DISASSEMBLY AND REASSEMBLY

Disassembly steps >>Z<< 1. Spring pin 2. Change shifter 3. Bracket 4. Transfer >>Y<< 5. Adapter gasket 6. Plug 7. Spring 8. Steel ball 9. Seal plug 10. Neutral return spring >>X<< 11. Neutral return plunger (B) >>X<< 12. Neutral return plunger (A)

Disassembly steps 13. Back-up lamp switch 14. Gasket 15. Steel ball 16. Bracket >>W<< 17. Air breather joint 18. Vapour hose 19. Air breather pipe 20. Breather cap 21. Air breather bracket 22 Clip 23. Plug <<A>> >>V<< 24. Transfer adapter 25. Lock pin 26. Control finger 27. Control shaft

Disassembly steps >>U<< 28. Under cover >>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 <<F>> >>J<< 50. OD-R synchroniser sleeve <<F>> >>J<< 51. OD-R synchroniser hub <<F>> >>J<< 52. Synchroniser spring <<F>> >>J<< 53. Synchroniser key <<F>> >>J<< 54. Synchroniser ring <<F>> 55. Reverse gear <<F>> 56. Needle bearing <<H>> >>I<< 57. Reverse gear bearing sleeve 58. Split pin 59. Slotted nut >>H<< 60. Thrust washer 61. Reverse idler gear 62. Needle bearing 63. Bolt 64. Reverse idler gear shaft 65. Bolt 66. Rear bearing retainer

Disassembly steps >>G<< 67. Front bearing retainer 68. Oil guide >>F<< 69. Oil seal >>E<< 70. Spacer <<G>> >>D<< 71. Countershaft centre bearing >>C<< 72. Mainshaft centre bearing >>B<< 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. Needle bearing 79. Synchroniser ring <<J>> 80. Counter shaft 81. Main shaft 82. Transmission case

Turn the control shaft to the anti-clockwise and remove the control finger from the groove in the shift lug, then remove the transfer adapter from the transmission case.

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 locking 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, OD-R synchroniser sleeve, synchroniser spring, synchroniser key, synchroniser ring, reverse gear and needle bearing.

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 reverse gear bearing sleeve.

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 counter shaft, 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)

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

Install the selected spacer into the maindrive gear bearing (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.

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

1.Before reassembly, make sure that the OD-R synchroniser hub and OD-R synchroniser sleeve faces the correct direction.

2.Insert the three keys into the grooves of the OD-R 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 OD-R synchroniser hub. Installer cap (MD998812) Installer-100 (MD998813) Installer-200 (MD998814) Installer adapter (38) (MD998818)

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 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.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

Turn the control shaft to the anti-clockwise and install the transfer adapter

Apply the specified sealant to air breather joint. Specified sealant: 3M Super Weatherstrip No. 8001 or equivalent

Apply grease to the sliding surfaces of the neutral return plungers before installation. 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 grease to the adapter gasket before installation. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

1.Drive in the spring pin in such a way that its slit is oriented as shown.