22B-1

GROUP 22B

MANUAL
TRANSMISSION
OVERHAUL
CONTENTS

GENERAL INFORMATION . . . . . . . . 22B-2 REVERSE IDLER GEAR . . . . . . . . . . 22B-40

DISASSEMBLY AND REASSEMBLY . . . . . 22B-40
GENERAL SPECIFICATIONS . . . . . . 22B-5
SPEEDOMETER GEAR . . . . . . . . . . . 22B-41
SERVICE SPECIFICATIONS. . . . . . . 22B-5 DISASSEMBLY AND REASSEMBLY . . . . . 22B-41

SNAP RING, SPACER AND THRUST SELECT LEVER . . . . . . . . . . . . . . . . . 22B-42

PLATE FOR ADJUSTMENT . . . . . . . 22B-6 DISASSEMBLY AND REASSEMBLY . . . . . 22B-42

TORQUE SPECIFICATIONS . . . . . . . 22B-8 CONTROL HOUSING . . . . . . . . . . . . . 22B-43

DISASSEMBLY AND REASSEMBLY . . . . . 22B-43
SEALANTS AND ADHESIVES . . . . . 22B-9
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-45
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-10 DISASSEMBLY AND REASSEMBLY . . . . . 22B-45

SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-10 TRANSMISSION CASE . . . . . . . . . . . 22B-48

DISASSEMBLY AND REASSEMBLY . . . . . 22B-48
TRANSMISSION . . . . . . . . . . . . . . . . 22B-14
DISASSEMBLY AND REASSEMBLY. . . . . 22B-14 DIFFERENTIAL. . . . . . . . . . . . . . . . . . 22B-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-24 DISASSEMBLY AND REASSEMBLY . . . . . 22B-50

INPUT SHAFT . . . . . . . . . . . . . . . . . . 22B-25 CENTER DIFFERENTIAL. . . . . . . . . . 22B-53

DISASSEMBLY AND REASSEMBLY. . . . . 22B-25 DISASSEMBLY AND REASSEMBLY . . . . . 22B-53
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-30
TRANSFER . . . . . . . . . . . . . . . . . . . . . 22B-56
OUTPUT SHAFT . . . . . . . . . . . . . . . . 22B-32 DISASSEMBLY AND REASSEMBLY . . . . . 22B-56
DISASSEMBLY AND REASSEMBLY. . . . . 22B-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-38
22B-2 MANUAL TRANSMISSION OVERHAUL
GENERAL INFORMATION

GENERAL INFORMATION
M1222000100153
MANUAL TRANSMISSION MODELS
Transmission model Combined engine Vehicle model
F5M42-2-Y4B1 4G63-D4-MPI CU2W
W5M42-1-Z4B1 4G63-D4-MPI CU2W
W5M42-1-V4B1 4G93-S4-MIVEC CU5W
 MANUAL TRANSMISSION OVERHAUL
GENERAL INFORMATION
22B-3
SECTIONAL VIEW
<F5M42>

AK302709
22B-4 MANUAL TRANSMISSION OVERHAUL
GENERAL INFORMATION

<W5M42>

AK302711
 MANUAL TRANSMISSION OVERHAUL
GENERAL SPECIFICATIONS
22B-5
GENERAL SPECIFICATIONS
M1222000200202

TRANSMISSION MODEL TABLE

Transmission Speedomerter Final gear Vehicle model Engine model Transfer
model gear ratio ratio gear ratio
F5M42-2-Y4B1 27/36 4.625 CU2W 4G63-D4-MPI −
W5M42-1-Z4B1 27/36 4.687 CU2W 4G63-D4-MPI 0.3018
W5M42-1-V4B1 27/36 4.352 CU5W 4G93-S4-MIVEC 0.3018
GEAR RATIO TABLE
F5M42-2-Y4B1 W5M42-1-Z4B1 W5M42-1-V4B1
1st 3.583
2nd 1.947
3rd 1.379
4th 1.030
5th 0.820
Reverse 3.363

SERVICE SPECIFICATIONS
M1222000300179

Item Standard value Minimum limit

Differential case preload 0.05 − 0.11 mm −
Input shaft front bearing end play 0 − 0.12 mm −
Input shaft 5th speed gear end play 0 − 0.09 mm −
Input shaft rear bearing end play 0 − 0.12 mm −
Synchronizer ring back surface to gear clearance − 0.5 mm
Output shaft front bearing end play 0 − 0.12 mm −
Output shaft 3rd speed gear end play 0 − 0.09 mm −
Output shaft rear bearing end play 0 − 0.09 mm −
Backlash between differential gear and pinion <F5M42> 0 − 0.15 mm −
Backlash between center differential gear and pinion 0.025 − 0.150 mm −
<W5M42>
22B-6 MANUAL TRANSMISSION OVERHAUL
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT

SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000186

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>

Thickness mm Identification symbol Thickness mm Identification symbol
0.71 71 1.01 01
0.74 74 1.04 04
0.77 77 1.07 07
0.80 80 1.10 J
0.83 83 1.13 D
0.86 86 1.16 K
0.89 89 1.19 L
0.92 92 1.22 G
0.95 95 1.25 M
0.98 98
SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD) <W5M42>
Thickness mm Identification symbol Thickness mm Identification symbol
0.74 74 1.04 04
0.77 77 1.07 07
0.80 80 1.10 J
0.83 83 1.13 D
0.86 86 1.16 K
0.89 89 1.19 L
0.92 92 1.22 G
0.95 95 1.25 M
0.98 98 1.28 N
1.01 01 1.31 E
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY)
Thickness mm Identification symbol Thickness mm Identification symbol
2.24 None 2.38 Brown
2.31 Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
Thickness mm Identification symbol Thickness mm Identification symbol
2.82 0 2.98 6
2.86 2 3.02 7
2.90 3 3.06 8
2.94 5 3.10 9
 MANUAL TRANSMISSION OVERHAUL
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22B-7
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY AND OUTPUT SHAFT
FRONT BEARING END PLAY)
Thickness mm Identification symbol Thickness mm Identification symbol
1.43 Green (2) 1.59 Yellow (2)
1.51 White (2)
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
Thickness mm Identification symbol Thickness mm Identification symbol
2.81 Green 2.97 Orange
2.85 White 3.01 Red
2.89 Yellow 3.05 Pink
2.93 Black 3.09 Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)
Thickness mm Identification symbol Thickness mm Identification symbol
2.31 Black (2) 2.55 Yellow
2.35 None 2.59 Black
2.39 Blue 2.63 Orange
2.43 Brown 2.67 Blue
2.47 Green 2.71 Brown
2.51 White
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION)
<F5M42>
Thickness mm Identification symbol Thickness mm Identification symbol
0.75 − 0.82 − 1.05 − 1.12 −
0.83 − 0.92 − 1.09 − 1.16 −
0.93 − 1.00 − 1.15 − 1.22 −
1.01 − 1.08 −
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN CENTER DIFFERENTIAL SIDE GEAR AND
PINION) <W5M42>
Thickness mm Identification symbol Thickness mm Identification symbol
0.48 − 0.55 − 0.74 − 0.81 −
0.56 − 0.65 − 0.82 − 0.89 −
0.66 − 0.73 −
22B-8 MANUAL TRANSMISSION OVERHAUL
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
M1222012100138

