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MANUAL TRANSMISSION (E-W) -

Output Shaft

22A-4-5

PWEE9508

May 1995

Mitsubishi Motors Corporation

BEARING CUP/OUTPUT SHAFT REMOVAL

(1) Place the output shaft on a soft surface.

(2) Tap the bearing cup partway off the output shaft with

a chisel.

(3) Locate the bearing remover MD998801 behind the bearing

cup.

(4) Press the output shaft out of the bearing cup.

PREPARATION BEFORE REASSEMBLY

<F5MR3>

BEARING BUSHES INSTALLATION

(1) Place the three bearing bushings on a hot plate.

(2) Heat the bearing bushings to 150

C maximum.

REASSEMBLY SERVICE POINTS

1ST GEAR WHEEL INSTALLATION

Locate the gear wheel together with the synchronizer ring

on the shaft.

SYNCHRONIZER SPRINGS INSTALLATION

(1) Place the hub on a workbench.

(2) Position the two synchronizer springs so that the wider

sections engage the recesses in the hub.

(3) Locate the synchronizer sleeve on the hub.

NOTE

Take special note of the engaging sleeve lugs.

OUTPUT SHAFT BEARING CUP INSTALLATION

(1) Place the output shaft under a press and support the

1st gear wheel.

(2) Press the bearing cup on to the output shaft with bearing

drift MB996013.

RMT0028

MD998801

Added

PWEE9508-B

Mitsubishi Motors Corporation

May 1996

RMT0029

RMT0030

MB996013

RMT0031

Summary of Contents for F5MR1

Page 1: ...NTS 22A 1 2 SEALANTS AND ADHESIVES 22A 1 2 2 SPECIAL TOOLS 22A 2 1 3 TRANSMISSION 22A 3 1 4 OUTPUT SHAFT 22A 4 1 5 DIFFERENTIAL 22A 5 1 6 CLUTCH HOUSING 22A 6 1 7 CONTROL LEVER 22A 7 1 8 INPUT SHAFT 2...

Page 2: ...22A 0 2 PWEE9508 E May 1995 Mitsubishi Motors Corporation NOTES...

Page 3: ...Input shaft bearing 4 Transmission case 5 Input shaft bearing 6 Rear cover 7 5th speed gear 8 5th speed synchronizer assembly 9 5th gear wheel 10 Output shaft 11 Output shaft bearing 12 4th speed gear...

Page 4: ...Guide bushing 4 Input shaft bearing 5 Transmission case 6 Input shaft bearing 7 Rear cover 8 5th speed gear 9 5th speed synchronizer assembly 10 5th gear wheel 11 Output shaft 12 Output shaft bearing...

Page 5: ...727 2nd 2 047 2 047 2 047 3rd 1 321 1 321 1 321 4th 0 966 0 966 0 971 5th 0 794 0 794 0 756 Reverse 3 545 3 545 3 545 Final reduction ratio 4 066 4 214 3 437 TORQUE SPECIFICATIONS Items Specifications...

Page 6: ...Lithium MoS2 Speedometer driven gear As required Multi purpose grease Differential side gear As required Multi purpose grease Differential pinion gear As required Multi purpose grease Differential pi...

Page 7: ...0930 Installer Removing small differential bearing F5MR1 F5MR2 MB990931 Installer Fitting output shaft bearing MB990932 Installer Fitting input and output shaft rear bearings MB990933 Installer Fittin...

Page 8: ...t Fitting large and small bearing cups F5MR3 MB996005 Counterhold Removing and installing differential gear F5MR3 MB996006 Bracket Removing output shaft front bearing MB996007 Bearing bush drift Fitti...

Page 9: ...019 Spring pin extractor Removing spring pins MD998020 Bearing puller Removing 5th gear synchronizer hub MD998245 Spring pin installer Installation of spring pin and lock pin MD998348 Bearing and gear...

