GR00004000 22B PDF

22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . .
GENERAL SPECIFICATIONS . . . . . .
SERVICE SPECIFICATIONS. . . . . . .
22B-3
22B-6
INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-27

INPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B-27
INPUT SHAFT INSPECTION . . . . . . . . . . .
22B-34
22B-6
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B-35
SNAP RING, SPACER AND

THRUST PLATE FOR ADJUSTMENT
TORQUE SPECIFICATION . . . . . . . .
22B-7
OUTPUT SHAFT DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B-35
OUTPUT SHAFT INSPECTION . . . . . . . . .
22B-43
22B-9
REVERSE IDLER GEAR . . . . . . . . . . 22B-45
SEALANTS . . . . . . . . . . . . . . . . . . . .
22B-10
LUBRICANTS . . . . . . . . . . . . . . . . . .
22B-10
SPECIAL TOOLS. . . . . . . . . . . . . . . .
22B-11
TRANSMISSION . . . . . . . . . . . . . . . .
22B-14
TRANSMISSION DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B-14
TRANSMISSION INSPECTION . . . . . . . . .
22B-26
REVERSE IDLER GEAR DISASSEMBLY

AND REASSEMBLY . . . . . . . . . . . . . . . . . .
22B-45
SPEEDOMETER GEAR . . . . . . . . . . . 22B-46

SPEEDOMETER GEAR DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . .
22B-46
SELECT LEVER . . . . . . . . . . . . . . . . . 22B-47

SELECT LEVER DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B-47
Continued on next page
22B-2
CONTROL HOUSING . . . . . . . . . . . .
CONTROL HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH HOUSING. . . . . . . . . . . . . .
CLUTCH HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .
22B-48
22B-48
22B-50
22B-50
TRANSMISSION CASE . . . . . . . . . . . 22B-53

TRANSMISSION CASE DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . .
22B-53
DIFFERENTIAL . . . . . . . . . . . . . . . . . 22B-55
DIFFERENTIAL DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B-55
MANUAL TRANSMISSION OVERHAUL

GENERAL INFORMATION
22B-3
GENERAL INFORMATION
M1222000100120
MANUAL TRANSMISSION MODELS

Transmission model
Combined engine
Vehicle model
F5M41-1-V7B3
4G13-S4-MPI
CS1A
F5M41-1-R7B5
4G18-S4-MPI
CS3A/CS3W
F5M42-2-R7B4
4G63-D4-MPI
CS9W
22B-4

GENERAL INFORMATION
SECTIONAL VIEW
<F5M41>
AK300634

GENERAL INFORMATION
22B-5
<F5M42>
AK300023
22B-6
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
M1222000200161
TRANSMISSION MODEL TABLE

Transmission
Speedomerter
model
gear ratio
Final gear
ratio
Vehicle model
Engine model
F5M41-1-V7B3
30/36
4.333
CS1A
4G13-S4-MPI
F5M41-1-R7B5
30/36
4.052
CS3A/CS3W
4G18-S4-MPI
F5M42-2-R7B4
30/36
4.058
CS9W
4G63-D4-MPI
GEAR RATIO TABLE

Item
F5M41
1st
3.583
2nd
1.947
3rd
1.343
1.379
4th
0.976
1.030
5th
0.804
0.820
Reverse
3.416
3.363
F5M42
SERVICE SPECIFICATIONS
M1222000300146
Item
Standard value
Minimum limit
Differential case preload <F5M41>
0.05 0.17 mm
Differential case preload <F5M42>
0.05 0.11 mm
Input shaft front bearing end play
0 0.12 mm
Input shaft 5th speed gear end play <F5M42>
0 0.09 mm
Input shaft rear bearing end play <F5M41>
0 0.09 mm
Input shaft rear bearing end play <F5M42>
0 0.12 mm
Synchronizer ring back surface to gear clearance
0.5 mm
Output shaft front bearing end play
0 0.12 mm
Output shaft 3rd speed gear end play
0 0.09 mm
Output shaft rear bearing end play
0 0.09 mm
Backlash between differential gear and pinion
0 0.15 mm

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22B-7
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000153
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M41>

Thickness mm
Identification symbol
Thickness mm
0.77
77
1.31
0.86
86
1.40
None
0.95
95
1.49
1.04
04
1.58
1.13
1.67
1.22
1.76
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>

Thickness mm
Thickness mm
0.71
71
1.01
01
0.74
74
1.04
04
0.77
77
1.07
07
0.80
80
1.10
0.83
83
1.13
0.86
86
1.16
0.89
89
1.19
0.92
92
1.22
0.95
95
1.25
0.98
98
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY)
Thickness mm
Thickness mm
2.24
None
2.38
Brown
2.31
Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY) <F5M42>
Thickness mm
Thickness mm
2.82
2.98
2.86
3.02
2.90
3.06
2.94
3.10
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY) <F5M41>
Thickness mm
Thickness mm
2.31
Black (2)
2.55
Yellow
2.35
None
2.59
Black
2.39
Blue
2.63
Orange
22B-8

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
Thickness mm
Thickness mm
2.43
Brown
2.67
Blue
2.47
Green
2.71
Brown
2.51
White
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY) <F5M42>
Thickness mm
Thickness mm
1.43
Green (2)
1.59
Yellow (2)
1.51
White (2)
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT FRONT BEARING END PLAY)
Thickness mm
Thickness mm
1.43
Green (2)
1.59
Yellow (2)
1.51
White (2)
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
Thickness mm
Thickness mm
2.81
Green
2.97
Orange
2.85
White
3.01
Red
2.89
Yellow
3.05
Pink
2.93
Black
3.09
Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY) <F5M41>
Thickness mm
Thickness mm
2.31
Black (2)
2.55
Yellow
2.35
None
2.59
Black
2.39
Blue
2.63
Orange
2.43
Brown
2.67
Blue
2.47
Green
2.71
Brown
2.51
White
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY) <F5M42>
Thickness mm
Thickness mm
2.31
Black (2)
2.55
Yellow
2.35
None
2.59
Black
2.39
Blue
2.63
Orange
2.43
Brown
2.67
Blue
2.47
Green
2.71
Brown
2.51
White
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION)
<F5M41>
Thickness mm
Thickness mm
0.72 0.79
0.98 1.02
0.80 0.84
1.02 1.06
22B-9
TORQUE SPECIFICATIONS
Thickness mm
Thickness mm
0.85 0.90
1.07 1.11
0.90 0.94
1.12 1.16
0.94 0.98
1.16 1.20
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION)
<F5M42>
Thickness mm
Thickness mm
0.75 0.82
1.05 1.12
0.83 0.92
1.09 1.16
0.93 1.00
1.15 1.22
1.01 1.08
TORQUE SPECIFICATIONS
M1222012100116
Part
Nm
Roll stopper bracket mounting bolt
70 10
Shift cable bracket mounting bolt
18 3
Select lever mounting bolt
18 3
Speedometer gear mounting bolt
3.9 1.0
Backup light switch
32 2
Restrict ball <F5M41>
32 2
Poppet spring
32 2
Harness bracket bolt
18 3
Harness bracket bolt <F5M42>
3.9 1.0
Interlock plate bolt
30 3
Control housing mounting bolt
18 3
Under cover mounting bolt <F5M42>
6.9 0.9
Reverse idler gear shaft mounting bolt
48 6
Clutch housing-transaxle case mounting bolt
44 5
Reverse shift lever bolt <F5M41>
18 3
Front bearing retainer mounting bolt
18 3
Select lever mounting nut
11 1
Stopper bracket mounting bolt
22.3 0.3
Clutch release bearing retainer mounting bolt
9.8 0.2
Differential drive gear mounting bolt
132 5
22B-10