Part N⋅m
Transfer - clutch housing mounting bolt <W5M42> 69 ± 10
Roll stopper bracket mounting bolt 70 ± 10
Shift cable bracket mounting bolt 18 ± 3
Select lever mounting bolt 18 ± 3
Speedometer gear mounting bolt 3.9 ± 1.0
Backup light switch 32 ± 2
Poppet spring 32 ± 2
Harness bracket bolt 18 ± 3
Harness bracket bolt <Except 2.4L model> 3.9 ± 1.0
Interlock plate bolt 30 ± 3
Control housing mounting bolt 18 ± 3
Under cover mounting bolt 6.9 ± 0.9
Reverse idler gear shaft mounting bolt 48 ± 6
Clutch housing-transaxle case mounting bolt 44 ± 5
Front bearing retainer mounting bolt 18 ± 3
Select lever mounting nut 11 ± 1
Stopper bracket mounting bolt 21.7 ± 0.3
Clutch release bearing retainer mounting bolt 9.8 ± 0.2
Differential drive gear mounting bolt 132 ± 5
Transfer cover mounting bolt <W5M42> 23 ± 3
 MANUAL TRANSMISSION OVERHAUL
SEALANTS AND ADHESIVES
22B-9
SEALANTS AND ADHESIVES
M1222000500106

Item Specified sealant

Clutch housing-transaxle case mating surface MITSUBISHI Genuine sealant part No. MD997740 or
Under cover-transaxle case mating surface equivalent
Control housing-transaxle case mating surface
Air breather 3M SUPER WEATHERSTRIP No.8001 or equivalent
Differential drive gear bolt 3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG) Surface Preparation
This transmission has several areas where the Thoroughly remove all substances deposited on the
form-in-place gasket (FIPG) is used for sealing. To FIPG application surface, using a gasket scraper.
ensure that the FIPG fully serves its purpose, it is Make sure that the FIPG application surface is flat
necessary to observe some precautions when and smooth. Also make sure that the surface is free
applying it. Bead size, continuity and location are of from oils, greases and foreign substances. Do not fail
paramount importance. to remove old FIPG that may remain in the fastener
Too thin a bead could cause leaks. Too thick a bead, fitting holes.
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To FIPG Application
prevent leaks or blocking of passages, therefore, it is Applied FIPG bead should be of the specified size
absolutely necessary to apply the FIPG evenly and free of any break. FIPG can be wiped away
without a break, while observing the correct bead unless it has completely hardened. Install the mating
size. parts in position while the FIPG is still wet (in less
FIPG hardens as it reacts with the moisture in the than 10 minutes after application). Do not allow FIPG
atmospheric air, and it is usually used for sealing to spread beyond the sealing areas during
metallic flange areas. installation. Avoid operating the transmission or
letting oils or water come in contact with the sealed
Disassembly area before a time sufficient for FIPG to harden
Parts sealed with a FIPG can be easily removed (approximately one hour) has passed.
without need for the use of a special method. In FIPG application method may vary from location to
some cases, however, the FIPG in joints may have to location. Follow the instruction for each particular
be broken by tapping parts with a mallet or similar case described later in this manual.
tool.
22B-10 MANUAL TRANSMISSION OVERHAUL
LUBRICANTS

LUBRICANTS
M1222000400132

TRANSMISSION
Item Specified lubricant
Each O-ring Hypoid gear oil SAE 75W-90 or 75W-85W conforming to
Each oil seal API classification GL-4
Select lever shoe MITSUBISHI genuine grease part No.0101011 or
Input shaft front oil seal equivalent

TRANSFER
Item Specified lubricant
Each O-ring Hypoid gear oil API classification GL-5 SAE 90
Each oil seal

SPECIAL TOOLS
M1222000600181

Tool Number Name Application

MB990935 Installer adapter Installation of differential case
taper roller bearing outer race
<F5M42> and center differential
case rear taper roller bearing
outer race <W5M42>

MB990938 Handle Use with Installer adapter

B990938

MB990927 Installer adapter Installation of sealing cap

MD998801 Bearing remover Installation and removal of

gears, bearings and sleeves

MD998812 Installer cap Use with Installer and Installer

adapter
 MANUAL TRANSMISSION OVERHAUL
SPECIAL TOOLS
22B-11
Tool Number Name Application
MD998813 Installer-100 Use with Installer cap and
Installer adapter

MD998816 Installer adapter (30) Installation of input shaft front

bearing

MD998825 Installer adapter (52) Installation of 1st-2nd speed

synchronizer hub, 3rd-4th
speed synchronizer hub and 1st
speed gear sleeve

MD998824 Installer adapter (50) Installation of 4th speed gear

sleeve, 5th speed gear and
thrust plate stopper

MD998818 Installer adapter (38) Installation of input shaft rear

bearing, roller bearing inner
race, reverse gear sleeve and
output shaft rear ball bearing

MD998917 Bearing remover Installation and removal of

gears, bearing and sleeves

MD998814 Installer-200 Use with Installer cap and

Installer adapter

MD998822 Installer adapter (46) Installation of 2nd speed gear

sleeve and 3rd speed gear
22B-12 MANUAL TRANSMISSION OVERHAUL
SPECIAL TOOLS

Tool Number Name Application

MD998819 Installer adapter (40) Installation of 5th-reverse
speed synchronizer hub, 4th
speed gear and 5th speed gear
sleeve

MD999566 Claw Removal of taper roller bearing

outer race

MD998772 Valve spring Removal of output shaft front

compressor roller bearing outer race

MD998346 Bearing outer race Removal of output shaft front

remover roller bearing outer race

MB990934 Installer adapter Installation of output shaft front

roller bearing outer race

MB991550 Bearing outer race Installation of center differential

installer case front taper roller bearing
outer race <W5M42>

MD998325 Differential oil seal Installation of differential oil seal

installer

MB990926 Installer adapter Installation of clutch housing

input shaft oil seal
 MANUAL TRANSMISSION OVERHAUL
SPECIAL TOOLS
22B-13
Tool Number Name Application
MD998823 Installer adapter (48) Installation of differential case
taper roller bearing <F5M42>
and center differential case rear
taper roller bearing <W5M42>

MB990930 Installer adapter Removal of center differential

case front taper roller bearing
bearing <W5M42>

MD998830 Installer adapter (66) Installation of center differential

case front taper roller bearing
<W5M42>

MB990937 Installer adapter Installation of transfer oil seal

<W5M42>

MD998800 Oil seal adapter Installation of transfer oil seal

<W5M42>

MB990887 Ring Installation of transfer oil seal

<W5M42>

MB990891 Bushing remover Using with ring

installer base

MB990936 Installer adapter Installation of transfer oil seal

<W5M42>
22B-14 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION

TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001000193

<F5M42>

4
18 ± 3 N·m 32 ± 2 N·m
3
3.9 ± 1.0 N·m 6
8
3.9 ± 1.0 N·m
7
11
18 ± 3 N·m
9
70 ± 10 N·m 5 10

1
70 ± 10 N·m

AK203151AC

Disassembly steps Disassembly steps (Continued)

1. Roll stopper bracket, front 8. Poppet spring
2. Roll stopper bracket, rear 9. Gasket
3. Shift cable bracket 10. Harness bracket
>>J<< 4. Select lever 11. Harness bracket
>>I<< 5. Speedometer gear
6. Backup light switch
7. Gasket
 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION
22B-15

14
Apply gear oil to all 18 ± 3 N·m
moving parts before
installation.
30 ± 3 N·m

15 12
20
13
44 ± 5 N·m

21
23
22

18
17
24 19

25 48 ± 6 N·m

16
6.9 ± 0.9 N·m

AK204218AC

Disassembly steps Disassembly steps (Continued)

12. Interlock plate bolt <<A>> >>F<< 20. Sealing cap
13. Gasket <<B>> >>E<< 21. Transaxle case
>>H<< 14. Control housing >>D<< 22. Outer race
15. Neutral return spring >>D<< 23. Spacer
>>G<< 16. Under cover 24. Magnet holder
17. Reverse idler gear shaft bolt 25. Magnet
18. Gasket
19. Reverse idler gear assembly
22B-16 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION

Apply gear oil to all 30

moving parts before
installation. 27 29
26
28
38 32
34

31 33

39
36

37

18 ± 3 N·m

35

AK204219AB

Disassembly steps Disassembly steps (Continued)

