22B-1

GROUP 22B

MANUAL
TRANSAXLE
OVERHAUL
<W5M51>
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 22B-2 CONTROL HOUSING . . . . . . . . . . . . . 22B-38

DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-38
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-3
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-41
TRANSAXLE . . . . . . . . . . . . . . . . . . . 22B-6 DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-41
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-15 TRANSMISSION CASE . . . . . . . . . . . 22B-45
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-45
INPUT SHAFT . . . . . . . . . . . . . . . . . . 22B-16
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-16 CENTER DIFFERENTIAL. . . . . . . . . . 22B-48
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-22 DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-48

OUTPUT SHAFT . . . . . . . . . . . . . . . . 22B-24 TRANSFER . . . . . . . . . . . . . . . . . . . . . 22B-52

DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-24 DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-32
SPECIFICATIONS . . . . . . . . . . . . . . . 22B-54
REVERSE IDLER GEAR . . . . . . . . . . 22B-35 FASTENER TIGHTENING
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-35 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 22B-54
GENERAL SPECIFICATIONS . . . . . . . . . . 22B-54
VEHICLE SPEED SENSOR. . . . . . . . 22B-36 SERVICE SPECIFICATIONS . . . . . . . . . . . 22B-55
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-36 SEALANTS AND ADHESIVES . . . . . . . . . . 22B-55
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 22B-55
SELECT LEVER. . . . . . . . . . . . . . . . . 22B-37 SNAP RINGS, SPACERS AND THRUST
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-37 PLATE FOR ADJUSTMENT . . . . . . . . . . . . 22B-56
22B-2 MANUAL TRANSAXLE OVERHAUL <W5M51>
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1222000100250

SECTIONAL VIEW

AK302763

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIAL TOOLS
22B-3
SPECIAL TOOLS
M1222000600277

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB990935 MB990935-01 or Installation of output shaft taper
Installer adapter General service tool roller bearing outer race and
center differential rear taper
roller bearing outer race

MB990938 MB990938-01 Use with Installer adapter

Handle

MD998801 MD998348-01 or Installation and removal of

Bearing remover General service tool gears, bearings and sleeves

MD998812 General service tool Use with Installer and Installer

Installer cap adapter

MD998813 General service tool Use with Installer cap and

Installer-100 Installer adapter

MD998818 MD998818 Installation of input shaft front

Installer adapter (38) bearing

MD998825 General service tool Installation of 1st speed gear

Installer adapter (52) sleeve, 3rd-4th speed
synchronizer hub, 4th speed
gear sleeve, 5th speed gear
and thrust plate stopper

MD998819 General service tool Installation of input shaft rear

Installer adapter (40) bearing and output shaft taper
roller bearing

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22B-4 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MD998917 General service tool Installation and removal of
Bearing remover gears, bearing and sleeves

MD998814 MIT304180 Use with Installer cap and

Installer-200 Installer adapter

MD998824 General service tool Installation of 1st-2nd speed

Installer adapter (50) synchronizer hub, 1st speed
gear sleeve, 2nd speed gear
sleeve and 3rd speed gear

MD998364 MD998364-01 Installation of gear, bearing and

Camshaft oil seal sleeve
installer

MD998821 MD998821 Installation of 4th speed gear,

Installer adapter (44) 5th speed gear sleeve and
5th-reverse speed synchronizer
hub

MD998820 MIT215013 Installation of reverse gear

Installer adapter (42) bearing sleeve

MD999566 General service tool Removal of taper roller bearing

Claw outer race

MB991445 MB991445 Installation of differential front

Bushing remover and taper roller bearing outer race
installer base

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIAL TOOLS
22B-5
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MB990928 MB990928-01 Installation of input shaft oil seal
Installer adapter

MD998800 General service tool Installation of differential oil seal

Oil seal installer and transfer oil seal

MB990930 MB990930-01 Removal of center differential

Installer adapter front taper roller bearing

MB990937 MB990937 or Installation of center differential

Installer adapter General service tool front taper roller bearing and
transfer oil seal

MD998823 General service tool Installation of center differential

Installer adapter (48) rear taper roller bearing

MD999506 − Installation of transfer oil seal

Crankshaft installer

MB990936 MB990936-01 or Installation of transfer oil seal

Installer adapter General service tool

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22B-6 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE

TRANSAXLE
DISASSEMBLY AND ASSEMBLY
M1222001000472

70 ± 10 N·m 18 ± 3 N·m
52 ± 7 ft-lb 13 ± 2 ft-lb
18 ± 3 N·m 32 ± 2 N·m
13 ± 2 ft-lb 23 ± 1 ft-lb 11
32 ± 2 N·m 12
23 ± 1 ft-lb
7
9
6 10
3.9 ± 1.0 N·m
34 ± 8 in-lb

5 8

2 70 ± 10 N·m
52 ± 7 ft-lb

69 ± 9 N·m 3
51 ± 7 ft-lb

AK501263 AB

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. TRANSFER >>H<< 7. SELECT LEVER
2. O-RING 8. VEHICLE SPEED SENSOR
3. FRONT ROLL STOPPER 9. BACKUP LIGHT SWITCH
BRACKET 10. GASKET
4. REAR ROLL STOPPER BRACKET 11. POPPET
5. ROLL STOPPER BRACKET 12. GASKET
ADAPTER
6. SHIFT CABLE BRACKET

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE
22B-7

15
18 ± 3 N·m
13 ± 2 ft-lb
30 ± 3 N·m
APPLY GEAR OIL 22 ± 2 ft-lb
TO ALL MOVING
PARTS BEFORE 16 13
INSTALLATION.