SEALANTS AND ADHESIVES
SEALANTS AND ADHESIVES

M1222000500139
Item
Specified sealant
Clutch housing-transaxle case mating surface
MITSUBISHI Genuine sealant part No. MD997740 or

equivalent
Under cover-transaxle case mating surface

Control housing-transaxle case mating surface
Air breather
3M SUPER WEATHERSTRIP No. 8001 or equivalent
Front bearing retainer bolt (countersink head bolt)

<F5M41>
3M STUD Locking No. 4170 or equivalent
Differential drive gear bolt

FORM-IN-PLACE GASKET (FIPG)
This transmission has several areas where the formin-place gasket (FIPG) is used for sealing. To ensure
that the FIPG fully serves its purpose, it is necessary
to observe some precautions when applying it. Bead
size, continuity and location are of paramount
importance.
Too thin a bead could cause leaks. Too thick a bead,
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To
prevent leaks or blocking of passages, therefore, it is
absolutely necessary to apply the FIPG evenly
without a break, while observing the correct bead
size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
Disassembly
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have
to be broken by tapping parts with a mallet or similar
tool.
Surface Preparation
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surface is flat
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.
FIPG Application
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 10 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during
installation. Avoid operating the transmission or
letting oils or water come in contact with the sealed
area before a time sufficient for FIPG to harden
(approximately one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
LUBRICANTS
M1222000400109
Item
Specified lubricant
Each O-ring
Hypoid gear oil SAE 75W-90 or 75W-85W conforming to

API classification GL-4
Each oil seal

Select lever shoe
MITSUBISHI genuine grease part No.0101011 or

equivalent
22B-11
SPECIAL TOOLS
SPECIAL TOOLS
M1222000600158
Tool
Number
Name
Application
MB990935
Installer adapter
Installation of differential case

taper roller bearing outer race
<F5M42>
MB990938
Handle
Use with Installer adapter
MB990927
Installer adapter
Installation of sealing cap
MD998801
Bearing remover
Installation and removal of

gears, bearings and sleeves
MD998917
Bearing remover
Installation and removal of

gears, bearing and sleeves
MD998812
Installer cap
Use with Installer and Installer

adapter
MD998813
Installer-100
Use with Installer cap and

Installer adapter
MD998816
Installer adapter (30) Installation of input shaft front

bearing
B990938
22B-12
Tool
SPECIAL TOOLS
Number
Name
Application
MD998825
Installer adapter (52) Installation of 1st-2nd speed

synchronizer hub <F5M42>,
3rd-4th speed synchronizer hub
and 1st speed gear sleeve
<F5M42>
MD998824
Installer adapter (50) Installation of 4th speed gear

sleeve, 5th speed gear
<F5M42> and thrust plate
stopper <F5M42>
MD998820
Installer adapter (42) Installation of 5th speed gear

sleeve <F5M42>, 2nd speed
gear sleeve <F5M41> and 3rd
speed gear <F5M41>
MD998819
Installer adapter (40) Installation of 5th speedreverse synchronizer hub, 4th

speed gear, 5th speed gear
sleeve <F5M42> and
differential case ball bearing
<F5M41>
MD998818
Installer adapter (38) Installation of input shaft rear

bearing, roller bearing inner
race, reverse gear sleeve
<F5M42> and output shaft rear
ball bearing <F5M42>
MD998814
Installer-200
MD998822
Installer adapter (46) Installation of 1st gear sleeve

<F5M41>, 1st-2nd speed
synchronizer hub <F5M41>,
2nd speed gear sleeve
<F5M42> and 3rd speed gear
<F5M42>
MD998817
Installer adapter (34) Installation of output shaft rear

ball bearing <F5M41>
Use with Installer cap and

Installer adapter
22B-13
SPECIAL TOOLS
Tool
Number
Name
Application
MD999566
Claw
Removal of taper roller bearing

outer race
MD998772
Valve spring
compressor
Removal of output shaft front

roller bearing outer race
MD998346
Bearing outer race

remover
Removal of output shaft front

MB990934
Installer adapter
Installation of output shaft front

MD998325
Differential oil seal

installer
Installation of differential oil seal
MB990926
Installer adapter
Installation of clutch housing

input shaft oil seal
MD998823
Installer adapter (48) Installation of differential case

taper roller bearing <F5M42>
22B-14
TRANSMISSION
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001000159
<F5M41>
18 3 Nm
18 3 Nm
12
3
3.9 1.0 Nm
32 2 Nm
4
6
32 2 Nm
10
8
70 10 Nm
11
9
7
70 10 Nm
1
AK300215AB
1.
2.
3.
>>P<< 4.
>>O<< 5.
6.
7.
Disassembly steps
Roll stopper bracket, front
Roll stopper bracket, rear
Shift cable bracket
Select lever
Speedometer gear
Backup light switch
Gasket
Disassembly steps (Continued)

8. Restrict ball
9. Gasket
10. Poppet spring
11. Gasket
12. Harness bracket
22B-15
TRANSMISSION
15
18 3 Nm
Apply gear oil to all
moving parts before
installation.
30 3 Nm
13
16
14
44 5 Nm
19
25
20
26
18
17
27
28
48 6 Nm
18 3 Nm
21
24
23
22
AK300214AB
>>N<<
>>L<<
<<A>> >>K<<
<> >>J<<
<<C>> >>I<<
13.
14.
15.
16.
17.
18.
19.
20.
21.
Disassembly steps
Gasket
Control housing
Neutral return spring
Reverse idler gear shaft bolt
Gasket
Sealing cap
Transaxle case
Reverse idler gear shaft
22.
23.
24.
>>H<< 25.
>>F<< 26.
27.
28.

Reverse idler gear
Reverse shift lever shoe
Reverse shift lever
Oil guide
Spacer
Magnet holder
Magnet
22B-16
TRANSMISSION
moving parts before
installation.
30
32
29
33
41
31
45
40
34
35
39
38
46
37
36
43
44
18 3 Nm
42
AK300216AB
Disassembly steps
>>E<< 29. Spring pin

>>E<<
>>E<<
<<D>> >>C<<
<<D>> >>C<<
>>C<<
>>C<<
>>C<<
30.
31.
32.
33.
34.
35.
36.
37.
38.
1st-2nd speed shift rail

1st-2nd speed shift fork
Spring pin
Spring pin
5th speed-reverse shift rail
5th speed-reverse shift fork
Reverse shift lug
Snap ring
Reverse interlock rail
>>C<< 39.
<<D>> >>C<< 40.
<<D>> >>C<< 41.
>>B<< 42.
<<F>> >>A<< 43.
<<F>> >>A<< 44.
45.
46.

