DISASSEMBLY AND REASSEMBLY

		1.	Spring pin
		2.	Transfer
		3.	Change shifter

		4.	Back-up lamp switch assembly
		5.	Clutch housing
		6.	Reverse restrict pin assembly
		7.	Cover
		8.	Wiring harness clamp bracket
		9.	Wiring harness clamp bracket
		10.	Air breather bracket
		11.	Air breather joint
		12.	Transfer adapter sub-assembly
		13.	Oil receiver pipe
		14.	Straight screw plug with head
		15.	Slotted spring pin
		16.	Reverse restrict pin assembly
		17.	Wiring harness clamp bracket
		18.	Front bearing retainer
		19.	Oil seal
		20.	Shaft snap ring
		21.	Shaft snap ring
		22.	Transmission case sub-assembly
		23.	Intermediate plate with sub-assembly
		24.	Transmission magnet

		25.	Control shaft assembly
		26.	Shift lever housing
		27.	Straight screw plug with head
		28.	Compression spring
		29.	Ball
		30.	Shaft snap ring
		31.	Gear shift fork shaft No.2
		32.	Gear shift fork No.2
		33.	Roller A
		34.	Shaft snap ring
		35.	Gear shift fork shaft No.1
		36.	Straight pin
		37.	Roller A
		38.	Gear shift fork No.1
		39.	Shaft snap ring
		40.	Slotted spring pin
		41.	Gear shift fork shaft No.3
		42.	Gear shift fork No.3
		43.	Roller A
		44.	Ball
		45.	Shaft snap ring
		46.	Gear shift fork shaft No.4
		47.	Ball
		48.	Compression spring
		49.	E-ring
		50.	Reverse shift arm
		51.	Reverse shift fork

		52.	Shaft snap ring
		53.	Transmission hub sleeve No.3
		54.	Gear spline piece No.5
		55.	Synchroniser outer race No.3
		56.	Counter shaft gear No.5
		57.	Shaft snap ring
		58.	Synchromesh shifting key spring No.3
		59.	Synchromesh shifting key spring No.3
		60.	Synchromesh shifting key No.3
		61.	Needle roller bearing
		62.	5th gear thrust washer
		63.	Straight pin
		64.	Rear bearing output shaft retainer
		65.	Shaft snap ring
		66.	Reverse idler gear
		67.	Cylindrical roller bearing
		68.	Counter shaft
		69.	Input shaft sub-assembly
		70.	Output shaft sub-assembly
		71.	Reverse shift arm bracket
		72.	Intermediate plate

DISASSEMBLY

1.Remove the spring pin.

2.Remove the transfer and the gear change shifter.

3.Remove the back-up lamp switch assembly.

4.Remove the clutch housing.

5.Remove the reverse restrict pin assembly (2 places).

6.Remove the cover.

7.Remove the flange bolt.

8.Remove the control shaft assembly.

9. Remove the shift lever housing.

10.Remove the transfer adaptor sub-assembly and the wiring harness clamp bracket (3 places) and air breather bracket.

11.Remove the air breather joint.

12.Remove the oil receiver pipe.

13.Remove the straight screw plug with head.

14.Remove the slotted spring pin.

15.Remove the reverse restrict pin assembly.

16.Remove the wiring harness clamp bracket.

17.Remove the front bearing retainer.

18.Remove the oil seal.

19.Remove the shaft snap ring.

20.Remove the shaft snap ring.

21.Remove the transmission case sub-assembly.

22.Remove the transmission magnet.

23.Remove the straight screw plug with head (3 places).

24.Remove the compression spring (3 places).

25.Remove the ball (3 places).

26.Remove the shaft snap ring of the gear shift fork shaft No.2 and the washer based hexagon bolt of the gearshift fork No.2.

27.Remove the gear shift fork shaft No.2.

28.Remove the gear shift fork No.2.

29.Remove the roller A.

30.Remove the shaft snap ring of the gear shift fork shaft No.1 and the washer based hexagon bolt of the gear shift fork No.1.

31.Remove the gear shift fork shaft No.1.

32.Remove the straight pin of the gear shift fork shaft No.1.

33.Remove the roller A.

34.Remove the gear shift fork No.1.

35.Remove the shaft snap ring of the gear shift fork shaft No.3.

36.Remove the slotted spring pin of the gear shift fork No.3 assembly.

37.Remove the gear shift fork No.3 and the gear shift fork shaft No.3.

