DISASSEMBLY AND REASSEMBLY

			Disassembly steps
		1.	Back-up lamp switch assembly
		2.	Clutch housing
		3.	Vehicle speed sensor
		4.	O-ring
		5.	Wiring harness clamp bracket
		6.	Wiring harness clamp bracket
		7.	Air breather bracket
		8.	Extension housing sub-assembly
		9.	Oil receiver pipe
		10.	Straight screw plug with head
		11.	Slotted spring pin
		12.	Reverse restrict pin assembly
		13.	Front bearing retainer
		14.	Oil seal
		15.	Shaft snap ring
		16.	Shaft snap ring
		17.	Transmission case sub-assembly
		18.	Intermediate plate with shaft sub-assembly
		19.	Transmission magnet

			Disassembly steps
		20.	Straight screw plug with head
		21.	Compression spring
		22.	Ball
		23.	Shaft snap ring
		24.	Gear shift fork shaft No.2
		25.	Gear shift fork No.2
		26.	Roller A
		27.	Shaft snap ring
		28.	Gear shift fork shaft No.1
		29.	Straight pin
		30.	Roller A
		31.	Gear shift fork No.1
		32.	Shaft snap ring
		33.	Slotted spring pin
		34.	Gear shift fork shaft No.3
		35.	Gear shift fork No.3
		36.	Roller A
		37.	Ball
		38.	Shaft snap ring
		39.	Gear shift fork shaft No.4
		40.	Ball
		41.	Compression spring
		42.	E-ring
		43.	Reverse shift arm
		44.	Reverse shift fork

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

DISASSEMBLY SERVICE POINTS

1.Remove the back-up lamp switch assembly.

2.Remove the clutch housing.

3.Remove the vehicle speed sensor.

4.Remove the extension housing sub-assembly and wiring harness clamp bracket and air breather bracket.

5.Remove the oil receiver pipe.

6.Remove the straight screw plug with head.

7.Remove the slotted spring pin.

8.Remove the reverse restrict pin assembly.

9.Remove the front bearing retainer.

10.Remove the oil seal.

11.Remove the shaft snap ring.

12.Remove the shaft snap ring.

13.Remove the transmission case sub-assembly.

14.Remove the transmission magnet.

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

16.Remove the compression spring (3 places).

17.Remove the ball (3 places).

18.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.

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

20.Remove the gear shift fork No.2.

21.Remove the roller A.

22.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.

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

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

25.Remove the roller A.

26.Remove the gear shift fork No.1.

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

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

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

30.Remove the roller A.

31.Remove the ball.

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

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

34.Remove the ball.

35.Remove the compression spring.

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

37.Remove the E-ring.

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

39.Remove the shaft snap ring (2 places).
40.Remove the rotor.
41.Remove the ball.

42.Remove the shaft snap ring.

43.Remove the transmission hub sleeve No.3.

44.Use special tools to remove the gear spline piece No.5.

Bearing puller (MD998020)
Side bearing puller cup (MB990811)

45.Remove the synchroniser outer race No.3.

46.Remove the counter shaft gear No.5.

47.Remove the shaft snap ring.

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

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

50.Remove the synchromesh shifting key No.3.

51.Remove the needle roller bearing.

52.Remove the 5th gear thrust washer.

53.Remove the straight pin.

54.Remove the rear bearing output shaft retainer.

55.Remove the snap ring.

56.Remove the reverse idler gear.

57.Remove the counter gear sub-assembly and cylindrical roller bearing.

58.Remove the input shaft sub-assembly.

59.Remove the output shaft sub-assembly.

60.Remove the reverse shift arm bracket.

REASSEMBLY SERVICE POINTS

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 gear sub-assembly into the intermediate plate and hold it. Insert the cylindrical roller bearing into the intermediate plate and the counter gear sub-assembly.

5.Install the reverse idler gear shaft and reverse idler gear sub-assembly to the intermediate plate.

6.Install the shaft snap ring to the radial ball bearing of the input shaft sub-assembly.

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.Use special tools to install the gear spline piece No.5.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (56) (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 which will make the gear spline piece No.5 axial play equal the standard value.
Standard value: 0 - 0.1 mm

22.Install the ball to the rotor.
23.Install the rotor to the output shaft.
24.Remove the shaft snap ring to the output shaft (2 places).

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

26.Install the E-ring.

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

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

29.Install the ball into the reverse shift fork.

30.

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.

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

32.Install the ball into the reverse shift fork.

33.Install the roller A to the intermediate plate.

34.Install the gear shift fork No.3 assembly 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 assembly, the intermediate plate and the reverse shift fork.

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

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

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

38.Install the roller A to the intermediate plate.

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

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

41.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.

42.Install the roller A to the intermediate plate.

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

44.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.

45.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.

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

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

48.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.

49.Install the transmission magnet to the intermediate plate.

50.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.
51.Apply a 1.2 mm diameter bead of liquid gasket to the intermediate plate mounting surface of the transmission case sub-assembly.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

52.Install the transmission case sub-assembly to the intermediate plate.

53.Install the snap ring to the cylindrical roller bearing.

54.Install the snap ring to the radial ball bearing.

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

Installer adapter (MB990929)
Installer bar (MB990938)

56.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.
57.Apply a 1.2 mm diameter bead of liquid gasket to the transmission case sub-assembly mounting surface of the front bearing retainer sub-assembly with seal.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

58.

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.

59.Install the reverse restrict pin assembly to the extension housing sub-assembly.

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

61.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.

62.Install the oil receiver pipe into the extension housing sub-assembly.

63.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.
64.Apply a 1.2 mm diameter bead of liquid gasket to the intermediate plate mounting surface of the extension housing sub-assembly.
Special sealant: MITSUBISHI MOTORS GENUINE Part No. MD974421 or equivalent

65.Install the extension housing 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.

66.Install the vehicle speed sensor and tighten the bolts to the specified torque of 11 ± 1 N·m.

67.

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

68.Tighten the back-up lamp switch assembly and of 44 ± 9 N·m.