W6MAA

Disassembly Steps 1-13:

Disassembly Steps 14-27:

Disassembly and Assembly Steps:

Assembly Steps:

1. Heat the transaxle case to about 100°C (212°F).

NOTE: Maximum temperature: 120°C (248°F).

2. Using special tools MB990810, MB991967 and MB991968, remove the differential side bearing outer race.

ASSEMBLY SERVICE POINTS
>>A<< REVERSE IDLER GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY/MAIN SHAFT ASSEMBLY INSTALLATION

1. Place the reverse idler gear assembly at the installation location without actually inserting it into the clutch housing.

CAUTION: Be careful not to scratch the input shaft oil seal. (Protect it from scratches by wrapping vinyl tape around the splined portion of the input shaft assembly.)

2. Insert the input shaft assembly and then the main shaft assembly into the clutch housing, leaving some space between each assembly and the housing.

CAUTION: Make sure to fit the lock pin at the end of the reverse idler gear assembly into the groove in the clutch housing.

3. Move the reverse idler gear assembly so that its parts fit into the spaces between the housing and the partially inserted shaft assemblies, and then insert the three assemblies together into the clutch housing.

>>B<< 1ST-2ND FORK ROD/1ST-2ND SHIFT FORK INSTALLATION

CAUTION:
^ The retaining pin is not reusable.
^ When installing the retaining pin, insert an Allen wrench into the hole on the other side of the fork rod to keep the fork from slipping down.

Install the 1st-2nd fork rod in the clutch housing and then install the 1st-2nd shift fork on the fork rod by hammering in the retaining pin.

>>C<< SHIFT CHECK SLEEVE INSTALLATION

CAUTION: The transmission assembly contains parts that resemble shift check sleeves. Make sure not to mistakenly install a similar part instead of the shift check sleeve (length: 36.25 mm).

Install the shift check sleeve.

>>D<< 3RD-4TH FORK ROD/INTER LOCK PIN/3RD-4TH BRACKET/3RD-4TH SHIFT FORK/C-RING/RETAINING PIN INSTALLATION

CAUTION: Apply Vaseline to the interlock pin and be careful not to drop it during installation.

1. Install the interlock pin on the 3rd-4th fork rod.
2. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.

CAUTION: The C-ring is not reusable.

3. Install the C-ring on the 3rd-4th shift fork

CAUTION: The retaining pin is not reusable. When installing the retaining pin, insert an Allen wrench into the hole on the other side of the fork rod to keep the fork from slipping down.

4. Hammer the retaining pin into the 3rd-4th bracket.

>>E<< INTERLOCK BALL INSTALLATION

CAUTION: Make sure that the interlock balls do not fall out of their locations.

Install the two interlock balls.

>>F<< 5TH-6TH FORK ROD/INTER LOCK PIN/5TH-6TH BRACKET/5TH-6TH SHIFT FORK/C-RING/RETAINING PIN INSTALLATION

CAUTION: Apply Vaseline to the interlock pin and be careful not to drop it during installation.

1. Install the interlock pin in the 5th-6th fork rod.

CAUTION: Install the 5th-6th fork rod with its three grooves facing the 5th-6th shift check parts.

2. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.

CAUTION: The C-ring is not reusable.

3. Install the C-ring on the 5th-6th bracket.

CAUTION:
^ The retaining pin is not reusable.
^ When installing the retaining pin, insert an Allen wrench into the hole on the other side of the fork rod to keep the fork from slipping down.

4. Hammer the retaining pin into the 5th-6th shift fork.

>>G<< INTERLOCK BALL INSTALLATION

CAUTION: Make sure that the interlock steel balls do not fall out of their locations.

Install the two interlock steel balls.

>>H<< REVERSE BRACKET FORK ROD/REVERSE BRACKET INSTALLATION

CAUTION: Install the reverse bracket fork rod with its two grooves facing the reverse shift check parts.

Install the reverse bracket fork rod and reverse bracket.

>>I<< REVERSE LEVER ASSEMBLY INSTALLATION

1. Install the shifter cap on the cam of the reverse lever assembly, and then install the reverse shift fork.
2. Raise the reverse shift fork and fit its cam in the reverse bracket.

>>J<

CAUTION:
^ The check balls are not reusable.
^ Confirm the lengths of the shift check sleeves and check springs before installing them. (A: short, B: long)
^ Be careful not to let the check balls drop into the air breathing grooves in the clutch housing.

