Transmission Disassembly and Assembly
TRANSAXLEDISASSEMBLY AND ASSEMBLY
Disassembly Steps 1-10:
Disassembly Steps 11-24:
Disassembly Steps 25-38:
Required Special Tools:
^ MB990927: Installer Adapter
^ MB990935: Installer Adapter
^ MB990938: Handle
DISASSEMBLY SERVICE POINTS
[A] SEALING CAP REMOVAL
1. Drive a screwdriver into the center of the sealing cap.
2. Use the screwdriver back to pry off the sealing cap.
[B] TRANSAXLE CASE REMOVAL
1. Remove all sixteen bolts securing the transaxle case to the clutch housing.
2. Use snap ring pliers to expand the indicated snap ring. The snap ring will release the grooved ball bearing, and the output shaft assembly will fall under its own weight.
CAUTION: Do not use a scraper or chisel to remove the transaxle case.
3. Remove the transaxle case from the clutch housing by gently prying on opposite sides at the same time.
[C] 3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/5TH SPEED-REVERSE SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th speed-reverse shift fork in the direction shown.
2. Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hole in the clutch housing.
3. Slide the 3rd-4th speed shift rail and 5th speed-reverse shift rail in the direction shown and remove them together with the shift forks.
[D] INPUT SHAFT AND OUTPUT SHAFT REMOVAL
Remove the input and output shafts together.
ADJUSTMENT BEFORE ASSEMBLY
SPACER SELECTION FOR DIFFERENTIAL CASE PRELOAD ADJUSTMENT
[Measurement using a Solder]
1. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential assembly into the transaxle case.
NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.
3. Install the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 4 ft-lb)
4. Remove the clutch housing, and then remove the differential assembly.
5. Remove the taper bearing outer race and take out crushed solders.
6. 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 2 to 5.
7. Measure the thickness of the crushed solder with a micrometer and select a spacer that will provide the standard preload value.
Standard value:
0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload
[Measurement using Plastigage]
1. Put plastigage [about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case.
2. Install the thinnest spacer.
3. Install the taper bearing outer race and differential assembly into the transaxle case.
NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.
4. Install the clutch housing and tighten the bolts to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 4 ft-lb)
5. Remove the clutch housing, and then remove the differential assembly.
6. Remove taper bearing outer race and the spacer.
7. If the Plastigages have not crushed, replace the spacer with a thicker one and repeat steps 2 to 7.
8. Measure the width of the crushed Plastigage at its widest part using a scale printed on the Plastigage package.
Standard value:
0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload
ASSEMBLY SERVICE POINTS
[A] OUTPUT SHAFT AND INPUT SHAFT INSTALLATION
Install the input and output shafts together.
[B] 5TH SPEED-REVERSE SHIFT FORK/5TH SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH SPEED SHIFT RAIL INSTALLATION
1. Shift the 3rd-4th speed synchronizer sleeve and 5th speed-reverse synchronizer sleeve in the direction shown.
2. Assemble the 3rd-4th speed shift rail and fork, and the 5th speed-reverse shift rail and fork.+
3. While fitting each shift fork in the groove of synchronizer sleeve, slide the shift rails in the direction shown and install.
4. 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 as shown so that the slit and center axis of the rail are aligned.
[D] SPACER AND OUTER RACE INSTALLATION
1. Install the spacer selected in the section "ADJUSTMENT BEFORE ASSEMBLY."
2. Using special tools MB990935 and MB990938, press the outer race into the transaxle case.
[E] TRANSAXLE CASE INSTALLATION
CAUTION: Squeeze sealant evenly onto the transaxle housing. Do not leave gaps or excess amounts, otherwise oil leaks are likely.
1. Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply a 1.5 mm (0.06 inch) diameter bead of sealant (Mitsubishi Part number MD997740 or equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto the transaxle housing while the sealant is still wet.
3. Align the transaxle case and expand the snap ring. After the case is on far enough for the snap ring to ride on the bearing, release the snap ring. Push down on the transaxle case, twisting it from side to side until the case contacts the housing.
4. Tighten the transaxle case mounting bolts to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 4 ft-lb)
5. Place the transaxle upside down and let the snap ring fit in the groove by the output shaft's own weight.
NOTE: After installation, keep the sealed area away from oil for approximately one hour.
[F] SEALING CAP INSTALLATION
1. Using special tools MB990927 and MB990938, press install the sealing cap onto the case.
2. Evenly press the sealing cap so it is fully seated and not at an angle.
[G] UNDER COVER INSTALLATION
CAUTION: Squeeze sealant onto the case. Do not leave gaps or excess amounts, otherwise oil leaks are likely.
1. Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply a 1.5 mm (0.06 inch) diameter bead of sealant (Mitsubishi Part number MD997740 or equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the case quickly while the sealant is still wet.
3. Install the under cover to the transaxle case and tighten the bolts to specified torque.
Tightening torque: 6.9 ± 0.9 Nm (61 ± 8 in-lb)
NOTE: After installation, keep the sealed area away from oil for approximately one hour.
[H] CONTROL HOUSING INSTALLATION
CAUTION: Squeeze sealant onto the case. Do not leave gaps or excess amounts, otherwise oil leaks are likely.
1. Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply a 1.5 mm (0.06 inch) diameter bead of sealant (Mitsubishi Part number MD997740 or equivalent) as illustrated onto the control housing.
NOTE: Be sure to install the housing to the case quickly while the sealant is still wet.
3. Install the control housing to the transaxle case and tighten the bolts to specified torque.
Tightening torque: 18 ± 3 Nm (13 ± 2 ft-lb)
NOTE: After installation, keep the sealed area away from the oil for approximately one hour.
[I] VEHICLE SPEED SENSOR INSTALLATION
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4) to the O-ring of the vehicle speed sensor. Install into the transaxle housing.
2. Tighten the bolt to specified torque.
Tightening torque: 3.9 ± 1.0 Nm (35 ± 9 in-lb)
[J] SELECT LEVER INSTALLATION
1. Apply grease (Mitsubishi Part number 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-lb)