DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. Control cable bracket 2. Speed sensor <Without ABS> 3. Wiring harness clamp <<A>> >>G<< 4. Back up lamp switch 5. Drain plug 6. Gasket 7. Drain plug 8. Gasket 9. Control bell crank dust cover 10. Selecting bell crank assembly

Disassembly steps 11. Rock ball assembly <<B>> >>F<< 12. Shaft and select lever shaft assembly 13. Compression spring <<C>> >>E<< 14. Flange bolt 15. Gasket <<D>> >>D<< 16. Transmission case 17. Reverse shaft arm bracket assembly >>C<< 18. Reverse idler gear shaft 19. Reverse idler gear sub-assembly

Disassembly steps <<E>> 20. Gear shift fork No.1 21. Slotted spring pin 22. Gear shift head No.1 23. Shaft snap ring 24. Gear shift fork shaft No.1 >>B<< 25. Straight pin 26. Shaft snap ring >>B<< 27. Slotted spring pin 28. Gear shift head No.3 >>B<< 29. Shaft snap ring 30. Compression spring >>B<< 31. Straight pin 32. Gear shift fork No.3 33. Gear shift fork shaft No.3 >>B<< 34. Shaft snap ring 35. Reverse shift fork >>B<< 36. Shaft snap ring 37. Gear shift fork No.2 38. Gear shift fork shaft No.2 <<E>> >>A<< 39. Input shaft assembly <<E>> >>A<< 40. Output shaft assembly 41. Differential assembly 42. Clutch housing case assembly

1.Using the special tool, detonation sensor wrench (MD998773), remove the inner race of back up lamp switch from the transmission case.

1.Using the remove the rock ball assembly.

2.Using the remove the rock ball assembly.

1.Reverse idler gear shaft installation flange bolt is removed.

1.Using the tyre-lever large remove the transmission case.

2.Push and fit the tapered roller bearing outer race by hand. 3.To fit the tapered roller bearing outer race, rotate the differential assembly by hand about 10 times.

4.Put the clutch housing assembly on the surface table and use a height gauge to measure the dimension "A" which is from the mating surface of the clutch housing assembly to the end surface of the tapered roller bearing outer race.

5.Put the straight edge on the mating surface of the transmission case assembly and measure the dimension "B" with a vernier caliper. 6.Select the shim whose dimension is the difference between "B" and "A."

7.Insert a wedge between the side gear and the pinion shaft to lock the side gear. 8.Install the differential assembly to the clutch housing assembly. Tighten the transmission case bolts to the specified torque of 30 ± 5 N·m.

9.Using special tool Side gear holding tool (MB991144), measure the rotational starting torque of differential case. When it is not within the standard range, reselect the shim. Standard value: Used part: 0.5 - 1.0 N·m New part: 0.8 - 1.6 N·m

2.Push and fit the tapered roller bearing outer race by hand. 3.To fit the tapered roller bearing outer race, rotate the output shaft assembly by hand. 4.Put the clutch housing assembly on the surface table. 5.Install the output shaft assembly and differential assembly to the clutch housing assembly. Tighten the transmission case bolts to the specified torque of 30 ± 5 N·m. 6.Place the selected shim, then install the output shaft assembly.

7.Measure the rotational starting torque of output shaft. When it is not within the standard range, reselect the shim. (Differential assembly + output shaft starting torque) - (differential assembly starting torque) = output shaft starting torque Standard value: Used part: 0.8 - 1.6 N·m New part: 3.2 - 6.3 N·m

2.Put the clutch housing assembly on the surface table and measure the dimension "A" which is from the mating surface of the clutch housing assembly to the end surface of the bearing outer race, with a height gauge.

3.Put the straight edge on the mating surface of the transmission case assembly and measure the dimension "B" with a vernier caliper. 4.Select the shim whose dimension is the difference between "B" and "A." 5.Install the output shaft assembly and differential assembly to the clutch housing assembly. Tighten the transmission case bolts to the specified torque of 30 ± 5 N·m. 6.Place the selected shim, then install the input shaft assembly.

1.Install the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft. 2.Before installing the transmission case assembly, confirm that the reverse idler gear addition mark is positioned as show in the illustration.

1.Apply a 1.2 mm diameter bead of sealant as illustrated onto the transmission case. Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent note Be sure to install the transmission case onto the transmission housing while the sealant is still wet (within 15 minutes). 2.Tighten the transmission case mounting bolts to the specified torque of 30 ± 5 N·m.

Using a Phillips screwdriver (8 mm in shank diameter) centre the bolt hole.

1.Apply a 1.2 mm diameter bead of sealant as illustrated onto the control housing. Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent note Be sure to install the housing to the case quickly while the sealant is still wet (within 10 minutes). 2.Install the control housing to the transmission case and tighten the bolts to specified torque of 18 ± 3 N·m. note After installation, keep the sealed area away from the oil for approximately one hour.

1.Using the special tool, detonation sensor wrench (MD998773), tighten the back up lamp switch to specified torque of 41 ± 11 N·m.