Transaxle Disassembly Service Points

F4M21, F5M21











F5M22











F5M31











F5M33















W5M31















W5M33




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 bolt [10 mm (.4 in.)] into the bolt 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.

B. SHIFT RAIL ASSEMBLY REMOVAL





(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) Remove the shift rail assembly as shown in the illustration so as not to hit the interlock plate and control finger.

C. INTERMEDIATE GEAR ASSEMBLY / INPUT SHAFT ASSEMBLY REMOVAL





(1) 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 FOR INPUT SHAFT FRONT INSTALLATION

C. INTERMEDIATE GEAR ASSEMBLY / INPUT SHAFT ASSEMBLY INSTALLATION





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

D. SEALANT APPLICATION TO BEARING RETAINER MOUNTING BOLT





Specified sealant:
3M STUD Locking No.4170 or equivalent.

E. SHIFT RAIL ASSEMBLY INSTALLATION





(1) Set the 1st-2nd speed shift sleeve at 2nd speed
(2) Set the 3rd-4th 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.





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





G. REVERSE IDLER GEAR SHAFT INSTALLATION
(1) Install in the direction as illustrated.

H. SPACERS SELECTION





(1) Place solder with a length of approximately 10 mm (0.4 in.) and a diameter of approximately 1.6 mm (0.06 in.) in the spacer mounting position.
(2) Tighten the case mounting bolt at 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 operations in (1) and (2).





(4) Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play and preload.

Standard value:
Input shaft
End play
0-0.05 mm (0.002 in.) F5M33
Intermediate gear
End play
0.05-0.17 mm (.002- .007 in.) F4M21, F5M21
Preload
0.05-0.10 mm (.002- .004 in.) F5M22

Output shaft
Preload
0.05-0.10 mm (.002-004 in.) All Models

Differential case
End play
0.05-0.17 mm (.002- .007 in.) F5M21
Preload
0.05-0.10 mm (.002.004 in.) F5M22





I. OIL SEAL FOR DRIVE SHAFT INSTALLATION

J. SEALANT APPLICATION TO TRANSAXLE CASE





(1) Squeeze out sealant from the tube uniformly without excess or discontinuity.

Specified sealant:
Mitsubishi genuine sealant Part No. MD997740 or equivalent.

K. REVERSE IDLER GEAR SHAFT BOLT INSTALLATION





(1) Center the shaft with a Phillips screwdriver [shaft diameter 8 mm (.32 in.)] or the like.
(2) Tighten the reverse idler gear shaft bolt to specified torque.

L. SNAP RING INSTALLATION





(1) Select the thickest snap ring that can be fitted into the snap ring groove.

M. DISHED WASHER INSTALLATION





(1) Install the dished washer with the face identified by mark (dent) toward lock nut.

N. LOCK NUTS FOR INPUT SHAFT / INTERMEDIATE GEAR INSTALLATION





(1) Install the special tool onto the input shaft.
(2) Screw a bolt [10 mm (.4 in.)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.





(3) Shift the transaxle in reverse using control level 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) Stake the lock nut.





O. SPRING PIN FOR OD-R SHIFT FORK INSTALLATION

P. SEALANT APPLICATION TO AIR BREATHER





Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or equivalent.

Q. SEALANT APPLICATION TO REAR COVER








Specified sealant:
Mitsubishi genuine sealant Part No. MD997740 or equivalent.





R. SEALANT APPLICATION TO MACHINE SCREW

Specified sealant:
3M STUD Locking No.4170 or equivalent





S. OIL SEAL INSTALLATION

T. OIL SEAL INSTALLATION





(1) Install the oil seal flange part so that the 3 mm (.12 in.) hole faces the bottom of the transaxle.





CAUTION:
- Apply transmission oil to the oil seal lip before installing.

U. SPACERS INSTALLATION





(1) Place two pieces of solder measuring about 10 mm (.39 in.) in length and 3 mm (.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 (.39 in.) in length and 3 mm (.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.

Standard value:
Front output shaft bearing preload:
0.08- 0.13 mm (.0031 - .0051 in.)
Front differential case end play:
0.05-0.17 mm (.0020 - .0067 in.)

V. SPACERS INSTALLATION





(1) Place two pieces of solder measuring about 10 mm (.39 in.) in length and 3 mm (.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 and select and install a spacer of thickness that gives standard end play and preload.

Standard value:
Intermediate gear preload:
0.08- 0.13 mm (.0031 - .0051 in.)
Center differential case preload:
0.08- 0.13 mm (.0031 - .0051 in.)
Input shaft end play:
0-0.05 mm (0 - .0020 in.) W5M33

W. TRANSAXLE CASE ADAPTER ASSEMBLY INSTALLATION





(1) Apply 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.

X. STEEL BALLS INSTALLATION





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

Y. SNAP RING INSTALLATION





(1) Choose a snap ring that gives the standard end play of the viscous coupling and install it.

Standard value:
Viscous coupling: 0.10- 0.26 mm (.0039 - .0102 in.)

Z. WAVE SPRING INSTALLATION





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