44 ± 5 N·m
14
32 ± 3 ft-lb

21
24
22

19
18
20
48 ± 6 N·m
35 ± 4 ft-lb

17
6.9 ± 0.9 N·m
25 61 ± 7 in-lb
23
26

AK302767 AG

DISASSEMBLY STEPS DISASSEMBLY STEPS

13. INTERLOCK PLATE BOLT 20. REVERSE IDLER GEAR
14. GASKET >>E<< 21. TRANSAXLE CASE
>>G<< 15. CONTROL HOUSING >>D<< 22. OUTER RACE
16. NEUTRAL RETURN SPRING >>D<< 23. OUTER RACE
>>F<< 17. UNDER COVER >>D<< 24. SPACER
18. REVERSE IDLER GEAR SHAFT >>D<< 25. SPACER
BOLT >>D<< 26. SPACER
19. GASKET

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22B-8 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE

30
APPLY GEAR OIL 29
TO ALL MOVING 27 33
PARTS BEFORE 36 31
INSTALLATION.

28
32
35

34

39

37

38

AK201617 Ai

DISASSEMBLY STEPS DISASSEMBLY STEPS

>>C<< 27. SPRING PIN <<B>> >>B<< 34. 5TH-REVERSE SPEED SHIFT
28. 1ST-2ND SPEED SHIFT RAIL RAIL
29. 1ST-2ND SPEED SHIFT FORK <<B>> >>B<< 35. 5TH-REVERSE SPEED SHIFT
>>C<< 30. SPRING PIN FORK
<<A>> >>C<< 31. SPRING PIN <<C>> >>A<< 36. CENTER DIFFERENTIAL
<<B>> >>B<< 32. 3RD-4TH SPEED SHIFT RAIL <<C>> >>A<< 37. OUTPUT SHAFT
<<B>> >>B<< 33. 3RD-4TH SPEED SHIFT FORK <<C>> >>A<< 38. INPUT SHAFT
39. CLUTCH HOUSING

Required Special Tools:

• MB990935: Installer Adapter
• MB990938: Handle

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE
22B-9
DISASSEMBLY SERVICE POINTS
.

<<A>> SPRING PIN REMOVAL

1. Shift the 5th-reverse shift fork in the direction shown in the
5TH-REVERSE
SHIFT FORK illustration.
2. Using a pin punch, remove the spring pin from the shift fork
and rail.

AK201618AE

<<B>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH

SPEED SHIFT FORK/5TH-REVERSE SPEED
SHIFT RAIL/5TH-REVERSE SPEED SHIFT FORK
REMOVAL
5TH-REVERSE
1. Pull out the shift rails from the shift rail holes in the clutch
SHIFT RAIL housing.
2. Remove the shift rails together with the shift forks.
3RD-4TH SPEED
SHIFT RAIL

AK201619AE

<<C>> CENTER DIFFERENTIAL/OUTPUT

SHAFT/INPUT SHAFT REMOVAL
Remove the input and output shafts together.
OUTPUT
SHAFT
INPUT
CENTER SHAFT
DIFFERENTIAL

AK201620AC

ADJUSTMENT BEFORE ASSEMBLY

SPACER SELECTION FOR INPUT SHAFT END PLAY/OUT-
PUT SHAFT PRELOAD/CENTER DIFFERENTIAL PRELOAD
.

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22B-10 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE

<Measurement using a solder>

CAUTION
• If soft solder is not available, select the spacer in accor-
dance with Plastigage method.
• If the spacer spacerappropriate for the standard value
cannot be selected using soft solder, select the spacer
in accordance with Plastigage method.
1. Install the input shaft, output shaft and center differential as
OUTPUT a set to the clutch housing.
SHAFT
INPUT NOTE: If necessary, replace the input shaft, output shaft,
CENTER SHAFT
DIFFERENTIAL center differential case and/or bearings before carrying out
these adjustments.

AK201620AC

2. Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39

SOLDERS
in) long] on the input shaft rear bearing at the positions
shown in the illustration.

AK201621AC

3. Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39

SOLDERS in) long) on the transaxle case at the positions shown in the
illustration.
4. Install the bearing outer races of the center differential and
output shaft.
5. Install the transaxle case and tighten the bolts to the
specified torque.
Tightening torque: 44 ± 5 N⋅ m (32 ± 3 ft-lb)
AK201622AC

SOLDERS

AK201623AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE
22B-11
6. Remove the transaxle case.
7. Remove the outer races and take out the crushed solders.
8. If the solders have not crushed, use thicker solders [1.6 mm
(0.063 in) diameter, about 10 mm (0.39 in) long] and repeat
steps 4 to 7.
9. Measure the thickness of the crushed solder with a
micrometer and select spacers that will provide the standard
end play/preload value.
AK201624
Standard value:
Input shaft end play: 0.05 −0.17 mm (0.0020 −0.0067
inch)
Output shaft preload: 0.13 −0.18 mm (0.0051 −0.0071
inch)
Center differential case preload: 0.05 −0.11 mm
(0.0020 −0.0043 inch)
.

<Measurement using Plastigage>

1. Install the input shaft, output shaft and center differential as
OUTPUT a set to the clutch housing.
SHAFT
INPUT NOTE: If necessary, replace the input shaft, output shaft,
CENTER SHAFT
DIFFERENTIAL center differential case and/or bearings before carrying out
these adjustments.

AK201620AC

2. Put plastigage [about 10 mm (0.39 in) long] on the input

PLASTIGAGE
shaft rear bearing at the positions shown in the illustration.

AK201621AF

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22B-12 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE

3. Put plastigage [about 10 mm (0.39 in) long] on the transaxle

PLASTIGAGE
case at the positions shown in the illustration.
4. Install the bearing outer races of the center differential and
output shaft.
5. Install the transaxle case and tighten the bolts to the
specified torque.
Tightening torque: 44 ± 5 N⋅ m (32 ± 3 ft-lb)
6. Remove the transaxle case.
AK201622AF 7. Remove the outer races and take out the crushed
plastigage.
8. If the Plastigages have not crushed, replace the spacer with
PLASTIGAGE
a thicker one and repeat steps 4 to 7.