>>C<< 26. Spring pin <<C>> >>B<< 34. 5th speed-reverse shift fork
27. 1st-2nd speed shift rail 35. Front bearing retainer
28. 1st-2nd speed shift fork <<D>> >>A<< 36. Input shaft
>>C<< 29. Spring pin <<D>> >>A<< 37. Output shaft
>>C<< 30. Spring pin 38. Differential
<<C>> >>B<< 31. 3rd-4th speed shift rail 39. Clutch housing
<<C>> >>B<< 32. 3rd-4th speed shift fork
<<C>> >>B<< 33. 5th speed-reverse shift rail
 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION
22B-17
<W5M42>

18 ± 3 N·m

7 32 ± 2 N·m
6
3.9 ± 1.0 N·m 9
11
3.9 ± 1.0 N·m
4 14
10
18 ± 3 N·m
5
8 13 12
70 ± 10 N·m

70 ± 10 N·m

3
69 ± 10 N·m

AK204184AB

Disassembly steps Disassembly steps (Continued)

1. Transfer 10. Gasket
2. O-ring 11. Poppet spring
3. Roll stopper bracket, front 12. Gasket
4. Roll stopper bracket, rear 13. Harness bracket
5. Roll stopper bracket, adaptor 14. Harness bracket <Except 2.4L
6. Shift cable bracket model>
>>J<< 7. Select lever
>>I<< 8. Speedometer gear
9. Backup light switch
22B-18 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION

14
Apply gear oil to all 18 ± 3 N·m
moving parts before
installation.
30 ± 3 N·m

15 12
20
13
44 ± 5 N·m

21
23
22

18
17
24 19

25 48 ± 6 N·m

16
6.9 ± 0.9 N·m

AK204218AC

Disassembly steps Disassembly steps (Continued)

15. Interlock plate bolt <<A>> >>F<< 23. Sealing cap
16. Gasket <<B>> >>E<< 24. Transaxle case
>>H<< 17. Control housing >>D<< 25. Outer race
18. Neutral return spring >>D<< 26. Spacer
>>G<< 19. Under cover 27. Magnet holder
20. Reverse idler gear shaft bolt 28. Magnet
21. Gasket
22. Reverse idler gear assembly
 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION
22B-19

33
Apply gear oil to all
moving parts before 30 32
installation.
29
31
41 35
37

34 36

42
39

40

18 ± 3 N·m

38

AK204189AB

Disassembly steps Disassembly steps (Continued)

>>C<< 29. Spring pin <<C>> >>B<< 36. 5th speed-reverse shift rail
30. 1st-2nd speed shift rail <<C>> >>B<< 37. 5th speed-reverse shift fork
31. 1st-2nd speed shift fork 38. Front bearing retainer
>>C<< 32. Spring pin <<D>> >>A<< 39. Input shaft
>>C<< 33. Spring pin <<D>> >>A<< 40. Output shaft
<<C>> >>B<< 34. 3rd-4th speed shift rail 41. Differential
<<C>> >>B<< 35. 3rd-4th speed shift fork 42. Clutch housing
22B-20 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION

DISASSEMBLY SERVICE POINTS <<C>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH

<<A>> SEALING CAP REMOVAL SPEED SHIFT FORK/5TH SPEED-REVERSE
SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK
REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th
Sealing cap speed-reverse shift fork in the direction shown.

3rd-4th
speed
shift fork

5th speed
AK204301 AB reverse
shift fork
1. Drive a screwdriver into the center of the sealing
cap.
2. Bend the screwdriver back to remove the sealing AK204222 AB

cap.
2. Pull up on the 3rd-4th speed shift rail and 5th
speed-reverse shift rail and take them out of the
<<B>> TRANSAXLE CASE REMOVAL
hole in the clutch housing.
1. Remove all sixteen bolts securing the transaxle
case to the clutch housing.
5th speed-
reverse
3rd-4th speed shift rail
shift rail

Snap ring AK204223 AB

AK204226 AB 3. Slide the 3rd-4th speed shift rail and 5th

speed-reverse shift rail in the direction shown and
2. Use snap ring pliers to expand the indicated snap remove them together with the shift forks.
ring. The snap ring will release the grooved ball
bearing, and the output shaft assembly will fall
<<D>> INPUT SHAFT AND OUTPUT SHAFT
under its own weight.
REMOVAL
CAUTION
Do not use a scraper or chisel to remove the Input shaft
transaxle case.
3. Remove the transaxle case from the clutch
housing by gently prying on opposite sides at the Output shaft
same time.

AK204224 AB

Remove the input and output shafts together.

 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION
22B-21
ADJUSTMENT BEFORE REASSEMBLY REASSEMBLY SERVICE POINTS
SPACER SELECTION FOR DIFFERENTIAL CASE >>A<< OUTPUT SHAFT/INPUT SHAFT
PRELOAD ADJUSTMENT INSTALLATION

Solders Input shaft

Output shaft

AK204227 AB AK204224 AB

1. Put solders (1.6 mm diameter, about 10 mm long) Install the input and output shafts together.
in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential >>B<< 5TH SPEED-REVERSE SHIFT FORK/5TH
assembly into the transaxle case. SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/3RD-4TH SPEED SHIFT RAIL
NOTE: If necessary, replace the differential case INSTALLATION
and taper bearing before carrying out these
adjustments.
3rd-4th speed
3. Install the clutch housing and tighten the bolts to synchronizer
the specified torque. sleeve

Tightening torque: 44 ± 5 N⋅m

5th speed-
4. Remove the clutch housing, and then remove the reverse
differential assembly. synchronizer
sleeve
5. Remove the outer race and take out crushed
solders.
AK204229AB

1. Shift the 3rd-4th speed synchronizer sleeve and

5th speed-reverse synchronizer sleeve in the
direction shown.

3rd-4th speed shift rail

3rd-4th speed
5th speed- shift fork
AKX00953 reverse
shift fork 5th speed-
6. Measure the thickness of the crushed solder with reverse
shift rail
a micrometer and select a spacer that will provide
the standard preload value.
Standard value: 0.05 − 0.11 mm preload AK204230 AB

2. Assemble the 3rd-4th speed shift rail and fork,

and the 5th speed-reverse shift rail and fork.
22B-22 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION

• Installer adapter (MB990935)

• Handle (MB990938)
5th speed-
reverse
shift rail >>E<< TRANSAXLE CASE INSTALLATION
3rd-4th speed
shift rail CAUTION
Squeeze sealant evenly onto the transaxle
housing. Do not leave gaps or excess amounts,
otherwise oil leaks are likely.

AK204223 AC

3. While fitting each shift fork in the groove of

synchronizer sleeve, slide the shift rails in the
direction shown and install.
4. Insert the 3rd-4th speed shift rail and 5th
speed-reverse shift rail into the rail hole in the
clutch housing.
AK204232AB
>>C<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork. 1. Apply a 2 mm diameter bead of sealant
(Mitsubishi Genuine Part number MD997740 or
Shift fork
Shift rail 2.5 mm equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto
the transaxle housing while the sealant is still wet
(within 15 minutes).