Install the two shift check sleeves, two check balls, two check springs and two check ball plugs into position.

>>K<< DIFFERENTIAL SIDE BEARING ADJUSTMENT SHIM INSTALLATION

CAUTION: Do not use more than two shims.

Install the appropriate adjustment shims that will provide the differential side bearing with a preload within the standard value range.
Standard value: 0.15 - 0.21 mm (0.0059 - 0.0083 inch)

1. Selecting appropriate shims
1) Measure the distance between the end surface and the adjustment shim fitting surface on the transaxle case (L1) Next, measure the distance between the clutch housing end surface and the differential side bearing end surface (L2).
2) Use the following equation to calculate the clearance L between the transaxle case and the differential side bearing outer race:
L = L1 -1-2
3) Select an adjustment shim (or a set of adjustment shims) with a thickness of L plus 0.15 mm (0.0059 inch) to 0.21 mm (0.0078 inch) (standard value range).

2. Measuring distances L1 and L2
1) Install the adjustment adapter (special tool: MB991969) into the differential side rear bearing hole in the transaxle case. Use the following equation to calculate the distance
L1 (see the illustration):
L1: 25.00 mm (0.9843 inch) (height of MB991969) measurement "a"
2) Attach the outer race onto the differential side bearing on the final gear side, and rotate the final gear set five or more times by hand while holding the outer race down lightly to keep it from tilting.

NOTE: Rotating the final gear in this way will help the bearing rollers to seat completely against their races.

CAUTION: Before making the following measurement, make sure to confirm that the outer race is level by measuring the height of the outer race surface at three different points.

3) Use a dial gauge to measure the distance between the differential side bearing outer race and the transaxle mounting surface of the clutch housing (L2).

>>L<< DIFFERENTIAL SIDE BEARING OUTER RACE INSTALLATION

1. Heat the transaxle case to about 100°C (212°F).

NOTE: Maximum temperature: 120°C (248°F).

2. Using special tool MB991966, install the differential side bearing outer race.

>>M<< ADJUSTMENT SHIM INSTALLATION (SHIM SELECTION FOR INPUT SHAFT END PLAY/MAIN SHAFT END PLAY/REVERSE IDLER GEAR END PLAY)

CAUTION: Use only one shim each for the main shaft rear bearing, input shaft rear bearing and reverse idler gear. Install the selected shims into the relevant locations.

NOTE: Refer to the following shim thickness determination procedure to select a shim for each location.



CAUTION:
^ If soft solder is not available, select the shim in accordance with Plastigage method.
^ If the shim appropriate for the standard value cannot be selected using soft solder, select the shim in accordance with Plastigage method.

1. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] on the input shaft rear bearing as indicated in the illustration.

2. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] on the main shaft rear bearing fitting surface in the transaxle case as indicated in the illustration.

3. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] on the surface of the reverse idler gear mounting boss in the transaxle case as indicated in the illustration and then Install the shim having the minimum thickness.
4. Install the snap ring temporarily in the main shaft rear bearing location in the transaxle case.
5. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole, and place the transaxle case over the clutch housing.

CAUTION: In the following step, use the same transaxle case bolts that were removed during disassembly.

6. Install and tighten the transaxle case bolts to the specified torque.
Tightening torque: 63 ±1 Nm (46 ±1 ft. lbs.)

CAUTION: In the following steps, make sure to use the same O-rings that were removed during disassembly.

7. Install the control assembly and tighten its bolts to the specified torque.
Tightening torque: 7.3 ±1.0 Nm (65 ±9 inch lbs.)
8. With the gear shifted into 2nd gear, raise the main shaft and install the snap ring tightly on the main shaft rear bearing.

NOTE: Refer to CONTROL ASSEMBLY INSTALLATION for the method for shifting the gear into 2nd.

9. Return the control assembly to the neutral position and remove its mounting bolts. Remove the control assembly.
10. Remove the transaxle case.
11. Remove the snap ring from the main shaft rear bearing, remove the transaxle case, and then take out crushed solders.
^ Input shaft and mainshaft
If the solders have not crushed, use thicker solders (1.6 mm diameter, about 10 mm long) and repeat steps 4 to 10.
^ Reverse idler gear
If the solders have not crushed, use thicker shim and repeat steps 4 to 10.