AK201623 AF

9. Measure the width of the crushed plastigage at its widest

part using a scale printed on the plastigage package.
Standard value:
Input shaft end play: 0.05 −0.17 mm (0.0020 −0.0067
inch)
Output shaft preload: 0.13 −0.18 mm (0.0051 −0.0071
inch)
Center differential case preload: 0.05 −0.11 mm
PLASTIGAGE
(0.0020 −0.0043 inch)
SPACER AK402081AC

ASSEMBLY SERVICE POINTS

.

>>A<< INPUT SHAFT/OUTPUT SHAFT/CENTER

DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and center differential as a
OUTPUT set.
SHAFT
INPUT
CENTER SHAFT
DIFFERENTIAL

AK201620AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE
22B-13
>>B<< 5TH-REVERSE SPEED SHIFT
FORK/5TH-REVERSE SPEED SHIFT
RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH
SPEED SHIFT RAIL INSTALLATION
1. Assemble the 3rd-4th speed shift rail and fork, and
3RD-4TH SPEED
SHIFT FORK 5th-reverse speed shift rail and fork.
5TH-REVERSE 5TH-REVERSE
SPEED SHIFT SPEED SHIFT
FORK RAIL

3RD-4TH SPEED
SHIFT RAIL AK201625AC

2. Fit each shift fork in the groove of synchronizer sleeve and

5TH-REVERSE
SPEED SHIFT install the shift fork and rail assembly.
RAIL 3. Insert the 3rd-4th speed shift rail and 5th speed-reverse shift
3RD-4TH SPEED rail into the rail hole in the clutch housing.
SHIFT RAIL

AK201626AE

>>C<< SPRING PIN INSTALLATION

SHIFT FORK 1. Align the pin holes in the shift rail and shift fork.
2.5 mm (0.098 in)
SHIFT RAIL 2. Insert the new spring pin. Push it in so that the slit and
center axis of the rail are aligned.

SPRING
PIN

AK204302 AD

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22B-14 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE

>>D<< SPACER AND OUTER RACE

INSTALLATION
1. Install the spacer selected in the section "ADJUSTMENT
BEFORE ASSEMBLY."
2. Using special tools MB990935 and MB990938, press install
the outer race into the transaxle case.
MB990938

MB990935

AK204231 AC

>>E<< TRANSAXLE CASE INSTALLATION

CAUTION
Squeeze out the sealant uniformly, while making sure that
it is not broken or excessively applied.
1. Apply a 2 mm (0.08 inch) diameter bead of sealant
(Mitsubishi genuine part number MD997740 or equivalent)
to the illustrated position of the transaxle case.
NOTE: Be sure to install the transaxle case while the seal-
ant is wet (within 15 minutes).
2. Install the transaxle case.
3. Tighten the transaxle case mounting bolts to the specified
AKX00886
torque.
Tightening torque: 44 ± 5 N⋅ m (32 ± 3 ft-lb)
NOTE: After installation, keep the sealed area away from oil
for approximately one hour.
.

>>F<< UNDER COVER INSTALLATION

CAUTION
Squeeze out the sealant uniformly, while making sure that
it is not broken or excessively applied.
1. Apply a 2 mm (0.08 inch) diameter bead of sealant
(Mitsubishi genuine part number MD997740 or equivalent)
to the illustrated position of the transaxle case.
NOTE: Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
2. Install the under cover to the transaxle case and tighten the
bolts to specified torque.
AK201627
Tightening torque: 6.9 ± 0.9 N⋅ m (61 ± 7 in-lb)
NOTE: After installation, keep the sealed area away from oil
for approximately one hour.
.

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSAXLE
22B-15
>>G<< CONTROL HOUSING INSTALLATION
CAUTION
Squeeze out the sealant uniformly, while making sure that
it is not broken or excessively applied.
1. Apply a 0.2 mm (0.08 inch) diameter bead of sealant
(Mitsubishi genuine part number MD997740 or equivalent)
to the illustrated position of the transaxle case.
NOTE: Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
2. Install the control housing to the transaxle case and tighten
the bolts to specified torque.
AK201628
Tightening torque: 18 ± 3 N⋅ m (13 ± 2 ft-lb)
NOTE: After installation, keep the sealed area away from oil
for approximately one hour.
.

>>H<< SELECT LEVER INSTALLATION

CONTROL SHAFT
1. Apply grease (Mitsubishi genuine grease part No. 0101011
or equivalent) to the control shaft sliding portion of the select
lever shoe.
SELECT 2. Install the select lever and tighten the bolts to specified
LEVER
SHOE torque.
Tightening torque: 18 ± 3 N⋅ m (13 ± 2 ft-lb)

AK204238 AC

INSPECTION
M1222001100242
.

