Install the input shaft sub-assembly and output shaft # 1 sub-assembly in
the transmission case simultaneously.
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3.Install the output shaft # 2 sub-assembly in the transmission case as shown in
the illustration.
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4.Set the reverse idler gear, the needle roller bearing, the reverse idler thrust washer
and the reverse idle gear shaft.
| note |
Fit the projection of the anti-rotation for the reverse idler thrust washer into the reverse
idle gear shaft as shown.
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5.Install them to the transmission case.
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6.Install the gear shift fork assembly #1.
7.Install the gear shift fork shaft #5 in the transmission case and then install
the gear shift head #3 on the gear shift fork shaft #5 by hammering in the
slotted spring pin.
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8.Insert the shift arm into the transmission case, fitting it in the groove of the gear
shift fork shaft #5.
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9.After insert the arm pivot into the transmission case and the shift arm, install the E-ring
into the arm pivot.
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10.Install the gear shift fork assembly # 2.
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11.Insert the shaft #1 in the order of fork #2, #1 and the transmission
case.
12.Insert the shaft # 2 in the order of gear shift fork assembly # 2,
gear shift head # 3, gear shift head # 2 with the shift arm and transmission
case.
13.Stick the slotted spring pin in the gear shift head #2.
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14.Install the reverse shift fork and the gear shift fork assembly #3.
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15.Insert the gear shift fork shaft #3 in the order of gear shift fork assembly #3,
reverse shift fork, and transmission case.
16.Insert the gear shift fork shaft #4 in the order of reverse shift fork and
transmission case.
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17.Tighten the washer based hexagon bolts to the specified torque of 20 ± 3 N·m.
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18.Stick the pins in the gear shift fork assembly #1, #2 and #3.
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19.
| caution |
As shown in the illustration, install the white painted spring only for the
reverse fork.
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Install the ball, the compression spring, the shift detente ball seat spring #1
and tighten the straight screw plug with head (four places) to the specified torque of 22 ± 6 N·m.
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20.Install the transmission oil separator to the transmission case and tighten the bolts
to the specified torque of 8.5 ± 2.5 N·m.
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21.Apply a 1.2 mm diameter bead of form-in-place gasket (FIPG) to the transmission case along
its circumference as shown in the drawing.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740 or equivalent
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22.Install the transmission case sub-assembly and tighten the bolts to the specified torque
of 29 ± 5 N·m.
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23.Extend the hole snap ring and install it on the radial ball bearing.
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24.Install stud bolt to the output shaft #2 sub-assembly.
25.Pull the output shaft #2 sub-assembly in the direction as shown in the illustration
and fit the hole snap ring into the bearing groove.
| note |
After installation, keep the sealed area away from oil for approximately one hour.
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26.Push the input shaft sub-assembly in the direction as shown in the illustration and fit
the hole snap ring into the bearing groove.
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27.Lift the output #1 sub-assembly.
28.Confirm that the dimension between the centers of Φ 2.5 mm holes on the hole
snap ring is in accordance with the illustration.
29.Check the hole snap ring fits securely into the bearing groove.
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30.Install the reverse idler shaft and new gasket. and then tighten the bolt to the specified
torque of 80 ± 10 N·m.
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31.Apply a 1.2 mm diameter bead of form-in-place gasket (FIPG) to the control shaft cover
along its circumference as shown in the drawing.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740 or equivalent
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32.Install the shift and select lever shaft assembly to the transmission case and tighten
the bolts to the specified torque of 19 ± 3 N·m.
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33.Install the straight pin to the specified torque of 30 ± 9 N·m.
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34.Install the lock ball assembly and tighten to the specified torque of 29 ± 8
N·m.
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35.Apply a 1.2 mm diameter bead of form-in-place gasket (FIPG) to the straight screw plug
along its circumference as shown in the drawing.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740 or equivalent
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36.Install the straight screw plug with head and tighten to the specified torque of 55 ± 16.5
N·m.
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37.Install the straight screw plug with head and tighten to the specified torque of 22 ± 6
N·m.
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38.Install the control shift lever to shift and select lever shaft assembly specified toque
of 12 ± 3 N·m
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39.Install the wiring harness clamp bracket to control shift lever specified toque of 19 ± 3
N·m
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40.Install the control cable bracket and whirring harness clamp bracket to the transmission
case and tighten the bolts to the specified torque of 19 ± 3 N·m.
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41.Install the lock ball assembly and tighten to the specified torque of 39 ± 11
N·m.
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42.Install the back-up lamp switch assembly and tighten to the specified torque of 40 ± 12
N·m.
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