12. Measurer the thickness of the crushed solder with a micrometer.
^ Input shaft and mainshaft
Select a shim that will provide the standard value.
Input shaft and mainshaft end play
^ Shim thickness: (T -0 mm) to [T -0.06 mm (0.0024 inch)]
^ T: The crushed solder thickness
Standard value: 0 - 0.06 mm (0 - 0.0024 inch)
^ Reverse idler gear
Based on the sum of the crushed thickness and the thickness of the shim used during measurement, select the thickness of the shim to obtain the standard clearance.
Reverse idler gear end play
^ Shim thickness: [T1 + T2 -0.04 mm (0.0016 inch) to [T1 + T2 -0-10 MM (0.0039 inch)]
T1 The crushed solder thickness
T2: Used shim thickness
Standard value: 0.04 - 0.10 mm (0.0016 - 0.0039 inch)

1. Put plastigage [about 10 mm (0.39 inch) diameter, about 10 mm (0.39 inch) long] on the input shaft rear bearing as indicated in the illustration.

2. Put plastigage [about 10 mm (0.39 inch) diameter, about 10 mm (0.39 inch) long] on the main shaft rear bearing fitting surface in the transaxle case as indicated in the illustration.

3. Put plastigage [about 10 mm (0.39 inch) diameter, about 10 mm (0.39 inch) long] on the surface of the reverse idler gear mounting boss in the transaxle case as indicated in the illustration and then Install the shim having the minimum thickness.
4. Install the snap ring temporarily in the main shaft rear bearing location in the transaxle case.
5. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole, and place the transaxle case over the clutch housing.

CAUTION: In the following step, use the same transaxle case bolts that were removed during disassembly.
6. Install and tighten the transaxle case bolts to the specified torque.
Tightening torque: 63 ±1 Nm (46 ±1 ft. lbs.)

CAUTION: In the following steps, make sure to use the same O-rings that were removed during disassembly.

7. Install the control assembly and tighten its bolts to the specified torque.
Tightening torque: 7.3 ±1.0 Nm (65 ±9 inch lbs.)
8. With the gear shifted into 2nd gear, raise the main shaft and install the snap ring tightly on the main shaft rear bearing.

NOTE: Refer to CONTROL ASSEMBLY INSTALLATION for the method for shifting the gear into 2nd.

9. Return the control assembly to the neutral position and remove its mounting bolts. Remove the control assembly.
10. Remove the transaxle case.
11. Remove the snap ring from the main shaft rear bearing, remove the transaxle case, and then take out crushed plastigage.
12. If the plastigage have not crushed, replace the shim with a thicker one and repeat steps 4 to 11.

13. Measure the shim width of the crushed plastigage at its widest part using a scale printed on the plastigage package.
Standard value
^ Input shaft end play: 0 mm - 0.06 mm (0 - 0.0024 inch)
^ Mainshaft end play: 0 mm - 0.06 mm (0 - 0.0024 inch)
^ Reverse idler gear end play: 0.04 - 0.10 mm (0.0016 - 0.0039 inch)

>>N<< TRANSAXLE CASE INSTALLATION

CAUTION: The snap ring is not reusable.

1. Install the snap ring temporarily in the main shaft rear bearing location in the transaxle case.

2. Apply sealant (Mitsubishi genuine sealant part No. MD997740 or equivalent) as indicated in the above illustration.
3. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole and place the transaxle case over the clutch housing.

CAUTION: Bolts (B) are not reusable.

4. Tighten all the bolts to the specified torque.
Tightening torque: 63 ± 1 Nm (46 ±1 ft. lbs.)

>>O<< CONTROL ASSEMBLY INSTALLATION

CAUTION: The O-ring is not reusable.

1. Install the control assembly and tighten the bolts to the specified torque.
Tightening torque: 7.3 ±1.0 Nm (65 ±9 inch lbs.)
2. With the gear shifted into 2nd, raise the main shaft and install the snap ring tightly on the main shaft rear bearing.

NOTE: To shift the gear into 2nd, move the lever in the order of the numbers indicated in the illustration.

>>P<< BACKUP LIGHT SWITCH INSTALLATION
1. Apply sealant (Mitsubishi genuine sealant part No. MD997740 or equivalent) to the threads on the backup light switch.
2. Install the backup light switch on the transaxle case.