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Home >> Mitsubishi >> 1990 >> Mirage L4-1468cc 1.5L SOHC >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Intermediate Shaft >> Service and Repair

Intermediate Shaft: Service and Repair




DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY

2. REMOVAL OF BALL BEARING - F5M21 / 5. 1ST SPEED GEAR




Use the special tool as illustrated.

CAUTION: Do not reuse the bearing removed from the shaft.

3. REMOVAL OF TAPER ROLLER BEARING - F5M22 / 5. 1ST SPEED GEAR




Use the special tool as illustrated.

CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.

11. REMOVAL OF 1ST-2ND SPEED SYNCHRONIZER HUB / 13. 2ND SPEED GEAR




Remove the 1st-2nd speed synchronizer assembly and 2nd speed gear together using the special tool as illustrated.

15. REMOVAL OF BALL BEARING - F5M21




Use the special tool as illustrated.

CAUTION: Do not reuse the bearing removed from the shaft.

16. REMOVAL OF TAPER ROLLER BEARING - F5M22




Use the special tool as illustrated.

CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.

INSPECTION
INTERMEDIATE GEAR




- Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear and seizure [portion (A)].
- Check the splines for damage and wear.

NEEDLE BEARING




- Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
- Check the needle bearing cage for deformation.

SYNCHRONIZER RING




- Check the clutch gear teeth for damage and breakage.
- Check the internal surface for damage, wear and broken threads.




- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace it it is out of specification.

Limit: 0.5 mm (0.02 in.)

SYNCHRONIZER SLEEVE AND HUB




- Combine the synchronizer sleeve and hub and check that they slide smoothly.
- Check that the sleeve is free from damage at its inside front and rear ends.
- Check for wear of the hub end surfaces (in contact with each speed gear).

CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING




- Check for wear of the synchronizer key center protrusion.
- Check the spring for weakness, deformation and breakage.

SPEED GEARS




- Check the bevel gear and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surface, damage and wear.
- Check the gear bore and front and rear ends for damage and wear.

SERVICE POINTS OF REASSEMBLY

16. INSTALLATION OF TAPER ROLLER BEARING - F5M22




Install the taper roller bearing over the intermediate shaft using the special tool as illustrated.

CAUTION: When installing the bearing, push the inner race only.

15. INSTALLATION OF BALL BEARING - F5M21




Install the bail bearing over the intermediate shaft using the special tool as illustrated.

12. 7. INSTALLATION OF SYNCHRONIZER RINGS




The 1st-2nd speed synchronizer rings have an identification mark.

11. INSTALLATION OF 1ST-2ND SPEED SYNCHRONIZER HUB / 10. SYNCHRONIZER KEY / 9. 1ST-2ND SPEED SYNCHRONIZER SLEEVE / 8. SYNCHRONIZER SPRING




1. Combine the 1st-2nd speed synchronizer hub and sleeve as illustrated.




2. Assemble the synchronizer spring so that its protrusion may be engaged in the groove of the synchronizer key.

NOTE: Take care to prevent the protrusions of the front and rear spring from sitting in the groove of the same key.




3. Install the 1st-2nd speed synchronizer assembly over the intermediate shaft using the special tools.

CAUTION:
1. When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring.
2. After installation of the synchronizer assembly, check that the 3rd speed gear rotates smoothly.

4. INSTALLATION OF BEARING SLEEVE




Install the 1st speed gear and bearing sleeve together using the special tool as illustrated.

3. INSTALLATION OF TAPER ROLLER BEARING - F5M22




Use the special tool as illustrated.

CAUTION: When installing the bearing, push the inner race only.

2. INSTALLATION OF BALL BEARING - F5M21




Use the special tool as illustrated.

1. INSTALLATION OF SNAP RING




Select and install a snap ring that will result in an intermediate gear bearing end play that is the standard value.

Standard value: 0.01 - 0.14 mm (0.0004 - 0.006 in.)
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