Spring pin

AK204302 AC

2. Insert the new spring pin. Push it in as shown so

that the slit and center axis of the rail are aligned.
Snap ring

>>D<< SPACER AND OUTER RACE

AK204226 AB
INSTALLATION
1. Install the spacer selected in the section 2. Align the transaxle case and expand the snap
"ADJUSTMENT BEFORE REASSEMBLY." ring. After the case is on far enough for the snap
ring to ride on the bearing, release the snap ring.
Push down on the transaxle case, twisting it from
side to side until the case contacts the housing.
MB990938
3. Tighten the transaxle case mounting bolts to the
specified torque.
Tightening torque: 44 ± 5 N⋅m
4. Place the transaxle upside down and let the snap
MB990935 ring fit in the groove by the output shaft's own
weight.
AK204231 AB
NOTE: After installation, keep the sealed area
2. Using special tools, press the outer race into the away from oil for approximately one hour.
transaxle case.
 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION
22B-23
>>F<< SEALING CAP INSTALLATION 1. Apply a 2 mm diameter bead of sealant
(Mitsubishi Genuine Part number MD997740 or
MB990938 equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the
case quickly while the sealant is still wet (within 15
MB990927 minutes).
2. Install the under cover to the transaxle case and
tighten the bolts to specified torque.
Tightening torque: 6.9 ± 0.9 N⋅m
AK204234 AB
NOTE: After installation, keep the sealed area
away from oil for approximately one hour.
1. Using special tools, press install the sealing cap
onto the case. >>H<< CONTROL HOUSING INSTALLATION
• Installer adapter (MB990927) CAUTION
• Handle (MB990938) Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
Sealing cap likely.

AK204233 AB

2. Evenly press the sealing cap so it is fully seated

AK204236AB
and not at an angle.
1. Apply a 0.2 mm diameter bead of sealant
>>G<< UNDER COVER INSTALLATION (Mitsubishi Genuine Part number MD997740 or
CAUTION equivalent) as llustrated onto the control housing.
Squeeze sealant onto the case. Do not leave NOTE: Be sure to install the housig to the case
gaps or excess amounts, otherwise oil leaks are quickly while the sealant is still wet (within 15
likely. minutes).
2. Install the control housing to the transaxle case
and tighten the bolts to specified torque.
Tightening torque: 18 ± 3 N⋅m
NOTE: After installation, keep the sealed area
away from the oil for approximately one hour.

AK204235AB
22B-24 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION

>>I<< SPEEDOMETER GEAR INSTALLATION 1. Apply grease (Mitsubishi Genuine Part number
0101011 or equivalent) to the control shaft sliding
O-ring
portion of the select lever shoe.
2. Install the select lever and tighten the bolts to
specified torque.
Tightening torque: 18 ± 3 N⋅m

INSPECTION
M1222001100101
BACKUP LIGHT SWITCH
AK204237 AB

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or

75W-85W conforming to API classification GL-4)
to the O-ring of the speedometer gear. Install into
the transaxle housing.
2. Tighten the bolt to specified torque.
Tightening torque: 3.9 ± 1.0 N⋅m

>>J<< SELECT LEVER INSTALLATION AKX00952

Check for continuity between terminals.

Control shaft
SWITCH CONDITION CONTINUITY
Select lever Pressed Open
shoe
Released Conductive

AK204238 AB
 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
22B-25
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222001600173

9
Apply gear oil to all 10
moving parts before 11
installation.
12
14
13
15
16

18 19 2
20 4

6
7
1
8
16 3
17

AK204391AB

Disassembly steps Disassembly steps (Continued)

>>M<< 1. Snap ring >>G<< 11. Synchronizer sleeve
<<A>> >>L<< 2. Ball bearing >>F<< 12. 3rd-4th speed synchronizer hub
<<B>> >>K<< 3. Thrust plate stopper >>E<< 13. Synchronizer ring
>>J<< 4. Thrust plate >>D<< 14. Synchronizer spring
<<C>> >>I<< 5. 5th speed gear 15. 3rd speed gear
6. 4th speed gear 16. Needle roller bearing
7. Needle roller bearing >>C<< 17. Snap ring
<<D>> >>H<< 8. 4th speed gear sleeve <<E>> >>B<< 18. Ball bearing
>>E<< 9. Synchronizer ring >>A<< 19. Oil seal
>>D<< 10. Synchronizer spring 20. Input shaft
22B-26 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT

DISASSEMBLY SERVICE POINTS 1. Using special tool Bearing remover (MD998801),

<<A>> BALL BEARING REMOVAL support the 5th speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 5th speed gear.
MD998801

<<D>> 4TH SPEED GEAR SLEEVE REMOVAL

MD998801
AK204239 AB

1. Using special tool Bearing remover (MD998801),

support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and AK204241 AB
remove the ball bearing.
1. Using special tool Bearing remover (MD998801),
<<B>> THRUST PLATE STOPPER REMOVAL support the 3rd speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 4th speed gear sleeve.

<<E>> BALL BEARING REMOVAL

MD998801

AK204293AB

Using a screwdriver, pry up at the position shown in

the illustration and remove the thrust plate stopper.

<<C>> 5TH SPEED GEAR REMOVAL

AK204242 AB

1. Using special tool Bearing remover (MD998801),

MD998801 support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.

AK204240 AB
 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
22B-27
REASSEMBLY SERVICE POINTS 1. Install the thickest snap ring that can be fitted in
>>A<< OIL SEAL INSTALLATION the snap ring groove of input shaft.
2. Make sure that the front bearing end play meets
the standard value.
Oil seal 3.5 mm Standard value: 0 − 0.12 mm

>>D<< SYNCHRONIZER SPRING INSTALLATION

AK204243 AC

Install the oil seal into the end of the input shaft as
shown.

>>B<< BALL BEARING INSTALLATION SYNCHRONIZER

Synchrnizer
SPRING
spring AK204263AB

MD998812 Install the synchronizer spring onto the synchronizer

ring as shown.
MD998813

MD998801 MD998816 >>E<< SYNCHRONIZER RING INSTALLATION

CAUTION
There are 3rd speed and 4th speed synchronizer
rings, if the wrong one is installed it will effect
the shift feeling.
AK204244AC

1. Using special tool Bearing remover (MD998801), Notch

support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, press install the ball bearing
with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998816)
AK204312 AB

>>C<< SNAP RING INSTALLATION

1. Ascertain whether or not there are identification
notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it completely
fits over the machined cone of the gear.

Snap ring

AK204245 AB
22B-28 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT

>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB 1. Check the installation direction of the
INSTALLATION synchronizer sleeve, and install it onto the 3rd-4th
Installation speed synchronizer hub.
direction
Projecting portion

Groove AK204295 AB

Deep grooves AK204199AB

1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input 2. Install the synchronizer sleeve so that the areas
shaft, and then set them on the press. with teeth that have raised tips (three areas total)
2. Make sure that the synchronizer ring has been are aligned with the areas on the synchronizer
perfectly matched to the 3rd speed gear cone. hub that have deep grooves between the teeth
3. Check the installation direction of the 3rd-4th (three areas total).
speed synchronizer hub, and put it on the input
shaft. >>H<< 4TH SPEED GEAR SLEEVE
INSTALLATION
MD998812
MD998812
MD998813
MD998813
MD998801 MD998825
MD998824
MD998801

AK204246 AC
AK204247 AC
4. Using special tools, press install the 3rd-4th
speed synchronizer hub with the press. 1. Using special tool Bearing remover (MD998801),
• Installer cap (MD998812) support the 2nd speed gear portion of the input
• Installer-100 (MD998813) shaft, and then set them on the press.
• Installer adapter (MD998825) 2. Using special tools, install the 4th speed gear
5. Make sure that the synchronizer ring can rotate sleeve with the press.
freely. • Installer cap (MD998812)
• Installer-100 (MD998813)
>>G<< SYNCHRONIZER SLEEVE INSTALLATION • Installer adapter (MD998824)

Identification
groove

Installation
direction

AK204296AC
 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
22B-29
>>I<< 5TH SPEED GEAR INSTALLATION Install the thrust plate stopper by pressing special
tools, by hand. Make sure that it is not tilted.
• Installer cap (MD998812)
MD998812 • Installer-100 (MD998813)
MD998813 • Installer adapter (MD998824)
MD998801 MD998824
>>L<< BALL BEARING INSTALLATION