Steel ball
3rd-4th speed shift rail
3rd-4th speed shift fork
Front bearing retainer
Input shaft
Output shaft
Differential
Clutch housing
22B-17
TRANSMISSION
<F5M42>
4
3
32 2 Nm
18 3 Nm
3.9 1.0 Nm
8
3.9 1.0 Nm
7
11
70 10 Nm
18 3 Nm
10
1
70 10 Nm
AK203151AC
1.
2.
3.
>>P<< 4.
>>O<< 5.
6.
7.
Disassembly steps
Roll stopper bracket, front
Roll stopper bracket, rear
Shift cable bracket
Select lever
Speedometer gear
Backup light switch
Gasket

8. Poppet spring
9. Gasket
10. Harness bracket
11. Harness bracket
22B-18
TRANSMISSION
14
moving parts before
installation.
18 3 Nm
30 3 Nm
15
12
44 5 Nm
22
20
13
21
23
18
17
19
24
48 6 Nm
25
16
6.9 0.9 Nm
AK204218AB
12.
13.
>>N<< 14.
15.
>>M<< 16.
17.
18.
19.
Disassembly steps
Gasket
Control housing
Neutral return spring
Under cover
Reverse idler gear shaft bolt
Gasket
Reverse idler gear assembly
<<A>> >>K<< 20.

<> >>J<< 21.
>>G<< 22.
>>G<< 23.
24.
25.

Sealing cap
Transaxle case
Outer race
Spacer
Magnet holder
Magnet
22B-19
TRANSMISSION
moving parts before
installation.
30
29
27
28
26
32
38
31
34
33
39
36
37
18 3 Nm
35
AK204219AB
Disassembly steps
>>E<< 26. Spring pin
<<E>>
<<E>>
<<E>>
<<E>>
>>E<<
>>E<<
>>D<<
>>D<<
>>D<<
>>D<<
<<F>> >>A<<
<<F>> >>A<<
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
1st-2nd speed shift rail

1st-2nd speed shift fork
Spring pin
Spring pin
3rd-4th speed shift fork
5th speed-reverse shift rail
5th speed-reverse shift fork
Front bearing retainer
Input shaft
Output shaft
Differential
Clutch housing
DISASSEMBLY SERVICE POINTS

<<A>> SEALING CAP REMOVAL
Sealing cap
AK204301 AB
1. Drive a screwdriver into the center of the sealing

cap.
2. Bend the screwdriver back to remove the sealing
cap.
22B-20
TRANSMISSION
<> TRANSAXLE CASE REMOVAL

1. Remove all sixteen bolts securing the transaxle
case to the clutch housing.
<<D>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH

SPEED SHIFT FORK/5TH SPEED-REVERSE
SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK
REMOVAL
Reverse
shift lug
Snap ring
AK204226 AB
2. Use snap ring pliers to expand the indicated snap

ring. The snap ring will release the grooved ball
bearing, and the output shaft assembly will fall
under its own weight.
!
CAUTION
Do not use a scraper or chisel to remove the

transaxle case.
3. Remove the transaxle case from the clutch
housing by gently prying on opposite sides at the
same time.
AK204179AB
1. While sliding the reverse shift lug in the direction

shown, remove the 5th speed shift fork, 5th speed
shift rail, reverse shift lug, snap ring, steel ball and
reverse interlock rail.
3rd-4th speed
shift rail
<<C>> REVERSE IDLER GEAR SHAFT REMOVAL

3rd-4th speed
synchronizer sleeve
AK204180AB
2. While sliding the 3rd-4th speed shift rail in the

direction shown, remove it together with the shift
fork.
AK204178AB
1. Shift the 3rd-4th speed synchronizer sleeve

toward the 4th speed side.
<<E>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH

SPEED SHIFT FORK/5TH SPEED-REVERSE
SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK
REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th speedreverse shift fork in the direction shown.
3rd-4th
speed
shift fork
5th speed
reverse
shift fork
AK204222 AB
22B-21
TRANSMISSION
2. Pull up on the 3rd-4th speed shift rail and 5th

speed-reverse shift rail and take them out of the
hole in the clutch housing.
3rd-4th speed
shift rail
5th speedreverse
shift rail
AK204223 AB
3. Slide the 3rd-4th speed shift rail and 5th speedreverse shift rail in the direction shown and
remove them together with the shift forks.
<<F>> INPUT SHAFT AND OUTPUT SHAFT
REMOVAL
<F5M41>
Input shaft
Output shaft
ADJUSTMENT BEFORE REASSEMBLY

SPACER SELECTION FOR DIFFERENTIAL CASE
PRELOAD ADJUSTMENT
Solders
AK204227 AB
1. Put solders (1.6 mm diameter, about 10 mm long)

in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential
assembly into the transaxle case.
NOTE: If necessary, replace the differential case
and taper bearing before carrying out these
adjustments.
3. Install the clutch housing and tighten the bolts to
the specified torque.
Tightening torque: 44 5 Nm
4. Remove the clutch housing, and then remove the
differential assembly.
5. Remove the outer race and take out crushed
solders.
AK204181AB
<F5M42>
Input shaft
Output shaft
AK300685
AK204224 AC
Remove the input and output shafts together.
6. Measure the thickness of the crushed solder with

a micrometer and select a spacer that will provide
the standard preload value.
Standard value:
0.05 0.17 mm preload <F5M41>
0.05 0.11 mm preload <F5M42>
22B-22
TRANSMISSION
REASSEMBLY SERVICE POINTS

>>A<< OUTPUT SHAFT/INPUT SHAFT
INSTALLATION
<F5M41>
Input shaft
>>C<< REVERSE INTERLOCK RAIL/STEEL

BALL/5TH SPEED-REVERSE SHIFT RAIL/
REVERSE SHIFT LUG/SNAP RING/5TH SPEEDREVERSE SHIFT FORK/3RD-4TH SPEED SHIFT
FORK/3RD-4TH SPEED SHIFT RAIL
INSTALLATION
Output shaft
3rd-4th speed
shift rail
3rd-4th speed
shift fork
AK204181AB
<F5M42>
AK204180AC
Input shaft
1. Install the 3rd-4th shift rail and fork.

Output shaft
5th speed shift fork
Reverse interlock rail
AK204224 AC
5th speed
shift rail
Steel ball
(inside)
Install the input and output shafts together.

>>B<< FRONT BEARING RETAINER
INSTALATION
Reverse
shift lug
Snap ring
Reverse
shift lug
Snap ring
5 mm
AK204183AB
Apply a sealant to the front bearing retainer mounting

bolts (countersunk bolts only).
3M STUD Locking NO. 4170 or equivalent
5th speed shift rail
AK204185AB
Reverse
interlock
rail
Steel ball
AK204186AB
2. Install the reverse interlock rail, stell ball, 5th

speed shift rail, 5th spped shift rork, reverse shift
lug and snap ring in the illustrated positions.
22B-23
TRANSMISSION
Reverse
shift lug
5th speedreverse
shift rail
3rd-4th speed
shift rail
AK204179AB
3. While sliding the reverse shift lug in the direction

shown, install the 5th speed shift fork, 5th speed
shift rail, reverse shift lug, snap ring, steel ball and
reverse interlock rail.
>>D<< 5TH SPEED-REVERSE SHIFT FORK/5TH
SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/3RD-4TH SPEED SHIFT RAIL
INSTALLATION
3rd-4th speed
synchronizer
sleeve
5th speedreverse
synchronizer
sleeve
AK204223 AC
3. While fitting each shift fork in the groove of

synchronizer sleeve, slide the shift rails in the
direction shown and install.
4. Insert the 3rd-4th speed shift rail and 5th speedreverse shift rail into the rail hole in the clutch
housing.
>>E<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork.
Shift fork
Shift rail
Spring pin
AK204229AB
1. Shift the 3rd-4th speed synchronizer sleeve and

