DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. Vehicle speed sensor 2. Sleeve clamp >>Y<< 3. Speedometer gear 4. Back-up lamp switch 5. Gasket 6. Steel ball 7. Harness bracket 8. Extension housing cover 9. Extension housing gasket 10. Stopper bracket 11. Return spring >>X<< 12. Air breather joint >>X<< 13. Nut >>X<< 14. Special bolt 15. Resistance spring 16. Steel ball 17. Neutral return plunger seal plug 18. Spring 19. Neutral return plunger (A) 20. Neutral return plunger (B) 21 Air breather bracket 22. Cord fastener 23. Corrugate clip bracket <<A>> >>W<< 24. Extension housing

Disassembly steps >>V<< 25. Under cover >>U<< 26. Snap ring >>U<< 27. Mainshaft rear bearing >>U<< 28. Snap ring >>T<< 29. Plug >>S<< 30. Spring 31. Steel ball >>R<< 32. Spring pin >>Q<< 33. Spring pin >>P<< 34. Spring pin 35. OD-R shift rail 36. 3RD-4TH speed shift rail 37. Interlock plunger 38. OD-R shift fork <<B>> >>O<< 39. Countershaft lock nut <<C>> >>N<< 40. Countershaft rear bearing <<D>> >>M<< 41. Countershaft overdrive gear >>M<< 42. 1ST-2ND Speed shift rail

Disassembly steps <<E>> >>L<< 43. Mainshaft lock nut 44. Counter reverse gear 45. Spacer <<F>> >>K<< 46. Bearing sleeve 47. Needle bearing 48. Overdrive gear 49. Synchroniser ring >>J<< 50. OD-R synchroniser sleeve >>J<< 51. Synchroniser spring <<F>> >>J<< 52. OD-R synchroniser hub >>J<< 53. Synchroniser key 54. Reverse gear 55. Needle bearing 56. Split pin 57. Slotted nut >>I<< 58. Thrust washer 59. Reverse idler gear 60. Needle bearing 61. Bolt 62. Reverse idler gear shaft 63. Bolt 64. Rear bearing retainer

Disassembly steps >>H<< 65. Front bearing retainer 66. Oil guide >>G<< 67. Oil seal >>F<< 68. Spacer <<G>> >>E<< 69. Countershaft centre bearing >>D<< 70. Bearing sleeve <<H>> >>C<< 71. Mainshaft centre bearing >>B<< 72. Snap ring 73. Snap ring <<I>> >>A<< 74. Maindrive gear bearing 75. Maindrive gear 76. 3RD-4TH Speed shift fork 77. 1ST-2ND Speed shift fork 78. Mainshaft front bearing 79. Synchroniser ring <<J>> 80. Countershaft 81. Mainshaft 82. Transmission case

Pull the extension housing toward the rear while pushing the change shifter toward the right.

1.Shift the 1st-2nd speed synchroniser sleeve to the second speed side and the OD-R synchroniser sleeve to the reverse side for double meshing. This prevents the countershaft from turning. 2.Remove the staked nut from the countershaft. 3.Remove the countershaft lock nut.

Using the special tool Bearing and gear puller (MD998348) to remove the countershaft rear bearing.

Using the special tool Steering wheel puller (MB990803) to remove the countershaft overdrive gear.

1.Shift the 1st-2nd speed synchroniser sleeve to the second speed side and the OD-R synchroniser sleeve to the reverse side for double meshing. This prevents the mainshaft from turning. 2.Remove the staked nut from the mainshaft. 3.Using the special tool Lock nut wrench (41) (MD998809) to remove the mainshaft lock nut.

1.Set special tools as shown in illustration. Bearing puller (MD998020) Bearing puller adapter (MD998028) 2.Screw the centre bolt of special tool, and pull out the bearing sleeve, together with OD-R synchroniser hub.

1.Using the special tool Counter gear bearing puller (MD998192) to remove the countershaft centre bearing.

1.Set special tool as shown in illustration. Bearing puller (MD998020) Bearing puller adapter (MD998028) 2.Screw the centre bolt of special tool, and pull out the mainshaft centre bearing.

1.Set special too as shown in illustration. Bearing puller (MD998020) 2.Screw the centre bolt of special tool, and pull out the maindrive gear bearing.

To facilitate the removal of countershaft, set the 1st-2nd synchroniser sleeve to the 1st gear side and the 3rd-4th synchroniser sleeve to the 3rd gear side.

