Part 1 of 3
TRANSAXLE DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINTS
A - SPRING PIN REMOVAL
Remove the spring pin.
B - LOCK NUTS REMOVAL
1. Unstake lock nuts of the input shaft and intermediate gear.
2. Shift the transaxle into reverse using the control lever and select lever.
3. Install the special tool on the input shaft.
4. Install the spinner handle and 10 mm (0.39 in.) bolt.
5. Remove the lock nuts.
C - VISCOUS COUPLING REMOVAL
Using a flat-blade screwdriver, pry oft the viscous coupling little by little.
D - OUTER RACE REMOVAL
Using the special tool, remove the outer race.
E - SPRING PINS REMOVAL
Remove the spring pins.
F - SHIFT RAIL ASSEMBLY REMOVAL
1. Shift the 1st-2nd speed shift fork into 2nd speed.
2. Shift the 3rd-4th speed shift fork into 4th speed.
3. Rotate the shift controls in the direction of the arrow in numerical order. Remove the shift lugs from the control finger and interlock plate.
4. Raise each of the shift rails upward and remove them from the clutch housing.
5. Remove all the shift rails and forks.
G - INTERMEDIATE GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY REMOVAL
Lift up the input shaft assembly and remove the intermediate gear assembly.
H - OUTER RACE REMOVAL
Using the special tool, remove the outer race.
INSPECTION
BACKUP LIGHT SWITCH
Actuate the switch and check for continuity with an ohmmeter. If there is no continuity, replace the backup light switch.
REASSEMBLY SERVICE POINTS
A - MAGNET HOLDER/MAGNET INSTALLATION
Install the magnet and magnet holder, ensuring they are installed in the correct direction.
B - OIL SEAL INSTALLATION
Using the special tool, install the rear output shaft oil seal.
C - OIL SEAL INSTALLATION
Using the special tool, install the drive shaft oil seals, making sure that the seal for each side is in its proper location.
CAUTION: Make sure that the notch in the L.H. oil seal flange is on the up side where it is installed.
D - OIL SEAL INSTALLATION
Using the special tool, install the input shaft front oil seal.
E - INPUT SHAFT ASSEMBLY/INTERMEDIATE GEAR ASSEMBLY INSTALLATION
Lifting up the input shaft assembly, install it together with the intermediate gear assembly.
F - SEALANT TO SCREW APPLICATION
Apply MOPAR Part No.4318031 or No.4318032 or equivalent sealant to screw threads.
CAUTION: Be Careful not to apply the adhesive to the bolt head.
G - SHIFT RAIL ASSEMBLY INSTALLATION
1. Shift the 1st-2nd synchronizer sleeve into 2nd speed.
2. Shift the 3rd-4th synchronizer sleeve into 4th speed.
3. Fit the shift forks of shift rail assembly to their groove of sleeves.
4. install the shift rails, rail holes of clutch housing.
5. Turn the shift rails in the directions indicated by the arrows ,in the order shown in the illustration, and engage the shift lugs to control finger and interlock plate.
H - SPRING PINS INSTALLATION
Using the special tool, drive the spring pins into position. Make sure that the slit in the spring pin is aligned with the shut rail center line.
CAUTION: Do not reuse the spring pins
I - OIL SEAL INSTALLATION
Using the special tool, install the drive shaft oil seal.
J - SPACER INSTALLATION
1. Place two of pieces of approximately 10 mm (0.39 in.) long, 1.6 mm (0.063 in.) diameter solder at the locations shown on the transaxle case and install each outer race.
2. Place two pieces of approximately 10 mm (0.39 in.) long, 1.6 mm (0.063 in.) diameter solder at the locations shown on the bearing outer race.
3. Install the transaxle case, and tighten bolts to specification.
4. Remove the transaxle case.
5. If the solder is not broken, repeat steps 1 through 4 with large diameter solder.
6. Using a micrometer, measure the thickness of the flattened solder and select a spacer of a thickness that gives the specified end play and preload.
Standard values:
Front output shaft preload - 0.08-0.13 mm (0.0031-0.0051 in.)
Front differential case end play - 0.05-0.17 mm (0.0020-0.0067 in.)
K - OIL GUIDE INSTALLATION
Install the oil guide or the transaxle case.
L - TRANSAXLE CASE INSTALLATION
Apply sealant Mitsubishi Genuine Part No.997740 or equivalent to the clutch housing side of the transaxle case.
CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuities
M - REVERSE IDLER GEAR SHAFT BOLT INSTALLATION
1. Center the shaft with a screwdriver [shaft diameter 8 mm (0.31 in.) or similar object].
2. Tighten the reverse idler gear shaft bolt to specification.
N - SPACER INSTALLATION
1. Place tour pieces of approximately 10 mm (0.39 in.) long, 1.6 mm (0.063 in.) diameter solder at the locations shown on the transaxle case adapter assembly and install each outer race.
2. Install the transaxle case adapter assembly and rear cover, and tighten bolts to specification.
3. Remove the transaxle case adapter assembly and rear cover.
4. If [he solder is not broken, carry out the work in steps 1 through 3 with large diameter solder.
5. Remove the outer races and remove the solder. Using a micrometer, measure the thickness of the flattened solder and select a spacer of a thickness that gives the specified end play and preload.
Standard values:
Input shaft end play - 0-0.05 mm (0-0.0020 in.)
Intermediate gear preload - 0.08-0.13 mm (0.0031-0.0051 in.)
Center differential case preload - 0.08-0.13 mm (0.0031-0.0051 in.)
O - TRANSAXLE CASE ADAPTER INSTALLATION
Apply sealant Mitsubishi Genuine Part No.997740 or equivalent to the transaxle case side of the transaxle case adapter assembly.
CAUTION: Squeeze out sealant from tube uniformly without excess or discontinuities.
P - STEEL BALL INSTALLATION
Move the center shaft so that the steel ball is seated securely into the groove in center shaft.
Q - SNAP RING INSTALLATION
Select the snap ring so that the end play in the viscous coupling is up to specification.
Standard value: 0.10-0.26 mm (0.0039-0.0102 in.)
R - SHIFT FORK/5TH SPEED SYNCHRONIZER ASSEMBLY INSTALLATION
Mate the 5th speed shift fork with the 5th gear synchronizer assembly and install them simultaneously.
S - LOCK NUTS INSTALLATION
1. Shift the transaxle into reverse using the control lever and select lever.
2. Install the special tool on the input shaft.
3. Fit the tool on the spinner handle and bolt.
4. Tighten the lock nut to specification and then loosen it completely before tightening it again to the specified torque.
5. Punch the lock nut into locked position. (Punch two places on the lock nut of the input shaft and one place on the lock nut of the intermediate gear.)
T - SPRING PIN INSTALLATION
1. Using the special tool, drive the spring pin into position.
2. Make sure that the slit in the spring pin is aligned with the shift rail center line.
CAUTION: Do not reuse the spring pin.
U - ADHESIVE TO AIR BREATHER APPLICATION
Apply adhesive, MOPAR Part No.4318025 or equivalent, to the areas with which the air breather makes contact, and install the air breather on the clutch housing.
V - SCREW BOLTS INSTALLATION
Apply MOPAR Part No.4318031 or No.4318032 or equivalent adhesive to screw bolts mounting portion.
W - REAR COVER INSTALLATION
Apply Mitsubishi Genuine Part No. MD997740 or equivalent sealant to the rear cover.
CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuities.
5TH SPEED SYNCHRONIZER DISASSEMBLY AND REASSEMBLY
INSPECTION
SYNCHRONIZER SLEEVE AND HUB
1. Mate the synchronizer sleeve and hub and check to see it they slide smoothly without binding.
2. Make sure that the sleeve is free from damage at its inside front and rear ends.
NOTE: It replacement is necessary, replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
1. Make sure that the center protrusion of the synchronizer key is riot worn.
2. The spring must offer proper tension with no deformation or damage.
REASSEMBLY SERVICE POINTS
A - SYNCHRONIZER HUB/SYNCHRONIZER KEY INSTALLATION
Install the synchronizer hub, and key in the directions as shown.
B - SYNCHRONIZER SPRINGS INSTALLATION
Install the synchronizer springs so that its protrusion fits into the synchronizer key. Make sure that the protrusions in the front and rear springs do not fit over the same key.
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - BALL BEARING REMOVAL
Using the special tool, remove the front bearing.
B - BEARING SLEEVE REMOVAL
Remove the bearing sleeve using the special tool as illustrated.
C - BALL BEARING REMOVAL
Using the special tool, remove the bearing sleeve and ball bearing.
D - 3RD SPEED GEAR REMOVAL
Using the special tool, remove the bearing sleeve, 3rd-4th speed synchronizer assembly, and 3rd speed gear.