5th speed-reverse synchronizer sleeve in the
direction shown.
5th speedreverse
shift fork
2.5 mm
AK204302 AC
2. Insert the new spring pin. Push it in as shown so

that the slit and center axis of the rail are aligned.
>>F<< SPACER INSTALLATION
Install the spacer selected in the section
"ADJUSTMENT BEFORE REASSEMBLY."
3rd-4th speed
shift fork
5th speedreverse
shift rail
>>G<< SPACER AND OUTER RACE

INSTALLATION
1. Install the spacer selected in the section
"ADJUSTMENT BEFORE REASSEMBLY."
AK204230 AB
2. Assemble the 3rd-4th speed shift rail and fork,

and the 5th speed-reverse shift rail and fork.
MB990938
MB990935
AK204231 AB
22B-24
TRANSMISSION
2. Using special tools, press the outer race into the

transaxle case.
Installer adapter (MB990935)
Handle (MB990938)
>>J<< TRANSAXLE CASE INSTALLATION

!
CAUTION
Squeeze sealant evenly onto the transaxle

housing. Do not leave gaps or excess amounts,
otherwise oil leaks are likely.
>>H<< OIL GUIDE INSTALLATION
Oil guide
AK204232AB
AK204188AB
install the oil guide as shown in the illustration.

<> REVERSE IDLER GEAR SHAFT
INSTALLATION
3rd-4th speed
synchronizer sleeve
AK204178AB
1. Shift the 3rd-4th speed synchronizer sleeve

toward the 4th speed side.
Reverse idler
gear shaft
AK204190AB
2. Face the threaded hole of the reverse idler gear

shaft toward the direction shown.
1. Apply a 2 mm diameter bead of sealant

(Mitsubishi Genuine Part number MD997740 or
equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto
the transaxle housing while the sealant is still wet
(within 15 minutes).
Snap ring
AK204226 AB
2. Align the transaxle case and expand the snap

ring. After the case is on far enough for the snap
ring to ride on the bearing, release the snap ring.
Push down on the transaxle case, twisting it from
side to side until the case contacts the housing.
3. Tighten the transaxle case mounting bolts to the
specified torque.
4. Place the transaxle upside down and let the snap
ring fit in the groove by the output shafts own
weight.
NOTE: After installation, keep the sealed area
away from oil for approximately one hour.

TRANSMISSION
>>K<< SEALING CAP INSTALLATION
22B-25
>>M<< UNDER COVER INSTALLATION

!
CAUTION
Squeeze sealant onto the case. Do not leave

gaps or excess amounts, otherwise oil leaks are
likely.
MB990938
MB990927
AK204234 AB
1. Using special tools, press install the sealing cap

onto the case.
Handle (MB990938)
Sealing cap
AK204233 AB
2. Evenly press the sealing cap so it is fully seated

and not at an angle.
AK204235AB
1. Apply a 2 mm diameter bead of sealant

equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the
case quickly while the sealant is still wet (within 15
minutes).
2. Install the under cover to the transaxle case and
tighten the bolts to specified torque.
Tightening torque: 6.9 0.9 Nm
away from oil for approximately one hour.
>>N<< CONTROL HOUSING INSTALLATION
>>L<< REVERSE IDELER GEAR SHAFT BOLT

INSTALLATION
CAUTION
Squeeze sealant onto the case. Do not leave

gaps or excess amounts, otherwise oil leaks are
likely.
AK300679
Using a Phillips screwdriver (8 mm in shank

diameter) center the bolt hole.
AK204236AB
1. Apply a 0.2 mm diameter bead of sealant

equivalent) as llustrated onto the control housing.
NOTE: Be sure to install the housig to the case
quickly while the sealant is still wet (within 15
minutes).
2. Install the control housing to the transaxle case
and tighten the bolts to specified torque.
22B-26
TRANSMISSION
away from the oil for approximately one hour.
>>O<< SPEEDOMETER GEAR INSTALLATION
O-ring
1. Apply grease (Mitsubishi Genuine Part number

0101011 or equivalent) to the control shaft sliding
portion of the select lever shoe.
2. Install the select lever and tighten the bolts to
specified torque.
INSPECTION
M1222001100134
BACKUP LIGHT SWITCH
AK204237 AB
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or

75W-85W conforming to API classification GL-4)
to the O-ring of the speedometer gear. Install into
the transaxle housing.
2. Tighten the bolt to specified torque.
Tightening torque: 3.9 1.0 Nm
>>P<< SELECT LEVER INSTALLATION
Control shaft
Select lever
shoe
AK204238 AB
AK300684
Check for continuity between terminals.

SWITCH CONDITION
CONTINUITY
Pressed
Open
Released
Conductive
22B-27
INPUT SHAFT
INPUT SHAFT
M1222001600140
<F5M41>
9
10

moving parts before
installation.
12
14
13
15
16
19 17
18
11
20
21
23
24
1
6
25
4
22
21
5
6
AK300291AB
DIsassembly steps
Snap ring
Ball bearing
3. Input collar
>>N<< 4. Synchronizer sleeve
<> >>M<< 5. 5th speed-reverse synchronizer
hub
6. Synchronizer lever
7. Synchronizer ring
8. 5th speed gear
9. Needle roller bearing
<<C>> >>I<< 10. 5th speed gear sleeve
11. 4th speed gear
>>P<< 1.
<<A>> >>O<< 2.
<<F>> >>H<<
>>E<<
>>D<<
>>G<<
>>F<<
>>E<<
>>D<<
13.
14.
15.
16.
17.
18.
19.
20.
21.
>>C<< 22.
<<G>> >>B<< 23.
>>A<< 24.
25.
DIsassembly steps (Continued)

4th speed gear sleeve
Synchronizer ring
Synchronizer spring
Synchronizer sleeve
Synchronizer ring
Synchronizer spring
3rd speed gear
Needle roller bearing
Snap ring
Ball bearing
Oil seal
Input shaft
22B-28
INPUT SHAFT
<F5M42>
9
moving parts before
installation.
11
10
12
14
13
15
16
19
18
20
4
6
7
16
17
AK204391AB
>>P<<
<<A>> >>O<<
<<D>> >>L<<
>>K<<
<<E>> >>J<<
<<F>> >>H<<
>>E<<
>>D<<
>>G<<
>>F<<
>>E<<
>>D<<
>>C<<
<<G>> >>B<<
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Disassembly steps
Snap ring
Ball bearing
Thrust plate stopper
Thrust plate
5th speed gear
4th speed gear
Synchronizer ring
Synchronizer spring
Synchronizer sleeve
Synchronizer ring
Synchronizer spring
3rd speed gear
Snap ring
Ball bearing
Oil seal
Input shaft

<<A>> BALL BEARING REMOVAL
MD998801
AK204239 AB
1. Using special tool Bearing remover (MD998801),

support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.
22B-29
INPUT SHAFT
<> 5TH SPEED-REVERSE SYNCHRONIZER

HUB REMOVAL
<<E>>5TH SPEED GEAR REMOVAL
MD998801
MD998917
AK204240 AB
AK203125AC

support the 5th speed gear, and then set them on
the press.
remove the 5th speed-reverse synchronizer hub.