38.Remove the roller A.

39.Remove the ball.

40.Remove the shaft snap ring of the gear shift fork shaft No.4.

41.Remove the gear shift fork shaft No.4.

42.Remove the ball.

43.Remove the compression spring.

44.Remove the reverse shift fork and the reverse shift arm.

45.Remove the E-ring.

46.Remove the reverse shift arm.

47.Remove the shaft snap ring.

48.Remove the transmission hub sleeve No.3.

49.Using special tools to remove the gear spline piece No.5.

Bearing puller (MD998020)

Side bearing puller cup (MB990811)

50.Remove the synchroniser outer race No.3.

51.Remove the counter shaft gear No.5.

52.Remove the shaft snap ring.

53.Remove the synchromesh shifting key spring No.3.

54.Remove the synchromesh shifting key spring No.3.

55.Remove the synchromesh shifting key No.3.

56.Remove the needle roller bearing.

57.Remove the 5th gear thrust washer.

58.Remove the straight pin.

59.Remove the rear bearing output shaft retainer.

60.Remove the snap ring.

61.Remove the reverse idler gear.

62.Remove the counter shaft and cylindrical roller bearing.

63.Remove the input shaft sub-assembly.

64.Remove the output shaft sub-assembly.

65.Remove the reverse shift arm bracket.

REASSEMBLY

1.Set the reverse shift arm bracket to the intermediate plate and tighten the bolts to the specified torque of 18 ± 5 N·m.

2.Install the output shaft sub-assembly to the intermediate plate.

3.Install the input shaft sub-assembly to the output shaft sub-assembly.

4.Insert the counter shaft into the intermediate plate and hold it. Insert the cylindrical roller bearing into the intermediate plate and the counter shaft.

5.Install the reverse idler gear to the intermediate plate.

6.Install the shaft snap ring to the radial ball bearing of the output shaft.

7.Set the rear bearing output shaft retainer and tighten the bolts to the specified torque of 18 ± 5 N·m.

note

Fit the rear bearing output shaft retainer into the reverse idler gear shaft slot.

8.Install the straight pin.

9.Check the installation direction of 5th gear thrust washer, and install it.

10.Install the needle roller bearing.

11.Install the synchromesh shifting key No.3 to the counter shaft gear No.5.

12.Install the synchromesh shifting key spring No.3 to the counter shaft gear No.5.

13.Install the synchromesh shifting key spring No.3 to the counter shaft gear No.5.

14.Install the shaft snap ring to the counter shaft gear No.5.

15.Check the clutch gear on the Gear spline piece for damaged and missing teeth.

16.Check the synchroniser outer race inner cone surface for damage or wear. Also check that the inside ridges are intact.

17.Install the counter shaft gear No.5.

18.

caution

Fit the protrusions of synchroniser ring between keys.

Install the synchroniser outer race No.3.

19.Using special tools to install the gear spline piece No.5.

Installer cup (MD998812)
Installer-100 (MD998813)
Installer adaptor (MD998827)

20.Check the installation direction of the transmission hub sleeve No.3 and install it on the counter shaft.

note

After installation, check the sleeve operate smoothly.

21.Select a snap ring to secure the thrust clearance. Install it into the gear spline piece No.5.
Standard value: 0 - 0.1 mm

22.Install the reverse shift arm to the reverse shift fork.

23.Install the E-ring.

24.Install the reverse shift fork and the reverse shift arm to the intermediate plate.

25.Install the compression spring into the reverse shift fork.

26.Install the ball into the reverse shift fork.

27.

caution

Install the gear shift fork shaft No.4 carefully in the specified direction. If the installation direction is wrong, the roller would be in the shaft concave and the gearshift fork shaft No.4 would not be installed.

Install the gear shift fork shaft No.4 into the intermediate plate and the reverse shift fork.

28.Install the shaft snap ring into the gear shift fork shaft No.4.

29.Install the ball into the reverse shift fork.

30.Install the roller A to the intermediate plate.

31.Install the gear shift fork No.3 on the transmission hub sleeve No.3 and hold it. Insert the gear shift fork shaft No.3 into the gear shift fork No.3, the intermediate plate and the reverse shift fork.

32.Install the slotted spring pin to the gear shift fork No.3.

33.Install the shaft snap ring to the gear shift fork shaft No.3.

34.Install the gear shift fork No.1 on the reverse gear.

35.Install the roller A to the intermediate plate.

36.Install the straight pin to the gear shift fork shaft No.1.

