Transaxle Disassembly and Assembly

DISASSEMBLY AND ASSEMBLY

- MB992221: Puller set

- MD998802: Input shaft Holder

- MB990801: Rear axle bearing outer race puller

- MB992038: Preload socket

- MB992219: Output shaft adapter

- MB992216: Installer

- MB992220: Input shaft adapter

- MB992212: Oil seal installer

- MB992075: Handle

- MB992000: Crankshaft adapter

DISASSEMBLY SERVICE POINTS

[[A]] SELECTING BELL CRANK ASSEMBLY AND CONTROL BELL CRANK DUST COVER REMOVAL

Remove the fixing nuts shown, then separate the control shift lever from the selecting bell crank assembly and control bell crank dust cover.

[[B]] SYNCHRONIZER HUB NO.3 REMOVAL

Using special tool MB992221, remove the synchronizer hub No.3.

[[C]] 5TH DRIVE GEAR MOUNTING LOCK NUT REMOVAL

1. Using special tool MD998802, lock the input shaft.

2. Remove the 5th drive gear mounting lock nut from output shaft assembly.

[[D]] 5TH DRIVE GEAR REMOVAL

Using special tool MB990801, remove the 5th drive gear.

ADJUSTMENT BEFORE ASSEMBLY

DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT

1. Set the differential assembly to the clutch housing case assembly.

2. Push and fit the tapered roller bearing outer race by hand.
3. To fit the tapered roller bearing outer race, rotate the differential assembly by hand about 10 times.

4. Put the clutch housing case assembly on the surface table and use a height gauge to measure the dimension "A" which is from the mating surface of the clutch housing case assembly to the end surface of the tapered roller bearing outer race.

8. Using special tool MB992038, measure the rotational starting torque of differential case.
When it is not within the standard range, reselect the shim.
Standard value: 0.8 - 1.6 Nm (7.08 - 14.16 in-lb)

OUTPUT SHAFT ASSEMBLY BEARING PRELOAD ADJUSTMENT

1. Set the output shaft assembly to the clutch housing case assembly.

2. Push and fit the tapered roller bearing outer race by hand.
3. To fit the tapered roller bearing outer race, rotate the output shaft assembly by hand.

4. Put the clutch housing case assembly on the surface table and measure the dimension "A"
which is from the mating surface of the clutch housing case assembly to the end surface of the bearing outer race, with a height gauge.

5. Put the straight edge on the mating surface of the transaxle case assembly and measure the dimension "B" with a vernier caliper.
6. Select the shim whose dimension is the difference between "B" and "A."
7. Install the output shaft assembly and differential assembly to the clutch housing case assembly. Tighten the transaxle case bolts to the specified torque.
Tightening torque: 29.0 ± 5.8 Nm (21 ± 3 ft-lb)
8. Place the selected shim, then install the output shaft assembly.
9. Install the rear bearing retainer to specified torque.
Tightening torque: 42.0 ± 8.4 Nm (31 ± 5 ft-lb)

10. Install the 5th gear mounting lock nut to measure rotational starting torque.

11. Measure the rotational starting torque of output shaft. When it is not within the standard range, reselect the shim.
Standard value: 0.8 - 1.6 Nm (7.08 - 14.16 in-lb)

ASSEMBLY SERVICE POINTS

]]A[[ REVERSE IDLER GEAR, REVERSE IDLER THRUST WASHER AND REVERSE IDLER SHAFT INSTALLATION

1. Install the reverse idler gear, reverse idler thrust washer and reverse idler shaft.
2. Before installing the transaxle case assembly, confirm that the reverse idler gear addition mark is positioned as show in the illustration.

]]B[[ GEAR SHIFT FORK ASSEMBLY NO.1 AND GEAR SHIFT FORK SHAFT NO.1 INSTALLATION

1. Fit the shaft snap ring onto the gear shaft fork shaft No. 1.

2. Bring up the notch in the gear shift fork shaft No. 3 to the reverse shift fork into neutral position, and move the roller in the reverse shift fork to the gear shift fork shaft No 3 side.

3. Pass the gear shift fork shaft No. 1 through the gear shift fork assembly No. 1 and reverse shift fork in that order, then install it to the clutch housing case assembly.

]]C[[ REVERSE SHIFT ARM BRACKET ASSEMBLY INSTALLATION

Fit the arm tip of the reverse shift fork into the mating slot in the reverse shift arm bracket assembly.

]]D[[ TRANSAXLE CASE ASSEMBLY 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 1.2 mm (0.05 inch) diameter bead of sealant as illustrated onto the transaxle case assembly.
Specified sealant: Mitsubishi Part No. MD974421 or equivalent

]]E[[ 5TH DRIVE GEAR INSTALLATION

1. Install special tool MB992219 until it hits the end face of the output shaft.

2. Install the 5th drive gear.

3. Set special tool MB992216 on top of the 5th drive gear.

4. Install the center bolt that is included in the set of special tool MB992216 as shown.

5. Press-fit the 5th drive gear as shown.

]]F[[ 5TH DRIVE GEAR MOUNTING LOCK NUT INSTALLATION

1. Using special tool MD998802, lock the input shaft.

2. Install the 5th drive gear mounting lock nut from output shaft assembly.
3. Tighten the 5th drive gear mounting lock nut to the specified torque.
Tightening torque: 123 ± 36.9 Nm (91 ± 26 ft-lb)
4. Stake the 5th gear mounting lock nut.

]]G[[ SYNCHRONIZER RING ASSEMBLY / SYNCHROMESH SHIFTING KEY SPRING NO.3 (A) / SYNCHROMESH SHIFTING KEY SPRING NO.3 (B) AND SYNCHRONIZER HUB NO.3 INSTALLATION

1. Install the synchromesh shifting key springs No. 3 onto the synchronizer ring assembly holding the claws and rotation stops of the key springs in the illustrated positions.

2. Make sure that the rotation stops of the synchromesh shifting key springs No. 3 fit into the mating holes in the synchronizer ring assembly.

3. Compress the key springs into place inside the hub as shown.

4. Install special tool MB992220 until it hits the end face of the input shaft.

5. Set special tool MB992216 on top of the synchronizer hub No. 3.

6. Install the center bolt that is a part of the set of special tool MB992216 as shown.

7. Press-fit the synchronizer hub No. 3 as shown.

]]H[[ SHAFT SNAP RING INSTALLATION

Select a shaft snap ring that allows distance of the thrust crevice of synchronizer hub No.3 to fall within the standard value range.
Standard value: 0 - 0.1 mm (0 - 0.004 in.)
NOTE:
Try on snap rings in the decreasing order of thickness, and install the first one that fits into the hub.

]]I[[ SYNCHRONIZER SLEEVE NO.3 INSTALLATION

Put the synchronizer sleeve No. 3 and gear shaft fork assembly No. 3 together, then install the synchronizer sleeve No. 3 in the illustrated direction.

]]J[[ TRANSAXLE CASE COVER SUB ASSEMBLY 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 1.2 mm (0.05 inch) diameter bead of sealant as illustrated onto the transaxle case cover sub assembly.
Specified sealant: Mitsubishi Part No. MD974421 or equivalent

]]K[[ OIL SEAL INSTALLATION

1. Using special tool MB992212 and MB992075, install the oil seal.
2. Pack grease to the oil seal lip area.
Specified grease: Mitsubishi Part No. 0101011 or equivalent

]]L[[ CONTROL SHIFT RETAINER GASKET INSTALLATION

Install the control shift retainer gasket to the control shaft cover with the projection of the gasket in the illustrated position.

]]M[[ PLUG INSTALLATION

Using special tool MB992000, install the plug.