MD998812
MD998818
AK204248 AB
MD998801
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, install the 5th speed gear onto
the input shaft with the press. AK204250 AC
• Installer cap (MD998812)
• Installer-100 (MD998813) 1. Using special tool Bearing remover (MD998801),
• Installer adapter (MD998824) support the 2nd speed gear portion of the input
shaft, and then set them on the press.
>>J<< THRUST PLATE INSTALLATION 2. Using special tools, install the ball bearing onto
the input shaft with the press.
Surface stamped
with identification • Installer cap (MD998812)
mark • Installer adapter (MD998818)

>>M<< SNAP RING INSTALLATION

Thrust plate
AK204249AB

1. Install the thickest thrust plates that can be fitted

Snap ring
in the groove of the input shaft. Install the thrust
plate so the surface stamped with the
identification mark is facing up.
AK204251 AB
2. Make sure that the 5th speed gear end play meets
the standard value. 1. Install the thickest snap ring that can be fitted in
Standard value: 0 − 0.09 mm the groove of the input shaft.
2. Make sure that the rear bearing end play meets
the standard value.
>>K<< THRUST PLATE STOPPER INSTALLATION
Standard value: 0 − 0.12 mm

MD998812

MD998813

MD998824

AK204294 AB
22B-30 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT

INSPECTION 1. Check the clutch gear teeth for damage and

M1222001700095 broken.
INPUT SHAFT
2. Check internal surface for damage, wear and
broken threads.

A
Gear Synchronizer
ring

AK204201AB

1. Check the outside diameter of the needle bearing AK204307 AB

mounting portion for damage, abnormal wear and

3. Force the synchronizer ring toward the clutch gear
seizure.
and check clearance "A". If "A" is less than the
2. Check the splines for damage and wear. limit, replace the synchronizer ring.
3. Check that the helical gear teeth surfaces are not Minimum limit: 0.5 mm
damaged or worn.

NEEDLE ROLLER BEARING SYNCHRONIZER SLEEVE AND HUB

1. Combine the needle roller bearing with the input Sleeve
shaft or bearing sleeve and gear, and check that it
rotates smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.

SYNCHRONIZER RING
Hub

AK204217 AB

1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.

SYNCHRONIZER SPRING
AK204298AB
Check that the spring is not sagging, deformed or
broken.
 MANUAL TRANSMISSION OVERHAUL
INPUT SHAFT
22B-31
1. Check that the helical and clutch gear tooth
SPEED GEARS surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.

AK204299AB
22B-32 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT

OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002200156

20
22
Apply gear oil to all
24
moving parts before
installation. 26
19 18
27
29 21

23 4
25
1
28
30 5

32 31
33 13
36 3 2

12
6
35 15 7
34 17 4
8
9
14 10 11

16 13
AK204392AB

Disassembly steps Disassembly steps (Continued)

>>Q<< 1. Snap ring 18. 2nd speed gear
<<A>> >>P<< 2. Ball bearing 19. Needle roller bearing
<<B>> >>O<< 3. Reverse gear sleeve <<E>> >>G<< 20. 2nd speed gear sleeve
4. Needle roller bearing 21. Inner synchronizer ring
5. Reverse gear 22. Synchronizer cone
>>M<< 6. Synchronizer ring 23. Outer synchronizer ring
>>L<< 7. Synchronizer spring >>D<< 24. Synchronizer spring
>>F<< 8. Synchronizer sleeve >>F<< 25. Synchronizer sleeve
<<C>> >>N<< 9. 5th speed-reverse synchronizer >>E<< 26. 1st-2nd speed synchronizer hub
hub 27. Outer synchronizer ring
>>M<< 10. Synchronizer ring >>D<< 28. Synchronizer spring
>>L<< 11. Synchronizer spring 29. Inner synchronizer ring
12. 5th speed gear 30. Synchronizer cone
13. Needle roller bearing 31. 1st speed gear
>>K<< 14. 5th speed gear sleeve 32. Needle roller bearing
>>J<< 15. 4th speed gear <<F>> >>C<< 33. 1st speed gear sleeve
>>I<< 16. Snap ring >>B<< 34. Snap ring
<<D>> >>H<< 17. 3rd speed gear
 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
22B-33
Disassembly steps (Continued) <<C>> 5TH SPEED-REVERSE SYNCHRONIZER
<<G>> >>A<< 35. Roller bearing inner race HUB REMOVAL
36. Output shaft
Synchronizer hub
DISASSEMBLY SERVICE POINTS
MD998801
<<A>> BALL BEARING REMOVAL

Ball bearing
MD998917

AK204254 AB

1. Using special tool Bearing remover (MD998801),

support the 4th speed gear, and then set them on
AK204252 AC
the press.
2. Push down on the output shaft with the press and
1. Using special tool Bearing remover (MD998917), remove the 5th speed-reverse synchronizer hub.
support the ball bearing, and then set them on the
press. <<D>> 3RD SPEED GEAR REMOVAL
2. Push down on the output shaft with the press, and
remove the ball bearing.

<<B>> REVERSE GEAR BEARING SLEEVE MD998917

3rd speed gear
REMOVAL

Reverse gear
MD998801 bearing sleeve

AK204255 AB

1. Using special tool Bearing remover (MD998917),

support the 2nd speed gear, and then set them on
the press.
AK204253 AB 2. Push down on the output shaft with the press and
remove the 3rd speed gear.
1. Using special tool Bearing remover (MD998801),
support the reverse gear, and then set them on <<E>> 2ND SPEED GEAR SLEEVE REMOVAL
the press.
2. Push down on the output shaft with the press and
remove the reverse gear bearing sleeve.
2nd speed gear sleeve
MD998917

AK204256 AC

1. Using special tool Bearing remover (MD998917),

support the 1st speed gear, and then set them on
the press.
22B-34 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT

2. Push down on the output shaft with the press and REASSEMBLY SERVICE POINTS
remove the 2nd speed gear sleeve. >>A<< ROLLER BEARING INNER RACE
INSTALLATION
<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

MD998812
MD998801 MD998818

1st speed gear sleeve Roller bearing

inner race
MD998801

AK204260 AB
AK204257 AC
1. Using special tool Bearing remover (MD998801),
1. Using special tool Bearing remover (MD998801), support the output shaft gear, and then set them
support the 1st speed gear sleeve, and then set on the press.
them on the press. 2. Using special tools, install the roller bearing inner
2. Push down on the output shaft with the press and race with the press.
remove the 1st speed gear sleeve. • Installer cap (MD998812)
• Installer adapter (MD998818)
<<G>> ROLLER BEARING INNER RACE
REMOVAL >>B<< SNAP RING INSTALLATION

Roller bearing
inner race
MD998917

Snap ring

AK204258 AB AK204261 AB

1. Using special tool Bearing remover (MD998917), 1. Install the thickest snap ring that can be fitted in
support the roller bearing inner race, and then set the groove of output shaft.
them on the press. 2. Make sure that the front bearing inner race end
2. Push down on the output shaft with the press and play meets the standard value.
remove the roller bearing inner race. Standard value: 0 − 0.12 mm

>>C<<1ST SPEED GEAR SLEEVE INSTALLATION

1. Set the output shaft on the press support stand.
 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
22B-35

MD998812 MD998812

MD998814 MD998814
1st speed 1st-2nd speed
gear sleeve synchronizer
hub MD998825
MD998825

AK204262 AC AK204265 AC

2. Using special tools, install the 1st speed gear 3. Using special tools, install the 1st-2nd speed
sleeve with the press. synchronizer hub with the press.
• Installer cap (MD998812) • Installer cap (MD998812)
• Installer-200 (MD998814) • Installer-200 (MD998814)
• Installer adapter (MD998825) • Installer adapter (MD998825)
4. Make sure that the outer synchronizer ring on the
>>D<< SYNCHRONIZER SPRING INSTALLATION 1st speed gear side can rotate freely.

