Part 1 of 2
MANUAL TRANSAXLE DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - INPUT SHAFT/INTERMEDIATE GEAR LOCK NUTS REMOVAL
1. Unstake look 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 (0.4 in.) 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.
B - 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 so as not to hit the interlock plate and control finger.
C - INTERMEDIATE GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY REMOVAL
1. Lift up the input shaft assembly and remove the intermediate gear assembly.
REASSEMBLY SERVICE POINTS
A - DRIVE SHAFT OIL SEAL INSTALLATION
B - INPUT SHAFT FRONT OIL SEAL 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 - 1ST-2ND SPEED SHIFT FORK/3RD-4TH SPEED SHIFT FORK SPRING PINS 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 (0.4 in.) and a diameter of approximately 1.6 mm (0.06 in.) in the spacer mounting position.
2. Tighten the case mounting bolt to the specified torque.
3. Remove the case and then take out the solder. If the solder is not broken, use solder with a larger diameter to carry out the operations in 1 and 2.
4. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play and preload.
Standard value:
Intermediate gear
End play: 0.05-0.17 mm (0.002-0.007 in.)
Output shaft
Preload: 0.05-0.10 mm (0.002-0.004 in.)
Differential case
End play: 0.05-0.17 mm (0.002-0.007 in.)
I - DRIVE SHAFT OIL SEAL INSTALLATION
J - SEALANT APPLICATION TO TRANSAXLE CASE
1. Squeeze out 3M SUPER WEATHERSTRIP No.8001 or equivalent sealant from the tube uniformly without excess or discontinuity.
K - REVERSE IDLER GEAR SHAFT BOLT INSTALLATION
1. Center the shaft with a phillips screwdriver with a shaft diameter of 8mm (0.32 in.) or equivalent.
2. Tighten the reverse idler gear shaft bolt to specification.
L - SNAP RING INSTALLATION
1. Select the thickest snap ring that will fit into the snap ring groove.
M - INPUT SHAFT/INTERMEDIATE GEAR LOCK NUTS INSTALLATION
1. Install the special tool onto the input shaft.
2. Screw a bolt 10mm (0.4 in.) into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
3. Shift the transaxle into reverse using the control lever and select lever.
4. Tighten the lock nut to specification, while using the bolt attached in step 2 as a spinner handle stopper.
5. Stake the lock nut.
N - OD-R SHIFT FORK SPRING PIN INSTALLATION
O - SEALANT APPLICATION TO AIR BREATHER
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or equivalent
P - SEALANT APPLICATION TO REAR COVER
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740 or equivalent
Q - SEALANT APPLICATION TO MACHINE SCREW
Specified sealant:
3M STUD Locking No.4170 or equivalent
SYNCHRONIZER SLEEVE AND HUB DISASSEMBLY AND REASSEMBLY
INSPECTION
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.
REASSEMBLY SERVICE POINTS
A - SYNCHRONIZER HUB/SYNCHRONIZER KEY/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.
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - FRONT BALL BEARING/FRONT TAPER ROLLER BEARING REMOVAL
B - 5th SPEED GEAR BEARING SLEEVE REMOVAL
C - 4TH SPEED GEAR/3RD SPEED GEAR REMOVAL
D - REAR BALL BEARING TAPER ROLLER BEARING/3RD SPEED GEAR REMOVAL
INSPECTION
INPUT SHAFT
1. Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
2. Check the splines for damage and wear.
NEEDLE BEARING
1. Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.
3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.
Limit: 0.5 mm (0.02 in.)
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 end surfaces (in contact with each 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.
SPEED GEARS
1. Check the synchronizer cone for rough surface, damage and wear.
2. Check the gear bore and front and rear ends for damage and wear.
REASSEMBLY SERVICE POINTS
A - 3RD-4TH SPEED SYNCHRONIZER HUB/3RD-4TH SPEED SYNCHRONIZER SLEEVE INSTALLATION
B - SYNCHRONIZER SPRING/SYNCHRONIZER KEY INSTALLATION
1. When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
C - 4TH SPEED GEAR BEARING SLEEVE INSTALLATION
D - SPACER INSTALLATION
1. Install with the side having the identification mark "1" on the 4th speed gear side. Spacers without identification mark may be installed in either direction.
E - REAR BEARING INNER RING INSTALLATION
F - REAR BALL BEARING INSTALLATION
G - SNAP RING INSTALLATION
1. Select the thickest snap ring that can be fitted in the snap ring groove. Input shaft rear bearing end play: 0.01-0.09 mm (0.0004 - 0.0035 in.)
CAUTION: Do not reuse the snap ring. The snap ring may be opened too wide by pliers, resulting in improper installation of the sleeve.
H - 5TH SPEED GEAR BEARING SLEEVE INSTALLATION
CAUTION: When press-fitting the sleeve to the input shaft, make sure that the sleeve flange is closely fitted to the bearing.
I - FRONT BALL BEARING/FRONT TAPER ROLLER BEARING INSTALLATION
J - SNAP RING INSTALLATION
1. Snap rings are available in three different thicknesses. Select the thickest one that fits in the snap ring groove.
Input shaft front bearing end play: 0.01-0.12 mm (0.0004-0.0047 in.)
CAUTION: Do not damage the input shaft oil seal contacting portion.