BACKUP LIGHT SWITCH

Check for continuity between terminals.
SWITCH CONDITION CONTINUITY
Pressed Open
Released Conductive

AK201630

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22B-16 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT

INPUT SHAFT
DISASSEMBLY AND ASSEMBLY
M1222001600366

12
14
APPLY GEAR OIL
TO ALL MOVING 13
PARTS BEFORE 15
INSTALLATION. 16
17

18
10 9
11
2
20
4
21
6
22 7
8 1

18 3

19 5

AKX00877AB

DISASSEMBLY STEPS DISASSEMBLY STEPS

>>L<< 1. SNAP RING >>E<< 12. 3RD-4TH SPEED
<<A>> >>K<< 2. BALL BEARING SYNCHRONIZER HUB
<<B>> >>J<< 3. THRUST PLATE STOPPER 13. OUTER SYNCHRONIZER RING
>>I<< 4. THRUST PLATE >>D<< 14. SYNCHRONIZER SPRING
<<C>> >>H<< 5. 5TH SPEED GEAR 15. SYNCHRONIZER CONE
6. 4TH SPEED GEAR 16. INNER SYNCHRONIZER RING
7. NEEDLE ROLLER BEARING 17. 3RD SPEED GEAR
<<D>> >>G<< 8. 4TH SPEED GEAR SLEEVE 18. NEEDLE ROLLER BEARING
9. SYNCHRONIZER RING >>C<< 19. SNAP RING
>>D<< 10. SYNCHRONIZER SPRING <<E>> >>B<< 20. BALL BEARING
>>F<< 11. SYNCHRONIZER SLEEVE >>A<< 21. OIL SEAL
22. INPUT SHAFT

Required Special Tools:

• MD998801: Bearing Remover • MD998818: Installer Adapter (38)
• MD998812: Installer Cap • MD998819: Installer Adapter (40)
• MD998813: Installer-100 • MD998825: Installer Adapter (52)

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT
22B-17
DISASSEMBLY SERVICE POINTS
.

<<A>> BALL BEARING REMOVAL

1. Using special tool MD998801, support the ball bearing, and
MD998801
then set them on the press.
2. Push down on the input shaft with the press and extract the
ball bearing.

AK201631AC

<<B>> THRUST PLATE STOPPER REMOVAL

Using a screwdriver, pry up the position shown in the illustration
and remove the thrust plate stopper.

AK201632

<<C>>5TH SPEED GEAR REMOVAL

1. Using special tool MD998801, support the 5th speed gear,
MD998801
and then set them on the press.
2. Push down on the input shaft with the press and take off the
5th speed gear.

AK201633AC

<<D>>4TH SPEED GEAR SLEEVE REMOVAL

1. Using special tool MD998801, support the 3rd speed gear,
MD998801 and then set them on the press.
2. Push down on the input shaft with the press and remove the
4th speed gear sleeve.

AK201634AC

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22B-18 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT

<<E>> BALL BEARING REMOVAL

1. Using special tool MD998801, support the ball bearing, and
then set them on the press.
MD998801
2. Push down on the input shaft with the press and extract the
ball bearing.

AK201635AC

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION

Install the oil seal into the illustrated position of the input shaft.

OIL SEAL 3.5 mm (0.138 in)

AK204243 AD

>>B<< BALL BEARING INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear
MD998812
portion of the input shaft, and then set them on the press.
MD998801
MD998813 2. Using special tools MD998812, MD998813 and MD998818,
press install the bearing with the press.
MD998818

AK201636 AC

>>C<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the snap
ring groove of input shaft.
2. Make sure that the ball bearing end play meets the standard
value.
Standard value: 0 −0.12 mm (0 −0.0047 inch)

SNAP RING

AK201637AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT
22B-19
>>D<< SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring to the illustrated position of the
synchronizer ring and outer synchronizer ring.

SYNCHRONIZER SPRING
AK201638AC

SYNCHRONIZER
SPRING
AKX00951AF

>>E<< 3RD-4TH SPEED SYNCHRONIZER HUB

INSTALLATION
1. Using special tool MD998801, support the 2nd speed gear
portion of the input shaft, and then set them on the press.
2. Make sure that the inner 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.
INSTALLATION
DIRECTION 4. Using special tools MD998812, MD998813 and MD998825,
press install the 3rd-4th speed synchronizer hub with the
GROOVE press.
AK302753AC
5. Make sure that the outer synchronizer ring can rotate freely.

MD998812
MD998801 MD998813

MD998825

AK201639 AC

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22B-20 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT

>>F<< SYNCHRONIZER SLEEVE INSTALLATION

1. Check the installation direction of the synchronizer sleeve,
IDENTIFICATION GROOVE and install it onto the 3rd-4th speed synchronizer hub.

INSTALLATION
DIRECTION
(1ST SPEED SIDE)

AK305817AF

TEETH WITH
2. Install the synchronizer sleeve so that the areas with teeth
RAISED TIPS 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).

DEEP GROOVES
BETWEEN THE TEETH AKX00928AB

>>G<< 4TH SPEED GEAR SLEEVE

INSTALLATION
1. Using special tool MD998801, support the 2nd speed gear
MD998812
portion of the input shaft, and then set them on the press.
MD998801 MD998813 2. Using special tools MD998812, MD998813 and MD998825,
MD998825 press install the 4th speed gear sleeve with the press.

AK201640 AC

>>H<< 5TH SPEED GEAR INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear
MD998812 portion of the input shaft, and then set them on the press.
MD998801 MD998813 2. Using special tools MD998812, MD998813 and MD998825,
press install the 5th speed gear in the input shaft.
MD998825

AK201641 AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT
22B-21
>>I<< THRUST PLATE INSTALLATION
1. Install the thickest thrust plates that can be fitted in the
SURFACE
STAMPED WITH groove of input shaft. Install the thrust plate so the surface
IDENTIFICATION stamped with the identification mark is facing up.
MARK
2. Make sure that the 5th speed gear end play meets the
standard value.
Standard value: 0 −0.09 mm (0 −0.0035 inch)

THRUST
PLATE AK201642AC

>>J<< THRUST PLATE STOPPER INSTALLATION

Install the thrust plate stopper by pressing special tools
MD998812 MD998812, MD998813 and MD998825 by hand. Make sure
that it is not tilted.

MD998813

MD998825

AK201643 AC

>>K<< BALL BEARING INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear
MD998812 portion of the input shaft, and then set them on the press.
2. Using special tools MD998812 and MD998819, press install
MD998801 MD998819 the ball bearing in the input shaft.

