M/T - KM200 Input Shaft Changed
89Mitsubishi07SUBJECT: KM200 SERIES MODIFIED INPUT SHAFT
NO. TSB-89-22-003
DATE September, 1989
MODEL Mirage, Galant, Sigma
PURPOSE
In order to assure torque retention of the input shaft lock nut, a snap ring was added to the input shaft of the KM200 (F5M) series transaxles. This change affects several components on the input shaft assembly, as well as part of the repair procedure.
Affected Transaxles and Applications KM201 (F5M21), KM206 (F5M22), KM210 (F5M31).
Transmission Model Year Engine Size
KM201 (F5M21) Mirage 1987, 1988 1.5L
Mirage 4-Dr. 1989 1.5L
KM206 (F5M22) Galant, Galant GS 1989 2.0L DOHC
Mirage Turbo 1987, 1988 1.6L
KM210 (F5M31) Galant 1985, 1986, 1987 2.4L
Mirage Turbo 2-Dr 1989 1.6L
Sigma V-6 1988, 1989 3.0L
PARTS DESCRIPTION
The new input shaft has a groove added for the snap ring.
INTERCHANGEABILITY
Input shaft, spacer, and snap ring are interchangeable only when replaced as a set.
POINTS OF ASSEMBLY
Refer to these instructions when assembling an input shaft that has a snap ring groove.
SELECTION OF SNAP RING.
Specification Clearance between installed snap ring and bearing:
0 - 0.09 mm (0 - 0.0035 in.)
PROCEDURE
Select the thickest snap ring that will fit in the snap ring groove. After installing the snap ring, attempt to slide a 0.09 mm (0.0035 in.) feeler gauge between the snap ring and the bearing. The correct snap ring will not allow the feeler gauge to enter. If the feeler gauge enters, select a thicker snap ring and recheck using the feeler gauge.
SNAP RING INSTALLATION
INSTALLATION OF SNAP RING IN THE KM201 AND KM206 TRANSAXLE.
Use snap ring pliers to install the new snap ring onto the input shaft.
Caution:
Do not reuse the old snap ring.
INSTALLATION OF SNAP RING IN THE KM210 TRANSAXLE.
Use Special Tool Set MD998808-01 to install the snap ring over the end of the shaft as shown.
Caution:
Do not reuse the old snap ring.
Installation of 5th speed gear sleeve.
Using Special Tool MD998320, press the 5th speed gear sleeve on the input shaft. When installed, make sure that the sleeve flange fits close to the bearing. Confirm that the sleeve is not caught on an improperly installed snap ring.