the press.
remove the 5th speed gear.
<<F>>4TH SPEED GEAR SLEEVE REMOVAL
<<C>>5TH SPEED GEAR SLEEVE REMOVAL

MD998801
4th speed gear
MD998801
AK204241 AB
AK204193AB

the press.
remove the 5th speed gear sleeve.

support the 3rd speed gear, and then set them on
the press.
remove the 4th speed gear sleeve.
<<G>> BALL BEARING REMOVAL
<<D>> THRUST PLATE STOPPER REMOVAL

MD998801
AK204242 AB
AK204293AB
Using a screwdriver, pry up at the position shown in

the illustration and remove the thrust plate stopper.

press.
22B-30
INPUT SHAFT
Standard value: 0 0.12 mm

>>A<< OIL SEAL INSTALLATION
>>D<< SYNCHRONIZER SPRING INSTALLATION

Oil seal
3.5 mm
AK204243 AC
Install the oil seal into the end of the input shaft as
shown.
SYNCHRONIZER
Synchrnizer
SPRING
spring
AK204263AB
Install the synchronizer spring onto the synchronizer

ring as shown.
>>B<< BALL BEARING INSTALLATION

>>E<< SYNCHRONIZER RING INSTALLATION
MD998812
MD998813
MD998801
MD998816
CAUTION
There are 3rd speed and 4th speed synchronizer

rings, if the wrong one is installed it will effect
the shift feeling.
Notch
AK204244AC

support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, press install the ball bearing
with the press.
Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998816)
>>C<< SNAP RING INSTALLATION
AK204312 AB
1. Ascertain whether or not there are identification

notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it completely
fits over the machined cone of the gear.
>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Installation
direction
Snap ring
AK204245 AB
1. Install the thickest snap ring that can be fitted in

the snap ring groove of input shaft.
2. Make sure that the front bearing end play meets
the standard value.
Groove
AK204295 AB
22B-31
INPUT SHAFT

2. Make sure that the synchronizer ring has been
perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th
speed synchronizer hub, and put it on the input
shaft.
MD998801
2. Install the synchronizer sleeve so that the areas

with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
>>H<< 4TH SPEED GEAR SLEEVE
INSTALLATION
MD998812
MD998812
MD998813
MD998813
MD998825
MD998801
AK204247 AC
AK204246 AC
4. Using special tools, press install the 3rd-4th

speed synchronizer hub with the press.
5. Make sure that the synchronizer ring can rotate
freely.
MD998824

2. Using special tools, install the 4th speed gear
sleeve with the press.
>>G<< SYNCHRONIZER SLEEVE INSTALLATION

>>I<< 5TH SPEED GEAR SLEEVE INSTALLATION
Identification
groove
MD998812
MD998813
MD998801
Installation
direction
MD998820
AK204296AC
1. Check the installation direction of the

synchronizer sleeve, and install it onto the 3rd-4th
speed synchronizer hub.
Projecting portion
Deep grooves
AK204199AB
AK204194AB

sleeve onto the input shaft with the press.
22B-32

INPUT SHAFT
>>J<< 5TH SPEED GEAR INSTALLATION
>>L<< THRUST PLATE STOPPER

INSTALLATION
MD998812
MD998812
MD998813
MD998801
MD998813
MD998824
MD998824
AK204248 AB

onto the input shaft with the press.
AK204294 AB
Install the thrust plate stopper by pressing special

tools, by hand. Make sure that it is not tilted.
>>M<< 5TH SPEED-REVERSE SYNCHRONIZER
HUB INSTALLATION
>>K<< THRUST PLATE INSTALLATION

Surface stamped
with identification
mark
Installation
direction
AK300567AB
Thrust plate
AK204249AB
1. Install the thickest thrust plates that can be fitted

in the groove of the input shaft. Install the thrust
plate so the surface stamped with the
identification mark is facing up.
2. Make sure that the 5th speed gear end play meets
the standard value.
1. Check that the 5th speed- reverse synchronizer

hub is in the correct installation direction, and put
it on the input shaft.
MD998812
MD998819
MD998801
AK204197AB

support the input shaft gear, and then set them on
the press.
3. Using special tools, install the 5th speed-reverse
synchronizer hub with the press.
22B-33
INPUT SHAFT
4. Make sure that the synchronizer ring on the 5th

speed gear side can rotate freely.
>>O<< BALL BEARING INSTALLATION

<F5M41>
>>N<< SYNCHRONIZER SLEEVE INSTALLATION

Identification groove
MD998812
MD998818
MD998801
Installation
direction
AK204213 AB
<F5M42>
MD998812
MD998818
AK204198AB
1. Install the synchronizer sleeve so that the

identification grooves are oriented in the direction
shown.
MD998801
Projecting portion
AK204250 AB
Deep grooves
AK204199AB
2. When the synchronizer sleeve is installed, check

that the deep groove portion of the synchronizer
hub is aligned with the projecting portion of the
sleeve.

2. Using special tools, install the ball bearing onto
the input shaft with the press.
>>P<< SNAP RING INSTALLATION
<F5M41>
Snap ring
AK300360AB
<F5M42>
Snap ring
AK204251 AB
22B-34

INPUT SHAFT

the groove of the input shaft.
2. Make sure that the rear bearing end play meets
the standard value.
Standard value:
0 0.09 mm <F5M41>
0 0.12 mm <F5M42>
Gear
INSPECTION
A
Synchronizer
ring
AK204307 AB
M1222001700125
3. Force the synchronizer ring toward the clutch gear

and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
Minimum limit: 0.5 mm
INPUT SHAFT
SYNCHRONIZER SLEEVE AND HUB

Sleeve
AK204201AB
1. Check the outside diameter of the needle bearing

mounting portion for damage, abnormal wear and
seizure.
2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not
damaged or worn.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input
shaft or bearing sleeve and gear, and check that it
rotates smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER RING
Hub
AK204217 AB
1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or
broken.
SPEED GEARS
AK204298AB
1. Check the clutch gear teeth for damage and

broken.
2. Check internal surface for damage, wear and
broken threads.
AK204299AB
1. Check that the helical and clutch gear tooth

surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
22B-35
OUTPUT SHAFT
3. Check that the gear inside diameter and front and

rear surfaces are not damaged and worn.
OUTPUT SHAFT
M1222002200134
<F5M41>
21

moving parts before
installation.
20
22
23
16
17
26
18
19
25
24
1
3
9
4
10
13 12
15
11
7
14
8
9
AK300292AB
Disassembly steps
Snap ring
Ball bearing
3. Collar
4. 5th speed gear
>>J<< 5. 4th speed gear
>>I<< 6. Snap ring
<<D>> >>H<< 7. 3rd speed gear
8. 2nd speed gear
<<E>> >>G<< 10. 2nd speed gear sleeve
11. Inner synchronizer ring
12. Synchronizer cone
>>Q<< 1.
<<A>> >>P<< 2.
13.
>>D<< 14.
>>F<< 15.
>>E<< 16.
17.
>>D<< 18.
19.
20.
21.
22.
<<F>> >>C<< 23.
>>B<< 24.