37.Install the gear shift fork shaft No.1 to the intermediate plate and the gear shift fork No.1.

38.Install the shaft snap ring to the gear shift fork shaft No.1. Tighten the washer based hexagon bolt to the specified torque of 19.5 ± 3.9 N·m.

39.Install the roller A to the intermediate plate.

40.Install the gear shift fork No.2 on the transmission hub sleeve No.2.

41.Install the gear shift fork shaft No.2 to the intermediate plate, the gear shift fork No.1 and the gear shift fork No.2.

42.Install the shaft snap ring to the gear shift fork shaft No.2. Tighten the washer based hexagon bolt to the specified torque of 19.5 ± 3.9 N·m.

43.Install the ball to the intermediate plate (3 places).

44.Install the compression spring to the intermediate plate (3 places).

45.Apply sealant to the threads. Tighten the straight screw plug with head to the specified torque of 18.5 ± 5.5 N·m (3 places).
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

note

The new bolt does not require sealant application as it is precoated with sealant.

46.Install the transmission magnet to the intermediate plate.

47.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.
48.Apply a 1.2 mm diameter bead of liquid gasket to the intermediate plate with shaft sub-assembly mounting surface of the transmission case sub-assembly.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

49.Install the transmission case sub-assembly to the intermediate plate with shaft sub-assembly.

50.Install the shaft snap ring to the cylindrical roller bearing.

51.Install the shaft snap ring to the radial ball bearing.

52.Using special tool, install the oil seal to the front bearing retainer.

Installer adapter (MB990929)
Handle (MB990938)

53.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.
54.Apply a 1.2 mm diameter bead of liquid gasket to the transmission case sub-assembly mounting surface of the front bearing retainer with seal.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

55.

caution

Do not damage to the oil seal lip during the installation.

Apply sealant to the threads. Install the front bearing retainer to the transmission case sub-assembly and tighten the bolts to the specified torque of 16.5 ± 5.0 N·m.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

note

The new bolt does not require sealant application as it is precoated with sealant.

56.Install the wiring harness clamp bracket to the transmission case sub-assembly and tighten the bolt to the specified torque of 18 ± 3 N·m.

57.Install the reverse restrict pin assembly to the transfer adapter sub-assembly.

58.Install the slotted spring pin to the reverse restrict pin assembly.

59.Apply sealant to the threads. Tighten the straight screw plug with head to the specified torque of 18.5 ± 5.5 N·m.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

note

The new bolt does not require sealant application as it is precoated with sealant.

60.Install the oil receiver pipe into the transfer adapter sub-assembly.

61.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.
62.Apply a 1.2 mm diameter bead of liquid gasket to the intermediate plate with shaft sub-assembly mounting surface of the transfer adapter sub-assembly.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

63.Apply sealant to the air breather joint of insertion portion. Install the air breather joint.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

64.Install the transfer adaptor sub-assembly. Install the wiring harness clamp bracket (3 places), air breather bracket and tighten the bolts to the specified torque of 37 ± 11 N·m.

65.

caution

When installing the shift lever housing, securely fit the shift lever housing into the head of the fork shaft.

Install the shift lever housing to the transfer adapter sub-assembly.

66.Install the control shaft assembly to the transfer adapter sub-assembly and the shift lever housing.

67.Tighten the flange bolt to the specified torque of 33 ± 3 N·m.

68.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.
69.Apply a 1.2 mm diameter bead of liquid gasket to the case mounting surface of the transfer adapter sub-assembly.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

70.Install the cover to the transfer adaptor sub-assembly and tighten the bolt with washer to the specified torque of 18 ± 5 N·m.

71.

caution

Install the reverse restrict pin assembly carefully in the accordance with the identification colour as shown in the illustration.

Tighten the reverse restrict pin assembly to the specified torque of 37 ± 11 N·m (2 places).

72.

caution

Install the bolt and washer (with sealant) to the position having the arrow as shown in the illustration.

Install the clutch housing into the transmission case sub-assembly. Tighten the bolt with washer to the specified torque of 36 ± 7 N·m (7 places). Tighten the bolt with washer (with sealant) to the specified torque of 34 ± 6 N·m (2 places).
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

73.Tighten the back-up lamp switch assembly to the specified torque of 44 ± 9 N·m.
74.Install the transfer and the gear change shifter. Tighten the bolts to the specified torque of 35 ± 6 N·m.
75.Install the spring pin.