Page 10: ...y 1996 Mitsubishi Motors Corporation Revised Tool Use Name Number MD998813 Installer 100 Fitting 4th gear wheel bearing bush F5MR3 MD998819 Installer adapter 40 Fitting 4th gear wheel bearing bush F5M...

Page 11: ...amp switch 2 Drain plug 3 Gasket 4 Filler plug 5 Gasket AA YA 6 Bolt AA YA 7 Rear cover AA YA 8 O ring AB WA 9 Bolt AB WA 10 Shim AB WA 11 Lock nut AC XA 12 Spring pin AC VA 13 5th speed shift fork AC...

Page 12: ...ll AI PA 30 Magnet AI NA 31 5th gear shift rail assembly AJ JA 32 Spring pin AJ JA 33 1st and 2nd shift rail assembly AK KA 34 Reverse idler gear shaft AL JA 35 Spring pin AL HA 36 3rd and 4th shift r...

Page 13: ...itch 2 Drain plug 3 Gasket 4 Filler plug 5 Gasket AA YA 6 Bolt AA YA 7 Rear cover AA YA 8 O ring AB WA 9 Bolt AB WA 10 Shim AB WA 11 Lock nut AC XA 12 Spring pin AC VA 13 5th speed shift fork AC VA 14...

Page 14: ...QA 29 Poppet ball AI PA 30 Magnet AI NA 31 5th gear shift rail assembly AJ 32 Spring pin AJ 33 1st 2nd gear shift rail assembly AK LA 34 Reverse idler gear shaft 35 Spring pin OA 36 3rd 4th gear shif...

Page 15: ...ZER SLEEVE REMOVAL 1 Support the shift rail assembly and remove the spring pin with spring pin extractor MD998019 2 Tap the 5th speed shaft fork 4 together with the synchronizer 5 off the shift rail a...

Page 16: ...olts 2 Tap lightly to separate the transmission case and clutch housing 3 Remove the transmission case note the shim on the output shaft NOTE When removing the transmission case hold the poppet spring...

Page 17: ...ssible and remove the shift rail assembly 10 AK REVERSE IDLER GEAR SHAFT REMOVAL 1 Raise the input and output shafts 2 Take the reverse idler gear shaft out of the clutch housing NOTE Hold the output...

Page 18: ...rail assembly out of the clutch housing 3 Inspect the input shaft NOTE The shaft must always be renewed in the event of wear or damage The shaft cannot be reconditioned AM INPUT SHAFT OUTPUT SHAFT REM...

Page 19: ...ift rail assembly AO PLASTIC COVER REMOVAL Remove the plastic cover from the release fork ball and socket joint AP BREATHER UNIT BREATHER HOSE REMOVAL Take the breather unit out of the transmission ca...

Page 20: ...and the output shaft in the clutch housing 2 Place the transmission case on the clutch housing insert a few retaining bolts around the shafts and tighten the bolts 3 Locate the mounting plate MB996012...

Page 21: ...ing faces in the transmission case with the specified sealant 2 Locate the two snap rings 1 3 Introduce the bearings from the outside of the transmission case with the groove facing up 4 Open the snap...

Page 22: ...REATHER HOSE BREATHER UNIT INSTALLATION Push the breather hose into the transmission case Fit the breather unit EA PLASTIC COVER INSTALLATION 1 Thoroughly clean the ball and socket joint 2 Apply Locti...

Page 23: ...tch housing NOTE When fitting the input shaft take care not to damage the oil seal IA INPUT SHAFT INSTALLATION NOTE When fitting the input shaft take care not to damage the oil seal JA 1ST AND 2ND SHI...

Page 24: ...nizer sleeve 4 Locate the two shafts in the clutch housing NA 5TH GEAR SHIFT RAIL ASSEMBLY INSTALLATION 1 Locate the shift rail assembly 9 2 Fit the poppet spring and ball 3 Depress the ball and raise...

Page 25: ...case over the shafts 3 Locate the balls and poppet springs for the 1st 2nd 3rd and 4th gear shift rail assemblies using two hex nut drivers 4 Now press the transmission case on to the mating face inse...