AK201644 AE

>>L<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the groove
of input shaft.
2. Make sure that the ball bearing end play meets the standard
value.
Standard value: 0 −0.12 mm (0 −0.0047 inch)
SNAP RING

AK201645AC

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22B-22 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT

INSPECTION
M1222001700200
.

INPUT SHAFT
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.

AKX00937

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
1. Check the clutch gear teeth for damage.
2. Check the internal surface for damage, wear and broken
threads.

AK204298AC

3. Force the synchronizer ring toward the clutch gear and

A
GEAR
check clearance "A." If "A" is less than the limit, replace.
SYNCHRO-
NIZER RING Minimum limit: 0.5 mm (0.020 inch)

AK204307 AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
INPUT SHAFT
22B-23
OUTER SYNCHRONIZER RING/INNER
SYNCHRONIZER RING/SYNCHRONIZER CONE
CAUTION
When any of the outer ring, inner ring or cone has to be
replaced, replace them as a set.
1. Check to ensure that the clutch gear tooth surface and cone
surface are not damaged and broken.

AK204309AC

2. Install the outer ring, inner ring and cone, press them
A against the gear, and check clearance "A." If "A" is less than
OUTER RING
CONE the limit, replace.
Minimum limit: 0.5 mm (0.020 inch)

INNER RING
GEAR AKX00888AB

SYNCHRONIZER SLEEVE AND HUB

1. Combine the synchronizer sleeve and hub, and check that
they slide smoothly.
SLEEVE 2. Check that the sleeve is free from damage at its inside
splines ends.

HUB

AK201697AC

SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or broken.
.

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22B-24 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT

SPEED GEARS
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 or worn.

AK204299AC

OUTPUT SHAFT
DISASSEMBLY AND ASSEMBLY
M1222002200361

APPLY GEAR OIL

TO ALL MOVING 24 23
PARTS BEFORE 25
INSTALLATION. 27 26
29 28
32 30
33 31 21 20
22
35 4

34 1
37
15 2
38 14
17 4
16
18 6 5
7
19
9 8
36 10
11
12
13
15
AK203133AC

DISASSEMBLY STEPS DISASSEMBLY STEPS

>>Q<< 1. SNAP RING <<B>> >>O<< 3. REVERSE GEAR BEARING
<<A>> >>P<< 2. TAPER ROLLER BEARING SLEEVE
4. NEEDLE ROLLER BEARING

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT
22B-25
DISASSEMBLY STEPS DISASSEMBLY STEPS
5. REVERSE GEAR <<E>> >>G<< 22. 2ND SPEED GEAR SLEEVE
6. INNER SYNCHRONIZER RING 23. INNER SYNCHRONIZER RING
7. SYNCHRONIZER CONE 24. SYNCHRONIZER CONE
8. OUTER SYNCHRONIZER RING 25. OUTER SYNCHRONIZER RING
>>L<< 9. SYNCHRONIZER SPRING >>D<< 26. SYNCHRONIZER SPRING
>>N<< 10. SYNCHRONIZER SLEEVE >>F<< 27. SYNCHRONIZER SLEEVE
<<C>> >>M<< 11. 5TH SPEED-REVERSE >>E<< 28. 1ST-2ND SPEED
SYNCHRONIZER HUB SYNCHRONIZER HUB
12. SYNCHRONIZER RING 29. OUTER SYNCHRONIZER RING
>>L<< 13. SYNCHRONIZER SPRING >>D<< 30. SYNCHRONIZER SPRING
14. 5TH SPEED GEAR 31. INNER SYNCHRONIZER RING
15. NEEDLE ROLLER BEARING 32. SYNCHRONIZER CONE
>>K<< 16. 5TH SPEED GEAR SLEEVE 33. 1ST SPEED GEAR
>>J<< 17. 4TH SPEED GEAR 34. NEEDLE ROLLER BEARING
>>I<< 18. SNAP RING <<F>> >>C<< 35. 1ST SPEED GEAR SLEEVE
<<D>> >>H<< 19. 3RD SPEED GEAR <<G>> >>B<< 36. TAPER ROLLER BEARING
20. 2ND SPEED GEAR >>A<< 37. OIL SEAL
21. NEEDLE ROLLER BEARING 38. OUTPUT SHAFT

Required Special Tools:

• MD998364: Camshaft Oil Seal Installer • MD998819: Installer Adapter (40)
• MD998801: Bearing Remover • MD998820: Installer Adapter (42)
• MD998812: Installer Cap • MD998821: Installer Adapter (44)
• MD998813: Installer-100 • MD998824: Installer Adapter (50)
• MD998814: Installer-200 • MD998917: Bearing Remover

DISASSEMBLY SERVICE POINTS

.

<<A>> TAPER ROLLER BEARING REMOVAL

MD998801 TAPER ROLLER
1. Using special tool MD998801, support the taper roller
BEARING bearing, and then set them on the press.
2. Push down on the output shaft with the press, and take out
the taper roller bearing.

AK201646 AC

<<B>> REVERSE GEAR BEARING SLEEVE

REMOVAL
1. Using special tool MD998801, support the reverse gear, and
MD998801 REVERSE GEAR then set them on the press.
BEARING SLEEVE
2. Push down on the output shaft with the press and remove
the reverse gear bearing sleeve.

AK201647 AE

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22B-26 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT
.

<<C>> 5TH SPEED-REVERSE SYNCHRONIZER

HUB REMOVAL
1. Using special tool MD998801, support the 4th speed gear,
SYNCHRONIZER
MD998801 HUB and then set them on the press.
2. Push down on the output shaft with the press and remove
the 5th speed-reverse synchronizer hub.

