Part 1 of 3

MANUAL TRANSAXLE DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINTS

A - LOCK NUTS FOR INPUT SHAFT INTERMEDIATE GEAR REMOVAL




1. Unstake lock nuts of the input shaft and intermediate gear.




2. Shift the transaxle in reverse using the control lever and select lever.




3. Install the special tool onto the input shaft.
4. Screw a 10 mm (0.39 in.) bolt into the bolt hole on the external surface 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.

B - SHIFT RAIL ASSEMBLY REMOVAL




1. Shift the 1st-2nd speed shift fork to the 2nd speed.
2. Shift the 3rdAth speed shift fork to the 4th speed.




3. Remove the shift rail assembly as shown in the illustration so as not to hit the interlock plate and control linger.

C - INTERMEDIATE GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY REMOVAL




Lift up the input shaft assembly and remove the intermediate gear assembly.




D - BEARING OUTER RACE REMOVAL

REASSEMBLY SERVICE POINTS




A - OIL SEAL FOR DRIVE SHAFT INSTALLATION

B - OIL SEAL INSTALLATION








Install the oil seal flange part so that the 3 mm (0.12 in.) hole faces the bottom of the transaxle.

CAUTION: Apply transaxle oil to the oil seal lip before installing.




C - OIL SEAL INSTALLATION




D - OIL SEAL FOR INPUT SHAFT FRONT INSTALLATION

E - INTERMEDIATE GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY INSTALLATION




Lifting up the input shaft assembly, install it simultaneously with the intermediate gear assembly.




F - SEALANT APPLICATION TO BEARING RETAINER MOUNTING BOLT
Specified sealant: 3M STUD Locking No.4170 or equivalent

G - SHIFT RAIL ASSEMBLY INSTALLATION




1. Set the 1st-2nd speed shift sleeve at 2nd speed.
2. Set the 3rd4th speed shift sleeve at 4th speed.
3. Install the shift forks to respective sleeves.




4. Insert the shift rail into the shift fork hole, while turning so as to prevent the shift lug from interfering with the stopper plate.
5. Turn the shift rail to engage shift lug.




H - SPRING PINS FOR 1ST-2ND SPEED SHIFT FORK/3RD-4TH SPEED SHIFT FORK INSTALLATION

I - REVERSE IDLER GEAR SHAFT INSTALLATION




Install the shaft toward the shown direction.

J - SPACERS SELECTION




1. Place solder with a length of approximately 10 mm (0.39 in.) and a diameter of approximately 1.6 mm (0.063 in.) in the spacer mounting position.
2. Tighten the case mounting bolt to the specified torque.
3. Remove the case and then take out the solder. If the solder is not broken, use solder with a larger diameter to carry out the steps (1) and (2).




4. Measure the thickness of the camshaft solder with a micrometer, select and install a spacer of thickness that gives standard end play and preload.
Input shaft End play: 0-0.05 mm (0-0.0020 in.)
Intermediate gear Preload: 0.05-0.10 mm (0.0020-0.0040 in.)
Output shaft Preload: 0.05-0.10 mm (0.0020-0.0040 in.)
Differential case Preload: 0.05-0.10 mm (0.002-0.0040 in.)




K - OIL SEAL FOR DRIVE SHAFT INSTALLATION

L - SPACERS INSTALLATION




1. Place two pieces of solder measuring about 10 mm (0.39 in.) in length and 3 mm (0.12 in.) in diameter at illustrated locations on the transaxle and install each outer race.




2. Place two pieces of solder measuring about 10 mm (0.39 in.) in length and 3 mm (0.12 in.) in diameter on the bearing outer race as shown in illustration.
3. Install the transaxle case and tighten the bolts to specified torque.
4. Remove the transaxle case and remove the solder.




5. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play.
Front output shaft bearing preload: 0.08-0.13 mm (0.0031-0.0051 In.)
Front differential case end play: 0.05-0.17 mm (0.0020-0.0067 In.)

M - SEALANT APPLICATION TO TRANSAXLE CASE




Squeeze out sealant from the tube uniformly without excess or discontinuity.
Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent

N - REVERSE IDLER GEAR SHAFT BOLT INSTALLATION




1. Center the shaft with a Phillips screwdriver [shaft diameter 8 mm (0.32 in.)] or the like.
2. Tighten the reverse idler gear shaft bolt to specified torque.

O - SPACERS INSTALLATION




1. Place two pieces of solder measuring about 10 mm (0.39 in.) in length and 3 mm (0.12 in.) in diameter at illustrated locations on the transaxle case adapter assembly and install each outer race.
2. Install the transaxle case adapter assembly and rear cover, and tighten the bolts to specified torque.
3. Remove the transaxle case adapter assembly and rear cover.




4. Remove each outer race and remove the solder. Measure the thickness of the crushed solder with a micrometer, select and install a spacer of thickness that gives standard end play and preload.
Intermediate gear preload: 0.08-0.13 mm (0.0031-0.0051 in.)
Center differential case preload: 0.08-0.13 mm (0.0031-0.0051 in.)
Input shaft end play: 0-0.05 mm (0-0.0020 in.)

P - TRANSAXLE CASE ADAPTER ASSEMBLY INSTALLATION




Apply the specified sealant (liquid gasket) to the transaxle case side of the transaxle case adapter assembly.
Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent

CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuity.

Q - STEEL BALLS INSTALLATION




Move the center shaft so that the steel balls are securely seated in the grooves.

R - SNAP RING INSTALLATION




Choose a snap ring that gives the standard end play of the viscous coupling and install it
Standard value: Viscous coupling: 0.10-0.28 mm (0.0039-0.0102 in.)

S - LOCK NUTS FOR INPUT SHAFT/INTERMEDIATE GEAR INSTALLATION




1. Install the special tool onto the input shaft.
2. Screw a bolt [10 mm (0.39 in.)] into the hole on the external surface of clutch housing and attach a spinner handle to the special tool.




3. Shift the transaxle in reverse using control lever and select lever.
4. Tighten the lock nut to the specified torque, while using the bolt attached in the above step as a spinner handle stopper.




5. Stake the lock nut.




T - SPRING PIN FOR OD-R SHIFT FORK INSTALLATION




U - SEALANT APPLICATION TO AIR BREATHER
Specified sealant: MOPAR Part No.4318025 or equivalent




V - SEALANT APPLICATION TO MACHINE SCREW
Specified sealant: MOPAR Part No.4318031 or MOPAR Part No.4318032 or equivalent

W - WAVE SPRING INSTALLATION




Install the wave spring so that the clasps come to the indicated position in the illustration.








X - SEALANT APPLICATION TO REAR COVER
Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent




5TH SPEED SYNCHRONIZER DISASSEMBLY AND REASSEMBLY

REASSEMBLY SERVICE POINTS




A - SYNCHRONIZER HUB/SYNCHRONIZER SLEEVE INSTALLATION

B - SYNCHRONIZER SPRING INSTALLATION




Position each spring with respect to the keys as illustrated.

INSPECTION

SYNCHRONIZER SLEEVE AND HUB




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 front and rear ends.
3. Check for wear of the hub front end (surface in contact with the 5th speed gear).

CAUTION: When replacing, replace the synchronizer hub and sleeve as a set

SYNCHRONIZER KEY AND SPRING




1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.




INPUT SHAFT DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINTS




A - FRONT TAPER ROLLER BEARING REMOVAL




B - BEARING SLEEVE FOR 5TH SPEED GEAR REMOVAL




C - REAR TAPER ROLLER BEARING/3RD SPEED GEAR REMOVAL