Outer synchronizer ring
Synchronizer spring
Synchronizer sleeve
1st-2nd speed synchronizer hub
Synchronizer spring
Synchronizer cone
Inner synchronizer ring
1st speed gear
1st speed gear sleeve
Snap ring
22B-36
OUTPUT SHAFT
<F5M42>
<<G>> >>A<< 25. Roller bearing inner race

26. Output shaft
20

moving parts before
installation.
22
24
26
19
18
27
29
21
23
25
1
28
30
32
31
13
33
3 2
36
12
34
15
35
17
14 10 11
6
4
13
16
>>Q<< 1.
<<A>> >>P<< 2.
<> >>O<< 3.
>>M<<
>>L<<
>>F<<
<<C>> >>N<<
4.
5.
6.
7.
8.
9.
>>M<< 10.
>>L<< 11.
12.
13.
>>K<< 14.
>>J<< 15.
>>I<< 16.
<<D>> >>H<< 17.
Disassembly steps
Snap ring
Ball bearing
Reverse gear sleeve
Reverse gear
Synchronizer ring
Synchronizer spring
Synchronizer sleeve
5th speed-reverse synchronizer
hub
Synchronizer ring
Synchronizer spring
5th speed gear
4th speed gear
Snap ring
3rd speed gear
AK300024AB
<<E>> >>G<<
>>D<<
>>F<<
>>E<<
>>D<<
<<F>> >>C<<
>>B<<
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

2nd speed gear
Synchronizer cone
Synchronizer spring
Synchronizer sleeve
1st-2nd speed synchronizer hub
Synchronizer spring
Synchronizer cone
1st speed gear
Snap ring
22B-37
OUTPUT SHAFT
<<G>> >>A<< 35. Roller bearing inner race

36. Output shaft

support the reverse gear, and then set them on
the press.
2. Push down on the output shaft with the press and
remove the reverse gear bearing sleeve.

<F5M41>
MD998801
Ball bearing
<<C>> 5TH SPEED-REVERSE SYNCHRONIZER

HUB REMOVAL
Synchronizer hub
MD998801
AK204202AB
<F5M42>
MD998917
AK204254 AB
Ball bearing

the press.
remove the 5th speed-reverse synchronizer hub.
<<D>> 3RD SPEED GEAR REMOVAL
AK204252 AB
1. Using special tools, support the ball bearing, and

then set them on the press.
Bearing remover (MD998801) <F5M41>
Bearing remover (MD998917) <F5M42>
2. Push down on the output shaft with the press, and
MD998917
3rd speed gear
<> REVERSE GEAR SLEEVE REMOVAL

AK204255 AB
MD998801
Reverse gear
bearing sleeve
AK204253 AB

support the 2nd speed gear, and then set them on
the press.
remove the 3rd speed gear.
22B-38
OUTPUT SHAFT
<<E>> 2ND SPEED GEAR SLEEVE REMOVAL

<F5M41>
MD998917

support the 1st speed gear sleeve, and then set
them on the press.
remove the 1st speed gear sleeve.
1st speed gear
<<G>> ROLLER BEARING INNER RACE

REMOVAL
AK204203AB
MD998917
Roller bearing
inner race
<F5M42>

MD998917
AK204258 AB
AK204256 AB

support the 1st speed gear, and then set them on
the press.
remove the 2nd speed gear sleeve.
<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

support the roller bearing inner race, and then set
them on the press.
remove the roller bearing inner race.

>>A<< ROLLER BEARING INNER RACE
INSTALLATION
<F5M41>
MD998801
MD998801
MD998812
MD998818
Sleeve
Roller bearing
inner race
AK204204AB
<F5M42>

MD998801
AK204257 AB
AK204260 AB

support the output shaft gear, and then set them
on the press.
2. Using special tools, install the roller bearing inner
race with the press.
22B-39
OUTPUT SHAFT
>>B<< SNAP RING INSTALLATION
as shown.
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
1. Set the output shaft on the press support stand.
<F5M41>
Snap ring
AK204261 AB

the groove of output shaft.
2. Make sure that the front bearing end play meets
the standard value.
Installation direction
AK204211AB
<F5M42>
>>C<<1ST SPEED GEAR SLEEVE

INSTALLATION
MD998812
AK204305 AB
MD998814
1st speed gear
sleeve
MD998822 <F5M41>
MD998825 <F5M42>
2. Check that the 1st-2nd speed synchronizer hub is

in the correct installation direction, and put it on
the output shaft.
<F5M41>
MD998812
AK204262 AB
2. Using special tools, install the 1st speed gear

sleeve with the press.
Installer adapter (MD998822) <F5M41>
1st-2nd speed
synchronizer
hub
MD998814
MD998822
AK204205 AB
>>D<< SYNCHRONIZER SPRING INSTALLATION

<F5M42>
MD998812
MD998814
1st-2nd speed
synchronizer
hub
MD998825
Synchronizer spring
AK204265 AB
AK204316AB
Install the synchronizer spring onto the outer

synchronizer ring
3. Using special tools, install the 1st-2nd speed

synchronizer hub with the press.
22B-40
OUTPUT SHAFT

4. Make sure that the outer synchronizer ring on the
1st speed gear side can rotate freely.
>>G<< 2ND SPEED GEAR SLEEVE

INSTALLATION
MD998812
>>F<< SYNCHRONIZER SLEEVE INSTALLATION
MD998813
<F5M41>
MD998820 <F5M41>
MD998822 <F5M42>
AK204266 AB
AK204212AC
<F5M42> Identification
groove
2. Using special tools, install the 2nd speed sleeve

onto the output shaft with the press.
>>H<< 3RD SPEED GEAR INSTALLATION
1. Check that the 2nd speed gear and the outer
synchronizer ring have been properly installed.
Also, make sure the claws on the synchronizer
cone (four places) are correctly fitted into the
holes in the 2nd speed gear (four places).
Installation
direction
AK204296 AB
MD998812
1. Check that the synchronizer sleeve is in the

correct direction for installation, and install it on
the 1st-2nd speed synchronizer hub.
Projecting portion
MD998814
3rd speed gear
MD998820 <F5M41>
MD998822 <F5M42>
AK204267AC
Deep grooves
AK204199AB
2. Install the synchronizer sleeve so that the areas

with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
2. Using special tools, install the 3rd speed gear

3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
22B-41
OUTPUT SHAFT
>>I<< SNAP RING INSTALLATION
Using special tools, install the 5th speed gear sleeve

>>L<< SYNCHRONIZER SPRING INSTALLATION
Snap ring
AK204268AB

2. Make sure that the 3rd speed gear end play
meets the standard value.
>>J<< 4TH SPEED GEAR INSTALLATION
SYNCHRONIZER
Synchrnizer
SPRING
spring
AK204263AB
Install the synchronizer spring onto the synchronizer

ring as shown.
>>M<< SYNCHRONIZER RING INSTALLATION
MD998812
MD998813
4th speed gear
MD998819
CAUTION
There is a 5th speed synchronizer ring and a

reverse synchronizer ring. Be careful not to
confuse the two when installing, as a mistake
can effect the shift feeling.
AK204269 AB

Notch
AK204393AB
>>K<< 5TH SPEED GEAR SLEEVE

INSTALLATION
MD998812
5th speed
gear sleeve
MD998813
MD998819
AK204300 AB
1. Check for the presence of identification notches

on the synchronizer ring.
No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring
2. Install the synchronizer ring so that it fits
completely over the machined cone of the gear.
>>N<< 5TH SPEED-REVERSE SYNCHRONIZER
HUB INSTALLATION
2. Make sure that the synchronizer ring is fitted
correctly on the cone of the 5th speed gear.
22B-42
OUTPUT SHAFT
>>P<< BALL BEARING INSTALLATION