AK201648 AC

<<D>> 3RD SPEED GEAR REMOVAL

1. Using special tool MD998917, support the 2nd speed gear,
and then set them on the press.
3RD
MD998917 SPEED GEAR 2. Push down on the output shaft with the press and remove
the 3rd speed gear.

AK201649 AC

<<E>> 2ND SPEED GEAR SLEEVE REMOVAL

1. Using special tool MD998917, support the 1st speed gear,
and then set them on the press.
MD998917 2ND SPEED 2. Push down on the output shaft with the press and remove
GEAR SLEEVE
the 2nd speed gear sleeve.

AK201650 AC

<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

1. Using special tool MD998801, support the 1st speed gear
sleeve, and then set them on the press.
MD998801 1ST SPEED 2. Push down on the output shaft with the press and remove
GEAR SLEEVE
the 1st speed gear sleeve.

AK201651AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT
22B-27
<<G>> TAPER ROLLER BEARING REMOVAL
1. Using special tool MD998801, support the taper roller
MD998801 TAPER ROLLER bearing, and then set them on the press.
BEARING
2. Push down on the output shaft with the press and remove
the taper roller bearing.

AK201652 AC

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION

Make sure that the oil seal is pressed into the position shown in
the illustration.
OIL SEAL 3.5 mm (0.138 in)

AK204243 AD

>>B<< TAPER ROLLER BEARING INSTALLATION

1. Using special tool MD998801, support the output shaft gear,
MD998812 and then set them on the press.
MD998801
MD998819 2. Using special tools MD998812 and MD998819, press install
TAPER the taper roller bearing with the press.
ROLLER
BEARING

AK201653 AC

>>C<<1ST SPEED GEAR SLEEVE INSTALLATION

1. Set the output shaft on the press support stand.
MD998812
2. Using special tools MD998812, MD998814, MD998824 and
MD998364, press install the 1st speed gear sleeve with the
MD998814 press.
1ST SPEED
GEAR SLEEVE
MD998824
MD998364

AK201654 AC

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22B-28 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT

>>D<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring to the illustrated position of the
outer synchronizer ring.

SYNCHRONIZER SPRING
AK201638AC

>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB

INSTALLATION
1. Set the output shaft on the press support stand.
2. Check that the 1st-2nd speed synchronizer hub is in the
correct installation direction, and put it on the output shaft.

INSTALLATION
DIRECTION

GROOVE
AK302754AC

3. Using special tools MD998812, MD998814, MD998824 and

MD998812 MD998364, press install the 1st-2nd speed synchronizer
hub with the press.
MD998814 4. Make sure that the outer synchronizer ring on the 1st speed
1ST-2ND SPEED gear side can rotate freely.
SYNCHRONIZER
HUB MD998824

MD998364
AK201655 AC

>>F<< SYNCHRONIZER SLEEVE INSTALLATION

1. Check that the synchronizer sleeve is in the correct direction
GROOVE
for installation, and install it on the 1st-2nd speed
synchronizer hub.

INATALLATION
DIRECTION

AK302755AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT
22B-29
TEETH WITH
2. Install the synchronizer sleeve so that the areas with teeth
RAISED TIPS 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).

DEEP GROOVES
BETWEEN THE TEETH AKX00928AB

>>G<< 2ND SPEED GEAR SLEEVE

INSTALLATION
1. Set the output shaft on the press support stand.
MD998812 2. Using special tools MD998812, MD998814, MD998824 and
MD998364, press install the 2nd speed sleeve onto the
MD998814 output shaft.
2ND SPEED
GEAR SLEEVE
MD998824

MD998364
AK201656 AC

>>H<< 3RD SPEED GEAR INSTALLATION

1. Check that the 2nd speed gear and the outer synchronizer
MD998812
ring have been properly installed. Also, make sure the claws
on the synchronizer cone (four places) are correctly fitted
MD998814 into the holes in the 2nd speed gear (four places).
2. Using special tools MD998812, MD998814, MD998824 and
3RD SPEED
GEAR
MD998824 MD998364, press install the 3rd speed gear onto the output
shaft.
MD998364
3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
AK201657 AC

>>I<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the groove
of output shaft.
2. Make sure that the 3rd speed gear end play meets the
SNAP RING standard value.
Standard value: 0 −0.09 mm (0 −0.0035 inch)

AK201658AC

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22B-30 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT

>>J<< 4TH SPEED GEAR INSTALLATION

1. Set the output shaft on the press support stand.
MD998812
2. Using special tools MD998812, MD998813, MD998821 and
MD998813 MD998364, press install the 4th speed gear onto the output
4TH SPEED shaft.
GEAR MD998821

MD998364

AK201659 AC

>>K<< 5TH SPEED GEAR SLEEVE

INSTALLATION
Using special tools MD998812, MD998813, MD998821 and
MD998812
MD998364, press install the 5th speed gear sleeve onto the
5TH SPEED MD998813 output shaft.
GEAR SLEEVE
MD998821

MD998364
AK201660 AC

>>L<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring to the illustrated position of the
synchronizer ring.

SYNCHRONIZER SPRING AK305144AC

>>M<< 5TH SPEED-REVERSE SYNCHRONIZER

HUB INSTALLATION
1. Set the output shaft on the press support stand.
2. Make sure that the synchronizer ring is fitted correctly on the
cone of the 5th speed gear.
3. Check that the 5th speed-reverse synchronizer hub is
oriented correctly for installation, and fit it on the output
INSTALLATION shaft.
DIRECTION

GROOVE
AK302758AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT
22B-31
4. Using special tools MD998812, MD998813, MD998821 and
MD998812 MD998364, press install the 5th speed-reverse synchronizer
hub with the press.
SYNCHRONIZER MD998813
HUB
MD998821
5. Make sure that the synchronizer ring on the 5th speed gear
side can rotate freely.