Page 26: ...mm SA LOCATING PIN INSTALLATION 1 Apply sealant Loctite 572 to the locating pin 2 Fit and tighten the locating pin TA RETAINING RING BEARING SLEEVE 5TH SPEED GEAR SYNCHRONIZER RING INSTALLATION 1 Loc...

Page 27: ...rail assembly 5 Press the hub on to the input shaft with the old lock nut 6 Remove the lock nut WA LOCK NUT SHIM BOLT INSTALLATION 1 Press the synchronizer hub into 5th gear 2 Push down the reverse id...

Page 28: ...16 PWEE9508 E May 1995 Mitsubishi Motors Corporation ZA BACK UP LAMP SWITCH INSTALLATION 1 Apply sealant Loctite 572 to the back up lamp switch 2 Fit and tighten the back up lamp switch Added PWEE9508...

Page 29: ...izer ring 4 3rd 4th synchronizer sleeve AG 5 Synchronizer springs AG 6 Rollers AB KA 7 3rd 4th synchronizer hub 8 Snap ring 9 Serrated ring 10 Synchronizer ring AC IA 11 3rd gear wheel 12 Serrated rin...

Page 30: ...wheel 4 Synchronizer ring AH MA 5 Bearing bushing 6 3rd 4th gear synchronizer sleeve AI 7 Synchronizer spring 8 Roller LA 9 3rd 4th gear synchronizer hub AH JA 10 3rd gear wheel AH HA 11 Bearing bush...

Page 31: ...Take the hub together with the synchronizer sleeve off the shaft AC 3RD GEAR WHEEL REMOVAL 1 Remove the snap ring 2 2 Take the blocker ring 3 together with the gear wheel and synchronizer ring off th...

Page 32: ...nchronizer sleeve 2 Remove the rollers 10 and springs 11 NOTE Make sure that no parts are lost AH OUTPUT SHAFT FROM GEAR WHEELS REMOVAL 1 Place the output shaft under a press and support the 1st gear...

Page 33: ...C maximum REASSEMBLY SERVICE POINTS AA 1ST GEAR WHEEL INSTALLATION Locate the gear wheel together with the synchronizer ring on the shaft BA SYNCHRONIZER SPRINGS INSTALLATION 1 Place the hub on a work...

Page 34: ...ARING BUSH INSTALLATION 1 Locate the bearing bush so that the oil passages of the bearing bush and the output shaft are opposed 2 Place the heated bearing bush using a pair of gripping pliers over the...

Page 35: ...g towards the gear wheel 2 Locate the gear wheel together with the synchronizer ring on the shaft 3 Locate the serrated ring 2 thickness 1 5 mm with the bevelled edge facing towards the gear wheel 4 F...

Page 36: ...l passages of the bearing bush and the output shaft are opposed 2 Place the heated bearing bush using a pair of gripping pliers over the output shaft on the synchronizer hub NOTE Allow the bearing bus...

Page 37: ...E Make sure that the lugs of the synchronizer ring engage the recesses in the synchronizer sleeve OA4TH GEAR WHEEL INSTALLATION 1 Locate the synchronizer ring 2 Locate the gear wheel on the bearing bu...

Page 38: ...MANUAL TRANSMISSION E W Output Shaft 22A 4 10 PWEE9508 E May 1995 Mitsubishi Motors Corporation NOTES PWEE9508 B Mitsubishi Motors Corporation May 1996 E...

Page 39: ...l during reassembly 3 5 1 7 11 8 13 16 6 10 9 15 12 14 2 4 Disassembly steps 1 O ring AA HA 2 Oil seal AB GA 3 Snap ring AD EA 4 Speedometer drive gear AD EA 5 Spring ring AD EA 6 Guard ring 7 Differe...

Page 40: ...0042 Lubricate all internal parts with gear oil during reassembly Disassembly steps 1 O ring AA HA 2 Oil seal AC FA 3 Nut 4 Guard ring AE DA 5 Speedometer drive gear 6 Differential case 7 Snap ring 8...