1. Check the installation direction of the ball bearing.
<F5M41>
MD998812
Ball bearing
MD998817
AK204306 AB
3. Check that the 5th speed-reverse synchronizer

hub is oriented correctly for installation, and fit it
on the output shaft.
AK204206 AB
<F5M42>
MD998812
MD998812
MD998813
MD998819
MD998818
Ball bearing
Synchronizer hub
AK204271 AB
AK204228 AB
4. Using special tools, press install the 5th speedreverse synchronizer hub with the press.
5. Make sure that the synchronizer ring on the 5th
speed gear side can rotate freely.
>>O<< REVERSE GEAR SLEEVE INSTALLATION
1. Make sure the synchronizer ring, reverse gear
and needle roller bearing have been correctly
installed.
2. Using special tools, install the ball bearing with

the press.
>>Q<< SNAP RING INSTALLATION
<F5M41>
Snap ring
MD998812
MD998818
Reverse
gear
Reverse gear
sleeve
AK204207AB
<F5M42>
AK204270 AB
2. Using special tools, press fit the reverse gear

sleeve. Make sure that the reverse gear and the
synchronizer ring can rotate freely during the
pressing process.
Snap ring
AK204272 AB
22B-43
OUTPUT SHAFT

2. Make sure that the rear bearing end play meets
the standard value.
A
Synchronizer
ring
Gear
INSPECTION
M1222002300119
OUTPUT SHAFT
AK204307 AB
3. Force the synchronizer ring toward the clutch gear

and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
OUTER SYNCHRONIZER RING/INNER
SYNCHRONIZER RING/SYNCHRONIZER CONE
AK204310AB
1. Check the splines for damage and wear.

2. Check that the helical gear teeth surfaces are not
damaged or worn.
CAUTION
When replacing, replace the outer ring, inner ring

and cone as a set.
NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the
bearing sleeve and gear, and check that it rotates
smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER RING
AK204309AB
1. Check that the clutch gear tooth surfaces and

cone surfaces are not damaged or broken.
Gear
A
Outer ring
Cone
AK204298AB
1. Check if the clutch gear teeth are damaged or

broken.
2. Check internal surface for damage, wear and
broken threads.
Inner ring
AK204259 AB
2. Install the outer ring, inner ring and cone, force

them toward the gear, and check clearance "A". If
"A" is less than the limit, replace them as a set.
22B-44
OUTPUT SHAFT
SYNCHRONIZER SLEEVE AND HUB
Check that the spring is not sagging, deformed or

broken.
Sleeve
SPEED GEARS
Hub
AK204217 AB
1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
SYNCHRONIZER SPRING
AK204314AB
AK204299AB
1. Check that the helical and clutch gear tooth

surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
22B-45
REVERSE IDLER GEAR
REVERSE IDLER GEAR

M1222012500103
<F5M42>

moving parts before
installation.
1
7
2
3
5
6
4
AK204396AB
1.
2.
3.
4.
Disassembly steps
Snap ring
Cone spring
Thrust washer
Steel ball
5.
6.
7.

Reverse idler gear
Reverse idler gear shaft
22B-46
SPEEDOMETER GEAR
SPEEDOMETER GEAR
M1222003400108

moving parts before
installation.
AK204397AB
1.
2.
Disassembly steps
E-clip
Speedometer driven gear
3.
4.

O-ring
Sleeve
22B-47
SELECT LEVER
SELECT LEVER
M1222012800096
6
5
8
2
9
11 1 Nm
3
4
10
AK204398AB
1.
2.
3.
4.
>>A<< 5.
6.
7.
>>A<< 8.
>>A<< 9.
10.
Disassembly steps
Dust cover
Nut
Spring washer
Washer
Select lever bushing
Select lever shoe
Select lever
Select lever bushing
Dust cover
Select lever shaft
REASSEMBLY SERVICE POINT

>>A<< DUST COVER AND SELECT LEVER
BUSHING INSTALLATION
Select lever
bushing
Dust cover
AK204311 AB
Make sure the dust cover and select lever bushing

installation direction is correct, and the distinguished
parts are correctly assembled as shown.
22B-48
CONTROL HOUSING
CONTROL HOUSING
M1222013100131
11
12
13
5
4
8
10
14
2
1
22.3 0.3 Nm
AK301760 AB
<<A>> >>E<<
>>D<<
>>C<<
>>B<<
>>A<<
1.
2.
3
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Disassembly steps
Spring washer
Stopper bracket
Lock pin
Interlock plate
Control finger
Spring pin
Stopper body
Spring
Control shaft
Air breather
Control shaft boot
Oil seal
Needle bearing
Control housing
DISASSEMBLY SERVICE POINT

<<A>> LOCK PIN REMOVAL
Lock pin
Control finger
AK204273 AB
Drive out the lock pin from the direction shown.
22B-49
CONTROL HOUSING

>>A<< NEEDLE BEARING INSTALLATION
1. Apply sealant (3M SUPER WEATHERSTRIP No.

8001 or equivalent) to the inserting portion of air
breather.
Control housing
Needle bearing
Model number
stamped side
Emboss
mark
0 0.5 mm
AK204176AC
Press fit the needle bearing into the control housing

side as shown.
Make sure that the side with the model number
stamped on it faces the end of the control housing as
shown.
AK204220 AB
2. Install the air breather so that the embossed mark

is in the direction shown in the figure.
>>D<< SPRING PIN INSTALLATION
>>B<< OIL SEAL INSTALLATION

Control shaft
Stopper body
Slit
Spring pin
AK204177AB
AK204303AB
Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W85W conforming to API classification GL-4) to the oil
seal lip area.
Drive in the spring pin so that the slit is in the

direction shown in the figure.
>>E<<LOCK PIN INSTALLATION
>>C<< AIR BREATHER INSTALLATION
AK204273 AC
Drive the lock pin in from the direction shown in the

figure.
AK204274AB
22B-50
CLUTCH HOUSING
CLUTCH HOUSING
M1222003700132
4
8
5
6
2
1
9.8 2.0 Nm
AK300521AB
>>E<<
>>D<<
<<A>> >>C<<
<> >>B<<
>>A<<
1.
2.
3
4.
5.
6.
7.
8.
Disassembly steps
Clutch release bearing retainer
Oil seal
Oil seal
Outer race <F5M42>
Outer race
Oil guide <F5M41>
Bushing
Clutch housing

<<A>> OUTER RACE REMOVAL
MD999566
AK204276 AB
Using special tool Claw (MD999566), remove the

outer race from the clutch housing.
22B-51
CLUTCH HOUSING
<> OUTER RACE REMOVAL

MD998772
>>B<< OUTER RACE INSTALLATION
MD998346
Model number
stamped side
AK204277AB
1. Set special tools as indicated in the figure.

Valve spring compressor (MD998772)
Bearing outer race remover (MD998346)
2. Turn the nut on special tool Bearing outer race
remover (MD998346) to pull up on the tool and
take out the outer race.
AK204279 AB
1. Check the installation direction of the outer race.