MD998364

AK201661 AC

>>N<< SYNCHRONIZER SLEEVE INSTALLATION

1. Check that the synchronizer sleeve is in the correct direction
GROOVE
for installation, and install it on the 5th speed-reverse
synchronizer hub.

INSTALLATION
DIRECTION

AK501268 AB

TEETH WITH
2. Install the synchronizer sleeve so that the areas with teeth
RAISED TIPS 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).

DEEP GROOVES
BETWEEN THE TEETH AKX00928AB

>>O<< REVERSE GEAR BEARING SLEEVE

INSTALLATION
1. Make sure the synchronizer ring, reverse gear and needle
MD998812 roller bearing have been correctly installed.
MD998820 2. Using special tools MD998812, MD998820 and MD998364,
REVERSE press fit the reverse gear sleeve. Make sure that the reverse
REVERSE GEAR SLEEVE
GEAR gear and the synchronizer ring can rotate freely during the
pressing process.
MD998364

AK201662AC

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22B-32 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT

>>P<< TAPER ROLLER BEARING INSTALLATION

Using special tools MD998812, MD998819 and MD998364,
MD998812
TAPER ROLLER
press install the taper roller bearing.
MD998819
BEARING

MD998364

AK201663 AC

>>Q<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the groove
STANDARD VALUE of output shaft.
SNAP RING
2. Make sure that the taper roller bearing end play meets the
standard value.
TAPER ROLLER
BEARING Standard value: 0 −0.09 mm (0 −0.0035 inch)

AKX00934 AC

INSPECTION
M1222002300197
.

OUTPUT SHAFT
1. Check the splines for damage and wear.
2. Check that the helical gear teeth surfaces are not damaged
or worn.

AK204310AC

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.
.

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT
22B-33
SYNCHRONIZER RING <FOR 5TH SPEED>
1. Check if the clutch gear teeth are damaged.
2. Check internal surface for damage, wear and broken
threads.

AK204298AC

3. Force the synchronizer ring toward the clutch gear and

A
GEAR
check clearance "A." If "A" is less than the limit, replace the
SYNCHRO-
NIZER RING synchronizer ring.
Minimum limit: 0.5 mm (0.020 inch)

AK204307 AC

OUTER SYNCHRONIZER RING/INNER

SYNCHRONIZER RING/SYNCHRONIZER CONE
<FOR REVERSE>
CAUTION
When replacing, replace the outer ring, inner ring and cone
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces
are not damaged or broken.

AK204309AC

2. Install the outer ring, inner ring and cone, force them toward
GEAR
the gear, and check clearance "A." If "A" is less than the
A limit, replace them as a set.
Minimum limit: 0.5 mm (0.020 inch)
OUTER RING

CONE

INNER RING
AK204259 AC

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22B-34 MANUAL TRANSAXLE OVERHAUL <W5M51>
OUTPUT SHAFT

OUTER SYNCHRONIZER RING/INNER

SYNCHRONIZER RING/SYNCHRONIZER CONE
<FOR 1 ST SPEED AND 2 ND SPEED>
CAUTION
When replacing, replace the outer ring, inner ring and cone
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces
are not damaged or broken.

AK203129AC

2. Install the outer ring, inner ring and cone, force them toward
GEAR A the gear, and check clearance "A." If "A" is less than the
limit, replace them as a set.
OUTER RING Minimum limit: 0.5 mm (0.020 inch)

CONE

INNER RING
AK203130AC

SYNCHRONIZER SLEEVE AND HUB

1. Combine the synchronizer sleeve and hub, and check that
they slide smoothly.
SLEEVE 2. Check that the sleeve is free from damage at its inside
splines ends.

HUB

AK201697AC

SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or broken.

AKX00943

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
REVERSE IDLER GEAR
22B-35
SPEED GEARS
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 or worn.

AK204299AC

REVERSE IDLER GEAR

DISASSEMBLY AND ASSEMBLY
M1222012500181

APPLY GEAR OIL

TO ALL MOVING
PARTS BEFORE
INSTALLATION.

7
2

AK204396AC

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. SNAP RING 5. REVERSE IDLER GEAR
2. CONE SPRING 6. NEEDLE ROLLER BEARING
3. THRUST WASHER 7. REVERSE IDLER GEAR SHAFT
4. STEEL BALL

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22B-36 MANUAL TRANSAXLE OVERHAUL <W5M51>
VEHICLE SPEED SENSOR

VEHICLE SPEED SENSOR

DISASSEMBLY AND ASSEMBLY
M1222007000050

APPLY GEAR OIL

TO ALL MOVING
PARTS BEFORE
INSTALLATION.
4

AK204397AC

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. E-CLIP 3. O-RING
2. SPEED SENSOR GEAR 4. SPEED SENSOR

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
SELECT LEVER
22B-37
SELECT LEVER
DISASSEMBLY AND ASSEMBLY
M1222012800148

7 1

8
11 ± 1 N·m
2
97 ± 8 in-lb

9 3

10

AK204398AC

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. DUST COVER 6. SELECT LEVER SHOE
2. NUT 7. SELECT LEVER
3. SPRING WASHER >>A<< 8. SELECT LEVER BUSHING
4. WASHER >>A<< 9. DUST COVER
>>A<< 5. SELECT LEVER BUSHING 10. SELECT LEVER SHAFT

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22B-38 MANUAL TRANSAXLE OVERHAUL <W5M51>
CONTROL HOUSING

ASSEMBLY SERVICE POINT

.

>>A<< DUST COVER AND SELECT LEVER BUSH-

ING INSTALLATION
Make sure the dust cover and select lever bushing installation
SELECT LEVER
BUSHING direction is correct, and distinguished parts are correctly
assembled. Refer to the figure at left.

