Transmission Disassembly and Assembly
TRANSAXLEDISASSEMBLY AND ASSEMBLY
Removal Steps 1-10:
Removal Steps 11-22:
Removal Steps 23-46 / Installation Steps 46-32:
Installation Steps 41-23:
DISASSEMBLY SERVICE POINTS
[A] STEEL BALL REMOVAL
Remove the steel balls at the illustrated positions from the shift lug and 5th speed shift fork.
[B] SPRING PIN REMOVAL
Knock the spring pin out of the 3rd-4th speed shift fork from the illustrated direction.
[C] REVERSE IDLER GEAR ASSEMBLY REMOVAL
Pull up the input shaft and output shaft together, and remove the reverse idler gear assembly.
[D] 3RD-4TH SPEED SHIFT FORK / 5TH SPEED SHIFT FORK / SHIFT LUG / 5TH SPEED SHIFT RAIL ASSEMBLY / INPUT SHAFT ASSEMBLY / OUTPUT SHAFT ASSEMBLY 1ST-2ND SPEED SHIFT FORK / 1ST-2ND SPEED SHIFT RAIL ASSEMBLY REMOVAL
With the differential assembly raised a little, remove the 3rd-4th speed shift fork, 5th speed shift fork, shift lug, 5th speed shift rail assembly, output shaft assembly, 1st-2nd speed shift fork, 1st-2nd speed shift rail assembly and input shaft assembly as a set.
[E] SPRING PIN REMOVAL
Knock the spring pin out of the 1st-2nd speed shift fork from the illustrated direction.
ASSEMBLY SERVICE POINTS
[A] 3RD-4TH SPEED SHIFT FORK / 5TH SPEED SHIFT FORK / SHIFT LUG / 5TH SPEED SHIFT RAIL ASSEMBLY / INPUT SHAFT ASSEMBLY / OUTPUT SHAFT ASSEMBLY REMOVAL
With the differential assembly raised a little, install the 3rd-4th speed shift fork, 5th speed shift fork, shift lug, 5th speed shift rail assembly, input shaft assembly and output shaft assembly as a set.
[B] SPRING PIN INSTALLATION
Install the spring pin to the shift rail so that the slit of the spring pin aligns with the center axis of the rail as shown.
[C] REVERSE IDLER GEAR ASSEMBLY INSTALLATION
Install the reverse idler gear assembly so that the notch of the reverse idler gear shaft and 1st-2nd speed synchronizer sleeve meet at the illustrated position.
[D] SPRING PIN INSTALLATION
Install the spring pin to the shift rail so that the slit of the spring pin aligns with the center axis of the rail as shown.
[E] 5TH-REVERSE SPEED SHIFT RAIL INSTALLATION
Install the 5th-reverse speed shift rail, with its identification groove to the clutch housing side.
[F] REVERSE SHIFT LEVER INSTALLATION
Install the reverse shift lever so that its identification mark is located at the illustrated position.
[G] TRANSAXLE CASE INSTALLATION
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 bead (approximately 2.5 mm (0.10 inch) thick) of specified sealant to the transaxle case as shown.
Specified sealant: Mitsubishi Part No. MD997740 or equivalent
[H] CONTROL HOUSING INSTALLATION
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 bead (approximately 3.5 mm (0.14 inch) thick) of specified sealant to the control housing as shown.
Specified sealant: Mitsubishi Part No. MD997740 or equivalent
[I] BACK-UP LIGHT SWITCH / 1ST-2ND SPEED RAIL SWITCH INSTALLATION
Install the back-up light switch and 1st2nd speed rail switch at the illustrated positions.
[J] SHIFT CABLE BRACKET INSTALLATION
1. Install the shift cable bracket loosely.
2. Put the control shaft into neutral.
3. Position the shift cable bracket so that the distance between the control shaft and shift cable bracket is within the standard value. Then fix the bracket securely.
Standard value: 154 - 156 mm (6.063 - 6.141 inch)
4. Install the select lever bracket loosely.
5. Put the select lever into the 3rd-4th speed position.
6. Position the select lever bracket so that the distance between the select lever and shift cable bracket is within the standard value. Then fix the bracket securely.
Standard value: 139.2 - 140.8 mm (5.481 - 5.543 inch)