Transaxle Disassembly and Reassembly

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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 (0.39 inch)] into the bolt hole around 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.

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.

INTERMEDIATE GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY REMOVAL

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

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

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

Install in the direction as illustrated.

>H< SPACERS SELECTION

1. Place solder with a length of approximately 10 mm (0.39 inch) and a diameter of approximately 1.6 mm (0.063 inch) 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 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 - 0.05 mm (0.0 - 0.0020 inch)
Intermediate gear preload: 0.05 - 0.10 mm (0.0020 - 0.0040 inch)
Output shaft preload: 0.05 - 0.10 mm (0.0020 - 0.0040 inch)
Differential case preload
Preload: 0.05 - 0.10 mm (0.0020 - 0.0040 inch)

>I< OIL SEAL FOR DRIVE SHAFT INSTALLATION

>J< 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

>K< REVERSE IDLER GEAR SHAFT BOLT INSTALLATION

1. Center the shaft with a Phillips screwdriver [shaft diameter 8 mm (0.31 inch)] or the like.
2. Tighten the reverse idler gear shaft bolt to the specified torque.

>L< 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 inch)] into the hole around 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.

>M< SPRING PIN FOR OD-R SHIFT FORK INSTALLATION

>N< SEALANT APPLICATION TO AIR BREATHER

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

>O< SEALANT APPLICATION TO REAR COVER

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

>P< SEALANT APPLICATION TO MACHINE SCREW

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

>Q< OIL SEAL INSTALLATION

>R< OIL SEAL INSTALLATION

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

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

>S< SPACERS INSTALLATION

1. Place two pieces of solder measuring about 10 mm (0.39 inch) in length and 3 mm (0.12 inch) 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 inch) in length and 3 mm (0.12 inch) in diameter on the bearing outer race as shown in illustration.
3. Install the transaxle case and tighten the bolts to the 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 preload and end play.
Standard value:
Front output shaft bearing preload: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
Front differential case end play: 0.05 - 0.17 mm (0.0020 - 0.0067 inch)

>T< SPACERS INSTALLATION

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

4. Remove outer races 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 (0.0031 - 0.0051 inch)
Center differential case preload: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
Input shaft end play: 0.0 - 0.05 mm (0.0 - 0.0020 inch)

>U< 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.

>V< STEEL BALLS INSTALLATION

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

>W< 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 - 0.26 mm (0.0039 - 0.0102 inch)

>X< WAVE SPRING INSTALLATION

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