>>F<< SYNCHRONIZER SLEEVE INSTALLATION

Identification
groove

Synchronizer spring Installation

direction
AK204316AC

Install the synchronizer spring onto the outer

synchronizer ring AK204296AC

as shown.
1. Check that the synchronizer sleeve is in the
correct direction for installation, and install it on
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB the 1st-2nd speed synchronizer hub.
INSTALLATION
1. Set the output shaft on the press support stand. Projecting portion

Installation direction

Deep grooves AK204199AB

AK204305 AC 2. Install the synchronizer sleeve so that the areas

with teeth that have raised tips (three areas total)
2. Check that the 1st-2nd speed synchronizer hub is are aligned with the areas on the synchronizer
in the correct installation direction, and put it on hub that have deep grooves between the teeth
the output shaft. (three areas total).
22B-36 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT

>>G<< 2ND SPEED GEAR SLEEVE >>I<< SNAP RING INSTALLATION

INSTALLATION
1. Set the output shaft on the press support stand.

MD998812

MD998813

Snap ring
MD998822
AK204268AB

1. Install the thickest snap ring that can be fitted in

AK204266 AC
the groove of output shaft.
2. Using special tools, install the 2nd speed sleeve 2. Make sure that the 3rd speed gear end play
onto the output shaft with the press. meets the standard value.
• Installer cap (MD998812) Standard value: 0 − 0.09 mm
• Installer-100 (MD998813)
• Installer adapter (MD998822)
>>J<< 4TH SPEED GEAR INSTALLATION
1. Set the output shaft on the press support stand.
>>H<< 3RD SPEED GEAR INSTALLATION
1. Check that the 2nd speed gear and the outer
synchronizer ring have been properly installed. MD998812
Also, make sure the claws on the synchronizer MD998813
cone (four places) are correctly fitted into the
4th speed gear
holes in the 2nd speed gear (four places). MD998819

MD998812

MD998814 AK204269 AB

3rd speed gear 2. Using special tools, install the 4th speed gear onto
MD998822
the output shaft with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
AK204267 AB • Installer adapter (MD998819)
2. Using special tools, install the 3rd speed gear
onto the output shaft with the press. >>K<< 5TH SPEED GEAR SLEEVE
• Installer cap (MD998812) INSTALLATION
• Installer-200 (MD998814)
• Installer adapter (MD998822) MD998812
3. Make sure that the 2nd speed gear and the outer MD998813
synchronizer ring can rotate freely. 5th speed
gear sleeve MD998819

AK204300 AB

Using special tools, install the 5th speed gear sleeve

onto the output shaft with the press.
• Installer cap (MD998812)
 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
22B-37
• Installer-100 (MD998813)
• Installer adapter (MD998819)

>>L<< SYNCHRONIZER SPRING INSTALLATION

Installation direction

AK204306 AB

3. Check that the 5th speed-reverse synchronizer

hub is oriented correctly for installation, and fit it
SYNCHRONIZER
Synchrnizer
SPRING
spring on the output shaft.
AK204263AB

Install the synchronizer spring onto the synchronizer

ring as shown. MD998812
MD998813
MD998819
>>M<< SYNCHRONIZER RING INSTALLATION
CAUTION Synchronizer hub
There is a 5th speed synchronizer ring and a
reverse synchronizer ring. Be careful not to
confuse the two when installing, as a mistake can
effect the shift feeling. AK204228 AB

4. Using special tools, press install the 5th

speed-reverse synchronizer hub with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998819)
Notch
5. Make sure that the synchronizer ring on the 5th
speed gear side can rotate freely.

AK204393AB >>O<< REVERSE GEAR SLEEVE INSTALLATION

1. Make sure the synchronizer ring, reverse gear
1. Check for the presence of identification notches and needle roller bearing have been correctly
on the synchronizer ring. installed.
No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring MD998812
MD998818
2. Install the synchronizer ring so that it fits
Reverse
completely over the machined cone of the gear. gear Reverse gear
sleeve
>>N<< 5TH SPEED-REVERSE SYNCHRONIZER
HUB INSTALLATION
1. Set the output shaft on the press support stand.
2. Make sure that the synchronizer ring is fitted AK204270 AB
correctly on the cone of the 5th speed gear.
2. Using special tools, press fit the reverse gear
sleeve. Make sure that the reverse gear and the
synchronizer ring can rotate freely during the
pressing process.
• Installer cap (MD998812)
22B-38 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT

• Installer adapter (MD998818) 1. Check the splines for damage and wear.
2. Check that the helical gear teeth surfaces are not
>>P<< BALL BEARING INSTALLATION damaged or worn.
1. Check the installation direction of the ball bearing.
NEEDLE ROLLER BEARING
MD998812 1. Combine the needle roller bearing with the
MD998818 bearing sleeve and gear, and check that it rotates
smoothly without noise or play.
Ball bearing 2. Check the needle roller bearing cage for
deformation.

SYNCHRONIZER RING

AK204271 AC

2. Using special tools, install the ball bearing with the

press.
• Installer cap (MD998812)
• Installer adapter (MD998818)

>>Q<< SNAP RING INSTALLATION

AK204298AB

1. Check if the clutch gear teeth are damaged or

broken.
2. Check internal surface for damage, wear and
broken threads.
Snap ring
A
Gear Synchronizer
AK204272 AC
ring

1. Install the thickest snap ring that can be fitted in

the groove of output shaft.
2. Make sure that the rear bearing end play meets
the standard value.
Standard value: 0 − 0.09 mm
AK204307 AB

INSPECTION 3. Force the synchronizer ring toward the clutch gear

M1222002300131
OUTPUT SHAFT and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
Minimum limit: 0.5 mm

AK204310AB
 MANUAL TRANSMISSION OVERHAUL
OUTPUT SHAFT
22B-39
OUTER SYNCHRONIZER RING/INNER 1. Combine the synchronizer sleeve and hub, and
SYNCHRONIZER RING/SYNCHRONIZER CONE check that they slide smoothly.
<FOR 1ST, 2ND SPEED> 2. Check that the sleeve is free from damage at its
CAUTION inside splines ends.
When replacing, replace the outer ring, inner ring
and cone as a set. SYNCHRONIZER SPRING

AK204395AB AK204314AB

1. Check that the clutch gear tooth surfaces and Check that the spring is not sagging, deformed or
cone surfaces are not damaged or broken. broken.

Gear A SPEED GEARS

Outer ring

Cone

Inner ring
AK203130AD

2. Install the outer ring, inner ring and cone, force AK204299AB
them toward the gear, and check clearance "A". If
"A" is less than the limit, replace them as a set. 1. Check that the helical and clutch gear tooth
surfaces are not damaged or worn.
Minimum limit: 0.5 mm
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
SYNCHRONIZER SLEEVE AND HUB
3. Check that the gear inside diameter and front and
Sleeve rear surfaces are not damaged and worn.

Hub

AK204217 AB
22B-40 MANUAL TRANSMISSION OVERHAUL
REVERSE IDLER GEAR

REVERSE IDLER GEAR

DISASSEMBLY AND REASSEMBLY
M1222012500136

Apply gear oil to

all moving parts
before installation.

3
4

AK302745AC

Disassembly steps REASSEMBLY SERVICE POINT

1. Snap ring >>A<< FRICTION DAMPER INSTALLATION
2. Thrust washer
3. Reverse idler gear
21.5 ± 0.2 mm
4. Needle roller bearing
>>A<< 5. Friction damper
6. Reverse idler gear shaft

AK302712AB

After apply gear oil to the outside and inside

circumferences of the friction damper, install it using
the special tool in position as shown in Fig.
 MANUAL TRANSMISSION OVERHAUL
SPEEDOMETER GEAR
22B-41
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
M1222003400089

Apply gear oil to all

moving parts before
installation.

