W5M51
TRANSAXLEDisassembly Steps 1-12:
Disassembly Steps 13-26:
Disassembly Steps 27-39:
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINTS
<> 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.
<> 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. Remove the shift rails together with the shift forks.
<
Remove the input and output shafts together.
ADJUSTMENT BEFORE ASSEMBLY
SPACER SELECTION FOR INPUT SHAFT END PLAY/OUT PUT SHAFT PRELOAD/CENTER DIFFERENTIAL PRELOAD
CAUTION:
^ If soft solder is not available, select the spacer in accordance with Plastigage method.
^ If the spacer appropriate for the standard value cannot be selected using soft solder, select the spacer in accordance with Plastigage method.
1. Install the input shaft, output shaft and center differential as a set to the clutch housing.
NOTE: If necessary, replace the input shaft, output shaft, center differential case and/or bearings before carrying out these adjustments.
2. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] on the input shaft rear bearing at the positions shown in the illustration.
3. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long) on the transaxle case at the positions shown in the illustration.
4. Install the bearing outer races of the center differential and output shaft.
5. Install the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 3 ft. lbs.)
6. Remove the transaxle case.
7. Remove the outer races and take out the crushed solders.
8. If the solders have not crushed, use thicker solders [1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long] and repeat steps 4 to 7.
9. Measure the thickness of the crushed solder with a micrometer and select spacers that will provide the standard end play/preload value.
Standard value:
Input shaft end play: 0.05 - 0.17 mm (0.0020 - 0.0067 inch)
Output shaft preload: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Center differential case preload: 0.05 - 0.11 mm (0.0020 - 0.0043 inch)
1. Install the input shaft, output shaft and center differential as a set to the clutch housing.
NOTE: If necessary, replace the input shaft, output shaft, center differential case and/or bearings before carrying out these adjustments.
2. Put plastigage [about 10 mm (0.39 inch) long] on the input shaft rear bearing at the positions shown in the illustration.
3. Put plastigage [about 10 mm (0.39 inch) long] on the transaxle case at the positions shown in the illustration.
4. Install the bearing outer races of the center differential and output shaft.
5. Install the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 44 ±5 Nm (32 ±3 ft. lbs.)
6. Remove the transaxle case.
7. Remove the outer races and take out the crushed plastigage.
8. If the Plastigages have not crushed, replace the spacer with a thicker one and repeat steps 4 to 7.
9. Measure the width of the crushed plastigage at its widest part using a scale printed on the plastigage package.
Standard value:
Input shaft end play: 0.05 - 0.17 mm (0.0020 - 0.0067 inch)
Output shaft preload: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Center differential case preload: 0.05 - 0.11 mm (0.0020 - 0.0043 inch)
ASSEMBLY SERVICE POINTS
>>A<< INPUT SHAFT/OUTPUT SHAFT/CENTER DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and center differential as a set.
>>B<< 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.
>>C<< 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.
>>D<< SPACER AND OUTER RACE INSTALLATION
1. Install the spacer selected in ADJUSTMENT BEFORE ASSEMBLY.
2. Using special tools MB990935 and MB990938, press install the outer race into the transaxle case.
>>E<< TRANSAXLE CASE 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 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 (32 ± 3 ft. lbs.)
NOTE: After installation, keep the sealed area away from oil for approximately one hour
>>F<< 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: 6.9 ± 0.9 Nm (61 ± 7 inch lbs.)
NOTE: After installation, keep the sealed area away from oil for approximately one hour
>>G<< 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: 18 ± 3 Nm (13 ± 2 ft. lbs.)
NOTE: After installation, keep the sealed area away from oil for approximately one hour
>>H<< SELECT LEVER INSTALLATION
1. Apply grease (Mitsubishi genuine grease part No. 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: 18 ± 3 Nm (13 ± 2 ft. lbs.)