Part 2
TRANSAXLEDISASSEMBLY AND ASSEMBLY(continued)
Disassembly Steps 1-15:
Required Special Tool:
ASSEMBLY SERVICE POINTS
1. Install the differential sub-assembly in the transaxle case.
2. Install the input shaft sub-assembly and output shaft No. 1 sub-assembly in the transaxle case simultaneously.
3. Install the output shaft No.2 sub-assembly in the transaxle case as shown in the illustration.
4. Set the reverse idler gear, the needle roller bearing, the reverse idler thrust washer and the reverse idle gear shaft.
NOTE: Fit the projection of the anti-rotation for the reverse idler thrust washer into the reverse idle gear shaft as shown.
5. Install them to the transaxle case.
6. Install the gear shift fork assembly No. 1.
7. Install the gear shift fork shaft No.5 in the transaxle case and then install the gear shift head No.3 on the gear shift fork shaft No.5 by hammering in the slotted spring pin.
8. Insert the shift arm into the transaxle case, fitting it in the groove of the gear shift fork shaft No.5.
9. After insert the arm pivot into the transaxle case and the shift arm, install the E-ring into the arm pivot.
10. Install the gear shift fork assembly No.2.
11. Insert the shaft No.1 in the order of fork No.2, No.1 and the transaxle case.
12. Insert the shaft No. 2 in the order of gear shift fork assembly No.2, gear shift head No.3, gear shift head No.2 with the shift arm and transaxle case.
13. Stick the slotted spring pin in the gear shift head No.2.
14. Install the reverse shift fork and the gear shift fork assembly No.3.
15. Insert the gear shift fork shaft No.3 in the order of gear shift fork assembly No.3, reverse shift fork, and transaxle case.
16. Insert the gear shift fork shaft No.4 in the order of reverse shift fork and transaxle case.
17. Tighten the washer based hexagon bolts to the specified torque of 20 ± 4 Nm (15 ± 3 ft. lbs.).
18. Stick the pins in the gear shift fork assembly No. 1, No.2 and No.3.
CAUTION: As shown in the illustration, install the white painted spring only for the reverse fork.
19. Install the ball, the compression spring, the shift detent ball seat spring No. 1 and the straight screw plug with head (four places).
20. Install the transmission oil separator to the transaxle case and tighten the bolts to the specified torque of 8.5 ± 2.5 Nm 75 ± 22 inch lbs.).
21. Apply a 1.2 mm (0.0472 inch) diameter bead of sealant (Mitsubishi Part number MD994421 or equivalent) as illustrated onto the transmission case.
22. Install the transmission case sub-assembly to the transaxle case sub-assembly and tighten the bolts to the specified torque of 30 ± 5 Nm (22 ± 4 ft. lbs.).
23. Extend the hole snap ring and install it on the radial ball bearing.
24. Install stud bolt to the output shaft No.2 sub-assembly.
25. Pull the output shaft No.2 sub-assembly in the direction as shown in the illustration and fit the hole snap ring into the bearing groove.
NOTE: After installation, keep the sealed area away from oil for approximately one hour
26. Push the input shaft sub-assembly in the direction as shown in the illustration and fit the hole snap ring into the bearing groove.
27. Lift the output No. 1 sub-assembly.
28. Confirm that the dimension between the centers of 0 2.5 holes on the hole snap ring is in accordance with the illustration.
29. Check the hole snap ring fits securely into the bearing groove.
30. Install the flange bolt and gasket to the specified torque of 50 ± 10 Nm (37 ± 7 ft. lbs.).
31. Apply a 1.2 mm (0.0472 inch) diameter bead of sealant (Mitsubishi Part number MD994421 or equivalent) as illustrated onto the control shaft cover.
32. Install the shift & select lever shaft assembly to the transmission case and tighten the bolts to the specified torque of 19 ± 3 Nm (14 ± 2 ft. lbs.).
33. Install the straight pin to the specified torque of 30 ± 9 Nm (22 ± 7 ft. lbs.).
34. Install the lock ball assembly and tighten to the specified torque of 30 ± 8 Nm (22 ± 6 ft. lbs.).
35. Install the straight screw plug with head and gasket (two places) and tighten to the specified torque of 39 ± 12 Nm (29 ± 9 ft. lbs.).
36. Install the straight screw plug with head and tighten to the specified torque of 39 ± 12 Nm (29 ± 9 ft. lbs.).
37. Install the straight screw plug with head and tighten to the specified torque of 23 ± 6 Nm (17 ± 4 ft. lbs.).
38. Apply grease to the hole and the sides of control bell crank dust cover.
39. Install the selecting bell crank assembly and control bell crank dust cover to the transmission case and tighten the bolts to the specified torque of 19 ± 3 Nm (14 ± 2 ft. lbs.).
40. Install the control cable bracket to the transmission case and tighten the bolts to the specified torque of 19 ± 3 Nm (14 ± 2 ft. lbs.).
41. Install the wiring harness clamp bracket to the transmission case and tighten the bolts to the specified torque of 9.0 ± 2.0 Nm (80 ± 17 ft. lbs.).
42. Install the transmission case hanger No. 1 to the transmission case and tighten the bolts to the specified torque of 19 ± 3 Nm (14 ± 2 ft. lbs.).
43. Install the lock ball assembly and tighten to the specified torque of 40 ± 12 Nm (30 ± 8 ft. lbs.).
44. Install the backup lamp switch assembly and tighten to the specified torque of 40 ± 12 Nm (30 ± 8 ft. lbs.).
45. Install the clamp to the transmission case and tighten the bolts to the specified torque of 12 ± 4 Nm (102 ± 40 inch lbs.).
46. Install the speedometer driven gear assembly to the transmission case and tighten the bolts to the specified torque of 5.5 ± 2.2 Nm (49 ± 19 inch lbs.).