Disassembly

<F5M51> 3.0L:

DISASSEMBLY SERVICE POINTS

<< A >>
SEALING CAP REMOVAL
1. Drive a screwdriver into the center of the sealing cap.
2. Bend the screwdriver back to remove the sealing cap.

<< B >>
TRANSAXLE CASE REMOVAL
1. Remove all sixteen bolts securing the transaxle case to the clutch housing.

2. Use snap ring pliers to expand the indicated snap ring. The snap ring will separate from the ball bearing groove, and the output shaft assembly will fall under its own weight.

CAUTION: Do not use a scraper or chisel to remove the transaxle case.

3. Remove the transaxle case from the clutch housing.

<< C >>
SPRING PIN REMOVAL
1. Shift the 5th-reverse shift fork in the direction shown in the illustration.
2. Using a pin punch, remove the spring pin from the shift fork and rail.

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

2. Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hole in the clutch housing.
3. Slide the 3rd-4th speed shift rail and 5th speed-reverse shift rail in the direction shown and remove them together with the shift forks.

<< E >>
3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/5TH-REVERSE SPEED SHIFT RAIL/5TH REVERSE SPEED SHIFT FORK REMOVAL
1. Pull out the shift rails from the shift rail holes in the clutch housing.
2. Remover the shift rails together with the shift forks.

<< F >>
INPUT SHAFT AND OUTPUT SHAFT REMOVAL
Remove the input and output shafts together.

<< G >>
DIFFERENTIAL/OUTPUT SHAFT/INPUT SHAFT REMOVAL
Remove the input and output shafts together.

<F5M42> 2.4L:

<F5M51> 3.0L:

ASSEMBLY SERVICE POINTS

>> A <<
OUTPUT SHAFT/INPUT SHAFT INSTALLATION
Install the input and output shafts together.

>> B <<
INPUT SHAFT/OUTPUT SHAFT/DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and differential as a set.

>> C <<
5TH SPEED-REVERSE SHIFT FORTH SPEED REVERSE SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/3RD4TH SPEED SHIFT RAIL INSTALLATION
1. Shift the 3rd-4th speed synchronizer sleeve and 5th speed reverse synchronizer sleeve in the direction shown.

2. Assemble the 3rd-4th speed shift rail and fork, and the 5th speed-reverse shift rail and fork.

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.

>> D <<
5TH-REVERSE SPEED SHIFT FORK/5TH-REVERSE SPEED SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH SPEED SHIFT RAIL INSTALLATION
1. Assemble the 3rd-4th speed shift rail and fork, and 5th reverse speed shift rail and fork.

2. Fit each shift fork in the groove of synchronizer sleeve and install the shift fork and rail assembly.
3. Insert the 3rd-4th speed shift rail and 5th speed-reverse shift rail into the rail hole in the clutch housing.

>> E <<
SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork.
2. Insert the new spring pin. Push it in so that the slit and center axis of the rail are aligned.

>> F <<
SPACER AND OUTER RACE INSTALLATION
1. Install the spacer selected in the section "ADJUSTMENT BEFORE ASSEMBLY."

2. Using special tools MB990935 and M13990938, press install the outer race into the transaxle case.

>> G <<
TRANSAXLE CASE INSTALLATION

CAUTION: Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.

2. Install the transaxle case and expand the snap ring.
3. Tighten the transaxle case mounting bolts to the specified torque.

Tightening torque:..............44 ± 5 Nm (33 ± 4 ft. lbs.)

4. Place the transaxle upside down and let the snap ring fit in the groove by taking advantage of the output shaft's own weight.

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

>> H <<
TRANSAXLE CASE INSTALLATION
Squeeze out the sealant uniformly, while making sure that it,is not broken or excessively applied.

1. Apply a 2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Genuine Part number MD997740 or equivalent) to the illustrated position of the transaxle case.

NOTE: Be sure to install the transaxle case while the sealant is wet (within 15 minutes).

2. Install the transaxle case.
3. Tighten the transaxle case mounting bolts to the specified torque.

Tightening torque:.............44 ± 5 Nm (33 ± 4 ft. lbs.)

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

>> I <<
SEALING CAP INSTALLATION
1. Using special tools MB990927 and M13990938, press install the sealing cap onto the case.

2. Evenly press the sealing cap so it is not placed at an angle.

>> J <<
UNDER COVER INSTALLATION

CAUTION: Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.

1. Apply a 2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Genuine Part number MD997740 or equivalent) to the illustrated position of the transaxle case. NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes).

2. Install the under cover to the transaxle case and tighten the bolts to specified torque.

Tightening torque:...........7 ± I Nm (61 ± 9 inch lbs.)

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

>> K <<
CONTROL HOUSING INSTALLATION

CAUTION: Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.

1. Apply a 0.2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Genuine Part number MD997740 or equivalent) to the illustrated position of the transaxle case.

NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes).

2. Install the control housing to the transaxle case and tighten the bolts to specified torque.

Tightening torque:.............19 ± 3 Nm (14 ± 2 ft. lbs.)

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

>> L <<
SPEEDOMETER GEAR INSTALLATION
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.

2. Tighten the bolt to specified torque.

Tightening torque:...........4 ± 1 Nm (35 ± 9 inch lbs.)

>> M <<
SELECT LEVER INSTALLATION

1. Apply grease (Mitsubishi Genuine Part number 0101011 or equivalent) to the control shaft sliding portion of the select lever shoe.
2. Install the select lever and tighten the bolts to specified torque.

Tightening torque:...............19 ± 3 Nm (14 ± 2 ft. lbs.)