AK204397AB

Disassembly steps Disassembly steps (Continued)

1. E-clip 3. O-ring
2. Speedometer driven gear 4. Sleeve
22B-42 MANUAL TRANSMISSION OVERHAUL
SELECT LEVER

SELECT LEVER
DISASSEMBLY AND REASSEMBLY
M1222012800074

7 1

8
2 11 ± 1 N·m

9 3

10

AK204398AB

Disassembly steps REASSEMBLY SERVICE POINT

1. Dust cover >>A<< DUST COVER AND SELECT LEVER
2. Nut BUSHING INSTALLATION
3. Spring washer
4. Washer Select lever
>>A<< 5. Select lever bushing bushing
6. Select lever shoe
7. Select lever
>>A<< 8. Select lever bushing
>>A<< 9. Dust cover
10. Select lever shaft

Dust cover
AK204311 AB

Make sure the dust cover and select lever bushing

installation direction is correct, and the distinguished
parts are correctly assembled as shown.
 MANUAL TRANSMISSION OVERHAUL
CONTROL HOUSING
22B-43
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
M1222013100153

6
9

7 3

11
12
5
13
4

8
10
14

2
1

22.3 ± 0.3 N·m

AK302747 AC

Disassembly steps DISASSEMBLY SERVICE POINT

1. Spring washer <<A>> LOCK PIN REMOVAL
2. Stopper bracket
<<A>> >>E<< 3 Lock pin
4. Interlock plate
5. Control finger
Lock pin
>>D<< 6. Spring pin
7. Stopper body
8. Spring
9. Control shaft
>>C<< 10. Air breather Control finger
11. Control shaft boot
>>B<< 12. Oil seal
AK204273 AB
>>A<< 13. Needle bearing
14. Control housing Drive out the lock pin from the direction shown.
22B-44 MANUAL TRANSMISSION OVERHAUL
CONTROL HOUSING

REASSEMBLY SERVICE POINTS 1. Apply sealant (3M SUPER WEATHERSTRIP No.

>>A<< NEEDLE BEARING INSTALLATION 8001 or equivalent) to the inserting portion of air
breather.
Control housing
Needle bearing
Model number Emboss
stamped side mark

0 – 0.5 mm

AK204176AC
AK204220 AB
Press fit the needle bearing into the control housing
side as shown. 2. Install the air breather so that the embossed mark
Make sure that the side with the model number is in the direction shown in the figure.
stamped on it faces the end of the control housing as
shown. >>D<< SPRING PIN INSTALLATION

>>B<< OIL SEAL INSTALLATION Control shaft

Stopper body
Installation direction

Slit
Spring pin
AK204177AB

AK204303AB
Drive in the spring pin so that the slit is in the
direction shown in the figure.
Apply gear oil (Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4) to >>E<< LOCK PIN INSTALLATION
the oil seal lip area.

>>C<< AIR BREATHER INSTALLATION

AK204273 AC

Drive the lock pin in from the direction shown in the

figure.
AK204274AB
 MANUAL TRANSMISSION OVERHAUL
CLUTCH HOUSING
22B-45
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
M1222003700176

4
6
7

3 5

1
9.8 ± 2.0 N·m
AK204400AC

Disassembly steps DISASSEMBLY SERVICE POINTS

1. Clutch release bearing retainer <<A>> OUTER RACE REMOVAL
>>E<< 2. Oil seal
>>D<< 3 Oil seal <F5M42>
<<A>> >>C<< 4. Outer race
<<B>> >>B<< 5. Outer race
>>A<< 6. Bushing
7. Clutch housing

MD999566

AK204276 AB

Using special tool Claw (MD999566), remove the

outer race from the clutch housing.
22B-46 MANUAL TRANSMISSION OVERHAUL
CLUTCH HOUSING

<<B>> OUTER RACE REMOVAL >>B<< OUTER RACE INSTALLATION

MD998772 MD998346

Model number
stamped side

AK204277AB AK204279 AB

1. Set special tools as indicated in the figure. 1. Check the installation direction of the outer race.
• Valve spring compressor (MD998772) Install the outer race so the side with the model
• Bearing outer race remover (MD998346) number stamping can be seen.
2. Turn the nut on special tool Bearing outer race
remover (MD998346) to pull up on the tool and
take out the outer race. MB990938

MB990934

REASSEMBLY SERVICE POINTS

>>A<< BUSHING INSTALLATION

AK204280 AB

2. Using special tools, press fit the outer race into

Seam of bushing Air vent the clutch housing.
• Handle (MB990938)
• Installer adapter (MB990934)

>>C<< OUTER RACE INSTALLATION

1. Check the installation direction of the outer race.
AK204278 AB

1. Press fit the bushing so the seam is away from

the air vent. MB990938

1 mm
MB990935 <F5M42>
MB991550 <W5M42>
AK204281 AC

2. Using special tools, press fit the outer race into

the clutch housing.
AK204291 AC • Handle (MB990938)
• Installer adapter (MB990935)
2. Be sure the bushing is fully seated as shown. It • Bearing outer race installer (MB991550)
must be 1 mm below the housing surface.
 MANUAL TRANSMISSION OVERHAUL
CLUTCH HOUSING
22B-47
>>D<<OIL SEAL INSTALLATION >>E<< OIL SEAL INSTALLATION

AK204282AB AK204284AC

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 1. Pack grease (MITSUBISHI genuine grease part
75W-85W conforming to API classification GL-4) No.0101011 or equivalent).
to the oil seal lip.

MB990938

MD998325

MB990926

AK204285 AB
AK204283 AB
2. Using special tools, press fit the oil seal into the
2. Using special tool Differential oil seal installer clutch housing.
(MD998325), press fit the oil seal into the clutch • Handle (MB990938)
housing. • Installer adapter (MB990926)
22B-48 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION CASE

TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY
M1222013400079

1
2

4 3 6
AK204407AB

Disassembly steps REASSEMBLY SERVICE POINTS

>>C<< 1. Oil seal >>A<< BUSHING INSTALLATION
>>B<< 2. Needle bearing
3. Oil guide
4. Snap ring
>>A<< 5. Bushing Seam of bushing
6. Transaxle

Air vent

AK204292 AB

1. Press fit the bushing so the seam is away from

the air vent.
 MANUAL TRANSMISSION OVERHAUL
TRANSMISSION CASE
22B-49

>>C<<OIL SEAL INSTALLATION

3 mm

AK204304 AC

2. Be sure the bushing is fully seated as shown. It

AK204286AB
must be 3 mm below the housing surface.
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or
>>B<< NEEDLE BEARING INSTALLATION 75W-85W conforming to API classification GL-4).
1. Check the installation direction of the needle
bearing.

MD998325
Model number
stamped side

AK204288 AB

2. Using special tool Differential oil seal installer

AK204287 AB
(MD998325), press fit the oil seal into the
2. Press fit the needle bearing until it is flush with the transaxle case.
case.
22B-50 MANUAL TRANSMISSION OVERHAUL
DIFFERENTIAL

DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
M1222002500146

<F5M42>

Apply gear oil to all

2
moving parts before
installation.