Using the special tools to install the maindrive gear bearing. Installer cap (MD998812) Installer-100 (MD998813) Installer-200 (MD998814) Installer adapter (42) (MD998820)

1.Install the thickest snap ring that can be fitted in the snap ring groove of maindrive gear. 2.Make sure that the maindrive gear bearing axial play meet the standard value. Standard value: 0 - 0.06 mm

Using the special tools to install the mainshaft centre bearing. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (40) (MD998819)

Use special tools to install the bearing sleeve. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (38) (MD998818)

Using the special tools to install the countershaft centre bearing. Installer adapter (30) (MD998816) Bearing installer (MD998199)

(Refer to adjustment of transmission-spacer selection for adjustment of maindrive gear bearing axial play ).

1.Using special tool Oil seal installer (MD998200) install the oil seal into the front bearing retainer.

2.Apply specified grease to the lip of the front bearing retainer oil seal. Specified lubricant: MITSUBISHI MOTORS GENUINE Part No. 0101011 or equivalent

1.Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand. 2.Apply the specified sealant to the entire circumference of the mounting surface of the front bearing retainer. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

Install the thrust washer its polished side faced to reverse idler gear.

1.Before reassembly, make sure that the hub and sleeve faces the correct direction.

2.Insert the three keys into the grooves of the synchroniser hub. 3.Install two synchroniser springs to the synchroniser. When the installing the springs, be sure to position each spring with respect to the keys as illustrated.

4.Use special tools to install the synchroniser hub. Installer cap (MD998812) Installer-100 (MD998813) Installer-200 (MD998814) Installer adapter (38) (MD998818)

1.Use the special tools to install the bearing sleeve. Installer cap (MD998812) Installer-100 (MD998813) Installer-200 (MD998814) Installer adapter (34) (MD998817)

1.Shift the 1st-2nd speed synchroniser sleeve to the second speed side and OD-R synchroniser sleeve to the reverse side for double meshing. This presents the mainshaft from turning. 2.Using the special tool Lock nut wrench (41) (MD998809) tighten the mainshaft lock nut to specified torque of 255 ± 10 N·m.

3.Stake the two places of the lock nut as shown in illustration. 4.Ensure that the overdrive gear rotates smoothly.

1.Install the 1st-2nd speed shift rail and countershaft overdrive gear simultaneously.

2.Use special tools to install the counter shaft overdrive gear. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (30) (MD998816)

Use special tools to install the countershaft rear bearing. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (30) (MD998816)

1.Tighten the countershaft lock nut to specified torque of 172 ± 14 N·m.

2.Stake the two places of the lock nut as shown in illustration. 3.Ensure that the OD gear rotates smoothly.

Press in the spring pin so that its slit is parallel with the shift rail.

Press in the spring pin so that its slit is parallel with the shift rail.

Press in the spring pin so that its slit is parallel with the shift rail.

Insert the spring with small end on the steel ball side. Three springs are identical to each other. Spring Identification colour For 1ST-2ND speed shift rail Pink For 3RD-4TH speed shift rail Yellow For OD-R shift rail Pink

1.Apply the specified sealant to the plug. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent 2.Screw plug as shown.

1.Install a snap ring of the same size as having been used.

2.Use the special tools to install the mainshaft rear bearing. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (34) (MD998817)

3.Install the thickest snap ring that can be fitted in the snap ring groove of mainshaft. 4.Make sure that the mainshaft rear bearing axial play meet the standard value. Standard value: 0 - 0.13 mm

1.Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand. 2.Apply the specified sealant to under cover. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

1.Install the extension housing while pushing the change shifter in the direction of the arrow and fit the control finger into the groove in the selector.

2.Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand. 3.Apply the specified sealant to extension housing as illustration. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

1.Apply the specified sealant to the bolt as shown. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

2.Apply the specified sealant to the nut threads. Specified sealant: 3M AAD Part No. 2353 or equivalent

3.Apply the specified sealant to the air breather joint as shown. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

1.Apply the specified grease to the O-ring of the speedometer. Specified lubricant: MITSUBISHI MOTORS GENUINE Part No. 01010111 or equivalent 2.Match the mating marks to the number to teeth on the speedometer driven gear. Install the speedometer gear. Transmission model Number of teeth R5M21-J-GFHY 26