Page 41: ...ing NOTE The open side of the bearing must be facing inwards 4 Support the clutch housing and press cut the differential assembly out AC DIFFERENTIAL GEAR ASSEMBLY REMOVAL 1 Lock the differential gear...

Page 42: ...GEAR REMOVAL 1 Remove the spring pin with spring pin extractor MD998019 2 Take out the shaft 4 together with the bush 5 3 Remove the pinion gears 6 together with the thrust washers AH SIDE GEAR REMOV...

Page 43: ...N 1 Locate the speedometer drive gear with the locking lug in the recess in the differential 2 Place the guard ring on the differential 3 Place the spring ring on the differential EA SPEEDOMETER DRIVE...

Page 44: ...Locate the differential in the clutch housing 2 Place the clutch housing under a press and support the differential 3 Using special tool MB996010 press the housing downwards until it abuts against th...

Page 45: ...MBLY F5MR1 F5MR2 4 6 5 7 3 2 1 8 Lubricate all internal parts with gear oil during reassembly Disassembly steps AA GA 1 Input shaft bearing AC EA 2 Output shaft bearing 3 Oil baffle AE DA 4 Large bear...

Page 46: ...3 4 6 5 7 3 2 1 RMT0046 Lubricate all internal parts with gear oil during reassembly Disassembly steps AB HA 1 Input shaft bearing cup AD FA 2 Output shaft bearing 3 Oil baffle AC BA 4 Large bearing c...

Page 47: ...with a punch 2 Locate puller MB996001 in the bearing and position bracket MB996006 between the jaws 3 Pull the bearing out of the housing 4 Remove the oil baffle 1 NOTE Remove all traces of the stakin...

Page 48: ...BEARING CUP REMOVAL 1 Remove the bearing cup with handle MB990938 and installer MB990932 2 In the case of a new clutch housing transfer the following parts threaded ends fitted dowels REASSEMBLY SERVI...

Page 49: ...EARING INSTALLATION 1 Fit the oil baffle 1 2 Coat the mating face with the specified sealant 3 Tap in the bearing with handle MB990938 and installer MB990931 4 Stake the lock washers upset about 1 mm...

Page 50: ...995 Mitsubishi Motors Corporation HA INPUT SHAFT BEARING CUP INSTALLATION 1 Coat the mating face with the specified sealant 2 Press the bearing cup against the stop with installer MB996011 Added PWEE9...

Page 51: ...2 9 5 13 7 8 3 Lubricate all internal parts with gear oil during reassembly Disassembly steps 1 Compression spring 2 Snap ring AA CA 3 Remote control arm 4 Spring pin 5 Spring pin AA CA 6 Selector do...

Page 52: ...shift lever AB BEARING BUSHES REMOVAL Tap out the two bearing bushes with 14 mm Hex socket REASSEMBLY SERVICE POINTS AA BEARING BUSHES INSTALLATION 1 Coat the mating faces of the housing with the spec...

Page 53: ...and socket joints and shift rail assembly shaft with grease 2 Fit the rubber seal 8 on the shift lever 3 Fit the rubber seal on the shift rail assembly 4 Locate the selector dog 5 and insert the remot...

Page 54: ...m AB AA 3 Bearing DISASSEMBLY SERVICE POINTS AA INPUT SHAFT BEARINGS TRANSMISSION CASE END REMOVAL Remove the bearing and the shim AB INPUT SHAFT BEARING CLUTCH HOUSING END REMOVAL 1 Place the input s...

Page 55: ...e bearing on the input shaft 2 Tap the bearing with a drift until it abuts against the stop on the input shaft BA INPUT SHAFT BEARING TRANSMISSION CASE END INSTALLATION 1 Fit the shim NOTE In the case...

Page 56: ...PWEE9508 E May 1995 Mitsubishi Motors Corporation NOTES...

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