3
6 8

5
4

8
132 ± 5 N·m
7 1

5
2
6

AK204408AB

Disassembly steps DISASSEMBLY SERVICE POINT

>>D<< 1. Differential drive gear <<A>> TAPER ROLLER BEARING REMOVAL
<<A>> >>C<< 2. Taper roller bearing
>>B<< 3. Lock pin
>>A<< 4. Pinion shaft MD998801
>>A<< 5. Pinion
>>A<< 6. Washer
>>A<< 7. Side gear
>>A<< 8. Spacer
9. Differential case

AK204289 AB

1. Using special tool Bearing remover (MD998801),

support the taper roller bearing, and then set them
on the press.
 MANUAL TRANSMISSION OVERHAUL
DIFFERENTIAL
22B-51
2. Push down on the differential case with the press Standard value: 0 − 0.15 mm
and remove the bearing. 5. If the backlash is out of specification, select a
spacer that should get the back lash with in the
standard value and re-measure the backlash.
REASSEMBLY SERVICE POINTS NOTE: Repeat until the backlash on both sides
>>A<< SPACER/SIDE are equal.
GEAR/WASHER/PINION/PINION SHAFT
INSTALLATION >>B<< LOCK PIN INSTALLATION
Differential case
Lock pin
Pinion shaft

AKX00768
AK204290 AB

1. After a spacer has been mounted on the back Install the lock pin so that it will be oriented in the
surface of the side gear, install the side gear in the direction shown.
differential case.
NOTE: When a new side gear is to be installed, >>C<< TAPER ROLLER BEARING INSTALLATION
mount a medium thickness spacer.
2. Set the washer on the back of each pinion, and
MD998812
put both pinions simultaneously in mesh with the Taper roller
side gears. While rotating them, install them in MD998823 bearing
position.

AK204319 AC

Using special tools, install the taper roller bearing

with the press.
• Installer cap (MD998812)
• Installer adapter (MD998823)
AKX00770

>>D<< DIFFERENTIAL DRIVE GEAR

3. Insert the pinion shaft.
INSTALLATION

AKX00766
AK204320AB

4. Measure the backlash between the side gear and

pinion.
22B-52 MANUAL TRANSMISSION OVERHAUL
DIFFERENTIAL

1. Apply sealant (3M STUD Locking No.4170 or 2. Tighten to the specified torque in the illustrated
equivalent) to the entire threaded portion of the sequence.
bolt. Tightening torque: 132 ± 5 N⋅m

3 1
5 8

7
6
2
4

AK204221 AC
 MANUAL TRANSMISSION OVERHAUL
CENTER DIFFERENTIAL
22B-53
CENTER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
M1222002800051

<W5M42>

1
3
Apply gear oil to all
moving parts before
installation.
2

5
11 12
6
7
12 132 ± 5 N·m

4
17

9
14 10

12

13 12 11
8

16 9
15
AK204225AB

Disassembly steps DISASSEMBLY SERVICE POINTS

>>D<< 1. Center differential drive gear <<A>> TAPER ROLLER BEARING REMOVAL
>>C<< 2. Center differential flange
<<A>> >>B<< 3. Taper roller bearing
>>C<< 4. Snap ring
>>C<< 5. Front output shaft
MD998917
>>C<< 6. Spacer
>>C<< 7. Side gear
>>C<< 8. Lock pin
>>C<< 9. Pinion shaft
>>C<< 10. Pinion shaft holder
>>C<< 11. Pinions
>>C<< 12. Washers
AK204264AB
>>C<< 13. Side gear
>>C<< 14. Spacer 1. Support the taper roller bearing with special tool
<<B>> >>A<< 15. Taper roller bearing
bearing remover (MD998917), and then set them
16. Speed meter drive gear
on the press.
17. Differential case
22B-54 MANUAL TRANSMISSION OVERHAUL
CENTER DIFFERENTIAL

2. Push down on the differential case with the press Using special tools, install the taper roller bearing
to remove the bearing. with the press.
• Installer cap (MD998812)
<<B>> TAPER ROLLER BEARING REMOVAL • Installer adapter (MD998823)

>>C<< SPACER, SIDE GEAR, WASHER, PINION

AND PINION SHAFT, PINION SHAFT HOLDER,
MD998917 MB990930 LOCK PIN, FRONT OUTPUT SHAFT, SNAP RING,
CENTER DIFFERENTIAL FLANGE,
INSTALLATION

AK204275AB

1. Support the taper roller bearing with special tools,

and then set them on the press.
• Bearing remover (MD998917)
• Installer adapter (MB990930)
2. Push down on the differential case with the press AK204315
to remove the bearing.
1. Mount a spacer on the back surface of the side
REASSEMBLY SERVICE POINTS gear, and then install the side gear in the
differential case.
>>A<< TAPER ROLLER BEARING INSTALLATION
NOTE: When a new side gear is to be installed,
use a medium thickness spacer (0.93 to 1.00
MD998812 mm).
MD998830
2. Place the washers on the back of the pinions, and
simultaneously mesh the four pieces with the side
gears. Place them into position while rotating
them. Then, install the pinion shaft holder.
3. Insert the pinion shaft.

AK204297AB Differential case

Lock pin
Using special tools, install the taper roller bearing Pinion shaft
with the press.
• Installer cap (MD998812)
• Installer adapter (MD998830)

>>B<< TAPER ROLLER BEARING INSTALLATION

AK204317AC

MD998823 MD998812 4. Install the lock pin so that it will be oriented in the
direction shown.
5. Install the front output shaft on the side gear, and
install the snap ring.
6. Mount a spacer on the back surface of the side
gear, and then install the side gear in the
differential case.
AK204308AB
NOTE: When a new side gear is to be installed,
use a medium thickness spacer.
 MANUAL TRANSMISSION OVERHAUL
CENTER DIFFERENTIAL
22B-55
7. Install the center differential flange by aligning the >>D<< CENTER DIFFERENTIAL DRIVE GEAR
matching marks, and temporarily tighten the four INSTALLATION
machine screws.

AK204320AB

AK204389
1. Apply sealant (3M STUD Locking No.4170 or
8. Measure the backlash between the side gear and equivalent) to the entire threaded portion of the
pinion. bolt.
Standard value: 0.025 − 0.150 mm
1 10
9. If the backlash is out of the standard value, select 3
8
a spacer and re-measure the backlash. 5 6
NOTE: Adjust until the backlash on both sides are
equal. 7 4
9 2

AK204318AB

2. Tighten to the specified torque in the illustrated

sequence.
Tightening torque: 132 ± 5 N⋅m
22B-56 MANUAL TRANSMISSION OVERHAUL
TRANSFER

TRANSFER
DISASSEMBLY AND REASSEMBLY
M1222004000084

1
2

5
6 3

7
11
8

9 Apply gear oil to all

moving parts before
installation.
10

23 ± 3 N·m AK204413AB

Disassembly steps >>B<< OIL SEAL INSTALLATION

1. Dust seal guide 1. Apply gear oil (Hypoid gear oil API classification
>>E<< 2. Oil seal GL-5 SAE 90).
>>D<< 3. Oil seal
>>A<< 4. O-ring MB990938
>>A<< 5. O-ring MB990937
>>A<< 6. O-ring
>>C<< 7. Oil seal
>>B<< 8. Oil seal
>>A<< 9. O-ring
10. Transfer cover
11. Transfer

REASSEMBLY SERVICE POINTS AK204414AB

>>A<< O-RING INSTALLATION
Install a O-ring to the transfer, and apply gear oil 2. Using special tools, press fit the oil seal into the
(Hypoid gear oil API classification GL-5 SAE 90) to transfer cover.
the O-ring. • Installer adapter (MB990937)
• Handle (MB990938)
 MANUAL TRANSMISSION OVERHAUL
TRANSFER
22B-57

>>C<< OIL SEAL INSTALLATION MB990891

1. Apply gear oil (Hypoid gear oil API classification
MB990887
GL-5 SAE 90).

MD998800

AK204416 AB

2. Using special tools, press fit the oil seal into the
transfer.
• Ring (MB990887)
AK204415AB
• Bushing remover installer base (MB990891)
2. Using special tool oil seal installer (MD998800),
press fit the oil seal into the transfer cover. >>E<< OIL SEAL INSTALLATION
1. Apply gear oil (Hypoid gear oil API classification
>>D<< OIL SEAL INSTALLATION GL-5 SAE 90).
1. Apply gear oil (Hypoid gear oil API classification
GL-5 SAE 90).
MB990933

AK204417AB

2. Using special tool installer adapter (MB990933),

press fit the oil seal into the transfer.
NOTES