Part 1
TRANSAXLE DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Lock Nuts For Input Shaft / Intermediate Gear Removal
1. Unstake lock nuts of the input shaft and intermediate gear.
2. Shift the transaxle in reverse using the control lever and select lever.
3. Install the special tool onto the input shaft.
4. Screw a bolt [10 mm (0.39 inch)] into the bolt hole on the periphery of clutch housing and attach a spinner handle to the special tool.
5. Remove the lock nut, while using the bolt as a spinner handle stopper.
Shift Rail Assembly Removal
1. Shift the 1st-2nd speed shift fork to the 2nd speed.
2. Shift the 3rd-4th speed shift fork to the 4th speed.
3. Remove the shift rail assembly as shown in the illustration so as not to hit the interlock plate and control finger.
1. Lift up the input shaft assembly and remove the intermediate gear assembly.
Reassembly Service Points
>A< Oil Seal For Drive Shaft Installation
>B< 0Il Seal For Input Shaft Front Installation
>C< Intermediate Gear Assembly / Input Shaft Assembly Installation
1. Lifting up the input shaft assembly, install it simultaneously with the intermediate gear assembly.
>D< Sealant Application To Bearing Retainer Mounting Bolt
Specified sealant: 3M STUD Locking No.4170 or equivalent
>E< Shift Rail Assembly Installation
1. Set the 1st-2nd speed shift sleeve at 2nd speed.
2. Set the 3rd-4th speed shift sleeve at 4th speed.
3. Install the shift forks to respective sleeves.
4. Insert the shift rail into the shift fork hole, while turning so as to prevent the shift lug from interfering with the stopper plate.
5. Turn the shift rail to engage shift lug.
>F< Spring Pins For 1st-2nd Speed Shift Fork / 3rd-4th Speed Shift Fork Installation
>G< Reverse Idler Gear Shaft Installation
1. Install in the direction as illustrated.
>H< Spacers Selection
1. Place solder with a length of approximately 10 mm (0.39 inch) and a diameter of approximately 1.6 mm (0.063 inch) in the spacer mounting position.
2. Install the transaxle case and then tighten the case mounting bolts to the specified torque.
3. Remove the case and then take out the solder. If the solder is not flattened, use solder with a larger diameter to carry out the operations in 1 and 2.
4. Measure the thickness of the flattened solder with a micrometer and select and install a spacer of thickness that gives standard end play and preload.
Standard value:
Input shaft, End play 0-0.05 mm (0-0.0020 inch)
Intermediate gear, Preload 0.05-0.10 mm (0.0020-0.0040 inch)
Output shaft, Preload 0.05-0.10 mm (0.0020-0.0040 inch)
Differential case, Preload 0.05-0.10 mm (0.0020-0.0040 inch)
>I< Oil Seal For Drive Shaft Installation
>J< Sealant Application To Transaxle Case
1. Squeeze out sealant from the tube uniformly without excess or discontinuity.
Specified sealant: Mitsubishi genuine sealant part No.MD997740 or equivalent
>K< Reverse Idler Gear Shaft Bolt Installation
1. Center the shaft with a Phillips screwdriver [shaft diameter 8 mm (0.31 inch)] or the like.
2. Tighten the reverse idler gear shaft bolt to specified torque.
>L< Lock Nuts For Input Shaft / Intermediate Gear Installation
1. Install the special tool onto the input shaft.
2. Screw a bolt [10 mm (0.39 inch)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
3. Shift the transaxle in reverse using control lever and select lever.
4. Tighten the lock nut to specified torque, while using the bolt attached in the above step as a spinner handle stopper.
5. Stake the lock nut.
>M< Spring Pin For OD-R Shift Fork Installation
>N< Sealant Application To Air Breather
Specified sealant: 3M SUPER WEATHERSTRIP No.8001 or equivalent
>O< Sealant Application To Machine Screw
Specified sealant: 3M STUD Locking No.4170 or equivalent
>P< Wave Spring Installation
1. Install the wave spring so that its both clasps come into contact with the rib end (A) of the reverse brake cone mounting section on the rear cover.
>Q< Sealant Application To Rear Cover
Specified sealant: Mitsubishi genuine sealant Part No.MD997740 or equivalent
5TH SPEED SYNCHRONIZER DISASSEMBLY AND REASSEMBLY
Reassembly Service Points
>A< Synchronizer Hub / Synchronizer Sleeve Installation
>B< Synchronizer Spring Installation
1. When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
5TH SPEED SYNCHRONIZER INSPECTION
Synchronizer Sleeve And Hub
1. Combine the synchronizer sleeve and hub and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub front end (surface in contact with the 5th speed gear).
CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.
Synchronizer Key And Spring
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.