Transaxle Disassembly and Reassembly
DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Sealing Cap Removal
1. Tap a chisel or screwdriver into the center of the sealing cap. Do not tap it in deeper than necessary.
Next, push over the chisel or screwdriver to remove the cap.
CAUTION: Do not tap the chisel or screwdriver between the cap and case.
Transaxle Case Removal
Expand the snap ring to remove it from the snap ring groove of the ball bearing.
NOTE: Expanding the snap ring causes the snap ring groove to move out of position because of the output shaft's own weight.
Shift the 3rd-4th speed synchronizer sleeve toward the 4th speed side.
1. While sliding the reverse shift lug in the direction shown, remove the 5th speed shift fork, 5th speed shift rail, reverse shift lug, snap ring, steel ball and reverse interlock rail.
2. While sliding the 3rd-4th speed shift rail in the direction shown, remove it together with the shift fork.
1. Shift the 3rd-4th speed shift fork and 5th speed-reverse shift fork in the direction shown.
2. Slide the 3rd-4th speed shift rail and 5th speed-reverse shift rail in the direction shown and remove them together with the shift fork.
Remove the input and output shafts together.
ADJUSTMENT BEFORE REASSEMBLY
Spacer Selection For Differential Case Preload Adjustment
1. Put solders [about 10 mm (0.39 inch) long, 1.6 mm (0.063 inch) in diameter] in the illustrated positions of the transaxle case and install the bearing outer race and differential.
2. Install the clutch housing and tighten the bolts to the specified torque.
3. If the solders are not crushed, put larger diameter solders and repeat Steps 1 and 2.
4. Measure the thickness (T) of the crushed solder with a micrometer and select a spacer according to the following equation.
Spacer thickness: [T + 0.05 mm (0.0020 inch)] to [T + 0.11 mm (0.0043 inch)]
Reassembly Service Points
>A< Output Shaft/Input Shaft Installation
While placing the reverse brake cone detent in the position shown, install the input and output shafts together.
>B< Output Shaft/Input Shaft Installation
Install the input and output shafts together.
>C< Front Bearing Retainer Installation
Apply a sealant to the front bearing retainer mounting bolts (countersunk bolts only).
Specified sealant: 3M TM AAD Part No.8730 or 8731 or equivalent
>D< Reverse Interlock Rail/Steel Ball/5th Speed Shift Rail/Reverse Shift Lug/Snap Ring/5th Speed Shift Fork/3rd-4th Speed Shift Fork/3rd-4th Speed Shift Rail Installation
1. Install the 3rd-4th shift rail and fork.
2. Install the reverse interlock rail, steel ball, 5th speed shift rail, 5th speed shift fork, reverse shift lug and snap ring in the illustrated positions.
3. While sliding the reverse shift lug in the direction shown, install the 5th speed shift fork, 5th speed shift rail, reverse shift lug, snap ring, steel ball and reverse interlock rail.
>E< 5th Speed-Reverse Shift Fork/5th Speed-Reverse Shift Rail/3rd-4th Speed Shift Fork/3rd-4th Speed Shift Rail Installation
1. Shift the 3rd-4th speed synchronizer sleeve and 5th speed-reverse synchronizer sleeve in the direction shown.
2. Install the 3rd-4th speed shift rail and fork and the 5th speed-reverse shift rail and fork.
3. While fitting each shift fork in the sleeve, slide the shift rails in the direction shown and install.
>F< Spring Pin Installation
>G< Spacer Installation
Install the spacer selected in the section "ADJUSTMENT BEFORE REASSEMBLY."
>H< Oil Guide Installation
>I< Reverse Idler Gear Shaft Installation
1. Shift the 3rd-4th speed synchronizer sleeve toward the 4th speed side.
2. Face the threaded hole of the reverse idler gear shaft toward the direction shown.
>J< Outer Race Installation
>K< Transaxle Case Installation
1. Apply sealant to the mating surface of the transaxle case. Be sure to install the transaxle within 15 minutes after applying sealant.
Specified sealant: MITSUBISHI genuine sealant part No.MD997740 or equivalent
CAUTION: Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
2. Install the transaxle case and expand the snap ring.
3. Tighten the transaxle case mounting bolts to the specified torque.
NOTE: Place the transaxle upside down and let the snap ring fit in the groove by taking advantage of the output shaft's own weight.
4. After installation, wait at least one hour. Never run the transaxle or let transmission oil touch the adhesion surface during that time.
>L< Sealing Cap Installation
Press-fit the new sealing cap all the way up to the illustrated position.
>M< Reverse Idler Gear Shaft Bolt Installation
Using a Phillips screwdriver [8 mm (0.31 inch) in shank diameter] center the bolt hole.
>N< Under Cover Installation
1. Apply the sealant to the mating surface of the transaxle case. Be sure to install the under cover within 15 minutes after applying sealant.
Specified sealant: MITSUBISHI genuine sealant part No.MD997740 or equivalent
CAUTION: Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
2. After installation, wait at least one hour. Never run the transaxle or let transmission oil touch the adhesion surface during that time.
>O< Control Housing Installation
1. Apply sealant to the mating surface of the transaxle case. Be sure to install the control housing within 15 minutes after applying sealant.
Specified sealant: MITSUBISHI genuine sealant part No.MD997740 or equivalent
CAUTION: Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
2. After installation, wait at least one hour. Never run the transaxle or let transmission oil touch the adhesion surface during that time.
>P< Speedometer Gear Installation
Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil: Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4
>Q< Select Lever Installation
Apply grease to the control shaft sliding portion of the select lever shoe.
Specified grease: MITSUBISHI genuine grease part No.0101011 or equivalent
INSPECTION
Back-Up Light Switch
Check for continuity between terminals.