Install the outer race so the side with the model
number stamping can be seen.
MB990938
MB990934

>>A<< BUSHING INSTALLATION
AK204280 AB
Seam of bushing
2. Using special tools, press fit the outer race into

the clutch housing.
Handle (MB990938)
Air vent
>>C<< OUTER RACE INSTALLATION

1. Check the installation direction of the outer race.
AK204278 AB
1. Press fit the bushing so the seam is away from

the air vent.
1 mm
MB990938
MB990935
AK204281 AB
AK204291 AC
2. Be sure the bushing is fully seated as shown. It

must be 1 mm below the housing surface.
2. Using special tools, press fit the outer race into

the clutch housing.
Handle (MB990938)
22B-52

CLUTCH HOUSING
>>D<<OIL SEAL INSTALLATION
>>E<< OIL SEAL INSTALLATION
AK204284AB
AK204282AB

75W-85W conforming to API classification GL-4)
to the oil seal lip.
1. Apply transmission oil (Hypoid gear oil SAE 75W90 or 75W-85W conforming to API classification
GL-4) to the oil seal lip.
MB990938
MD998325
MB990926
AK204283 AB
2. Using special tool Differential oil seal installer

(MD998325), press fit the oil seal into the clutch
housing.
AK204285 AB
2. Using special tools, press fit the oil seal into the
clutch housing.
Handle (MB990938)
22B-53
TRANSMISSION CASE
TRANSMISSION CASE
M1222013400109
1
2
6
AK204407AB
>>C<< 1.
>>B<< 2.
3.
4.
>>A<< 5.
6.
Disassembly steps
Oil seal
Needle bearing
Oil guide
Snap ring
Bushing
Transaxle

>>A<< BUSHING INSTALLATION
Seam of bushing
Air vent
AK204292 AB
1. Press fit the bushing so the seam is away from

the air vent.
22B-54
TRANSMISSION CASE
>>C<<OIL SEAL INSTALLATION
3 mm
AK204304 AC
2. Be sure the bushing is fully seated as shown. It

must be 3 mm below the housing surface.
AK204286AB

75W-85W conforming to API classification GL-4).
>>B<< NEEDLE BEARING INSTALLATION

1. Check the installation direction of the needle
bearing.
MD998325
Model number
stamped side
AK204288 AB
AK204287 AB
2. Press fit the needle bearing until it is flush with the

case.
2. Using special tool Differential oil seal installer

(MD998325), press fit the oil seal into the
transaxle case.
22B-55
DIFFERENTIAL
DIFFERENTIAL
M1222002500124

moving parts before
installation.
4
7
5
3
9
132 5 Nm
6
2
7
10
AK300293AB
>>E<<
<<A>> >>D<<
<> >>C<<
>>B<<
>>A<<
>>A<<
>>A<<
>>A<<
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Disassembly steps
Differential drive gear
Ball bearing <F5M41>
Taper roller bearing <F5M42>
Lock pin
Pinion shaft
Pinion
Washer
Side gear
Spacer
Differential case

MD998801
AK204208AB

press.
2. Push down on the differential case with the press
and remove the bearing.
22B-56

DIFFERENTIAL
<> TAPER ROLLER BEARING REMOVAL

MD998801
AK300683
AK204289 AB
3. Insert the pinion shaft.

support the taper roller bearing, and then set them
on the press.
2. Push down on the differential case with the press
and remove the bearing.

>>A<< SPACER/SIDE GEAR/WASHER/PINION/
PINION SHAFT INSTALLATION
AK300681
4. Measure the backlash between the side gear and

pinion.
5. If the backlash is out of specification, select a
spacer that should get the back lash with in the
standard value and re-measure the backlash.
NOTE: Repeat until the backlash on both sides
are equal.
AK300682
1. After a spacer has been mounted on the back

surface of the side gear, install the side gear in
the differential case.
NOTE: When a new side gear is to be installed,
mount a medium thickness spacer (1.01 1.08
mm).
2. Set the washer on the back of each pinion, and
put both pinions simultaneously in mesh with the
side gears. While rotating them, install them in
position.
>>B<<LOCK PIN INSTALLATION

Differential case
Lock pin
Pinion shaft
AK204290 AB
Install the lock pin so that it will be oriented in the

direction shown.
22B-57
DIFFERENTIAL
>>C<< TAPER ROLLER BEARING

INSTALLATION
MD998812
MD998823
>>E<< DIFFERENTIAL DRIVE GEAR

INSTALLATION
Taper roller
bearing
AK204319 AC
Using special tools, install the taper roller bearing

with the press.
AK204320AB
1. Apply sealant (3M STUD Locking No.4170 or

equivalent) to the entire threaded portion of the
bolt.
<F5M41>
>>D<< BALL BEARING INSTALLATION
5
MD998812
Ball bearing
MD998819
AK204210 AB
<F5M42>
AK204209AC
Using special tools, install the ball bearing with the

press.
7
6
2
4
AK204221 AB
2. Tighten to the specified torque in the illustrated

sequence.
127(6

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22B-1

INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-27

INPUT SHAFT INSPECTION . . . . . . . . . . .

SNAP RING, SPACER AND

OUTPUT SHAFT DISASSEMBLY AND

OUTPUT SHAFT INSPECTION . . . . . . . . .

TRANSMISSION DISASSEMBLY AND

REVERSE IDLER GEAR DISASSEMBLY

SPEEDOMETER GEAR . . . . . . . . . . . 22B-46

SELECT LEVER . . . . . . . . . . . . . . . . . 22B-47

Continued on next page

TRANSMISSION CASE . . . . . . . . . . . 22B-53

MANUAL TRANSMISSION OVERHAUL

MANUAL TRANSMISSION MODELS

MANUAL TRANSMISSION OVERHAUL

MANUAL TRANSMISSION OVERHAUL

MANUAL TRANSMISSION OVERHAUL

TRANSMISSION MODEL TABLE

GEAR RATIO TABLE

Differential case preload <F5M41>

Differential case preload <F5M42>

Input shaft front bearing end play

Input shaft 5th speed gear end play <F5M42>

Input shaft rear bearing end play <F5M41>

Input shaft rear bearing end play <F5M42>

Synchronizer ring back surface to gear clearance

Output shaft front bearing end play

Output shaft 3rd speed gear end play

Output shaft rear bearing end play

Backlash between differential gear and pinion

MANUAL TRANSMISSION OVERHAUL

SNAP RING, SPACER AND THRUST PLATE FOR

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M41>

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>

MANUAL TRANSMISSION OVERHAUL

MANUAL TRANSMISSION OVERHAUL

Roll stopper bracket mounting bolt

Shift cable bracket mounting bolt

Select lever mounting bolt

Speedometer gear mounting bolt

Backup light switch

Restrict ball <F5M41>

Harness bracket bolt

Harness bracket bolt <F5M42>

Interlock plate bolt

Control housing mounting bolt

Under cover mounting bolt <F5M42>

Reverse idler gear shaft mounting bolt

Clutch housing-transaxle case mounting bolt

Reverse shift lever bolt <F5M41>

Front bearing retainer mounting bolt

Select lever mounting nut

Stopper bracket mounting bolt

Clutch release bearing retainer mounting bolt

Differential drive gear mounting bolt

MANUAL TRANSMISSION OVERHAUL

SEALANTS AND ADHESIVES

Clutch housing-transaxle case mating surface

MITSUBISHI Genuine sealant part No. MD997740 or