DUST COVER
AK204311 AC

CONTROL HOUSING
DISASSEMBLY AND ASSEMBLY
M1222013100272

6
9

7 3

11
12
13 5
4

8
10
14

2
1

21.7 ± 0.3 N·m

16.1 ± 0.2 ft-lb AK500015 AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
CONTROL HOUSING
22B-39
DISASSEMBLY STEPS DISASSEMBLY STEPS
1. SPRING WASHER 8. NEUTRAL RETURN SPRING
2. STOPPER BRACKET 9. CONTROL SHAFT
<<A>> >>E<< 3 LOCK PIN >>C<< 10. AIR BREATHER
4. INTERLOCK PLATE 11. CONTROL SHAFT BOOT
5. CONTROL FINGER >>B<< 12. OIL SEAL
>>D<< 6. SPRING PIN >>A<< 13. NEEDLE BEARING
7. STOPPER BODY 14. CONTROL HOUSING

DISASSEMBLY SERVICE POINT

.

<<A>> LOCK PIN REMOVAL

Drive out the lock pin in the direction shown.

LOCK PIN

CONTROL
FINGER

AK204273 AD

ASSEMBLY SERVICE POINTS

.

>>A<< NEEDLE BEARING INSTALLATION

Press fit the needle bearing into the control housing side as
CONTROL HOUSING shown.
NEEDLE BEARING Make sure that the side with the model number stamped on it
faces the end of the control housing as shown.
MODEL NUMBER
STAMPED SIDE

0 – 0.5 mm(0 – 0.02 in)

AK204176AD

>>B<< OIL SEAL INSTALLATION

Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W con-
forming to API classification GL-4) to the oil seal lip area.

AK204303AC

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22B-40 MANUAL TRANSAXLE OVERHAUL <W5M51>
CONTROL HOUSING

>>C<< AIR BREATHER INSTALLATION

1. Apply sealant (3M™ AAD Part Number 8001 or equivalent)
to the inserting portion of air breather.

AK204274AC

2. Install the air breather so that the embossed mark is in the

direction shown in the illustration.

EMBOSS
MARK

AK204220 AC

>>D<< SPRING PIN INSTALLATION

Drive in the spring pin so that the slit is in the direction shown in
CONTROL SHAFT the illustration.
STOPPER BODY INSTALLATION
DIRECTION

SLIT
SPRING PIN
AK204177AC

>>E<<LOCK PIN INSTALLATION

Drive the lock pin in the direction shown in the illustration.

AK204273 AE

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
CLUTCH HOUSING
22B-41
CLUTCH HOUSING
DISASSEMBLY AND ASSEMBLY
M1222003700240

3
7

5*

9.8 ± 2.0 N·m

86 ± 17 in-lb
1 AK201683 AC

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. CLUTCH RELEASE BEARING >>A<< 6. COVER-A
RETAINER >>A<< 7. COVER-B
>>E<< 2. OIL SEAL 8. CLUTCH HOUSING
<<A>> >>D<< 3. OUTER RACE NOTE: *: Refer to the needle bearing and bushing instal-
<<B>> >>C<< 4. OUTER RACE lation procedures only when replacing the transaxle case.
>>B<< 5. BUSHING*

Required Special Tools:

• MB990928: Installer Adapter
• MB990935: Installer Adapter
• MB990938: Handle
• MB991445: Bushing Remover and Installer Base
• MD999566: Claw

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22B-42 MANUAL TRANSAXLE OVERHAUL <W5M51>
CLUTCH HOUSING

DISASSEMBLY SERVICE POINT

.

<<A>> OUTER RACE REMOVAL

Using special tool MD999566, remove the outer race from the
MD999566 clutch housing.

OUTER RACE
AK201665AC

<<B>> OUTER RACE REMOVAL

Using special tool MD999566, remove the outer race from the
clutch housing.
MD999566

AK201666 AC

ASSEMBLY SERVICE POINTS

.

>>A<< COVER-B/COVER-A INSTALLATION

Install the covers directed as shown in the illustration.
COVER-B
COVER-A

AK201667 AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
CLUTCH HOUSING
22B-43
>>B<< BUSHING INSTALLATION
1. Press fit the bushing so the seam is away from the air vent.

AIR VENT

SEAM OF
BUSHING
AK201668 AC

2. Be sure the bushing is fully seated as shown. It must be 1

mm (0.04 inch) below the housing surface.

1 mm (0.04 in)

AK204291AD

>>C<< OUTER RACE INSTALLATION

Using special tools MB990938 and MB990935, press fit the
MB990938 outer race into the clutch housing.

MB990935

AK201669 AE

>>D<< OUTER RACE INSTALLATION

1. Check the installation direction of the outer race.
MB990938 2. Using special tools MB990938 and MB991445, press fit the
MB991445 outer race into the clutch housing.

AK201670AC

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22B-44 MANUAL TRANSAXLE OVERHAUL <W5M51>
CLUTCH HOUSING

>>E<< OIL SEAL INSTALLATION

1. Pack grease (Mitsubishi genuine grease part No. 0101011
or equivalent) in the oil seal lip area.

AK204284AD

2. Using special tools MB990938 and MB990928, press fit the

oil seal into the clutch housing.
MB990928 MB990938

AK201671 AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSMISSION CASE
22B-45
TRANSMISSION CASE
DISASSEMBLY AND ASSEMBLY
M1222013400251

2*

5*

4
6

3 AK203131AC

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

>>D<< 1. OIL SEAL >>A<< 5. BUSHING*
>>C<< 2. NEEDLE BEARING* 6. TRANSAXLE
>>B<< 3 OIL GUIDE NOTE: *:Refer to the needle bearing and bushing instal-
>>B<< 4. OIL GUIDE lation procedures only when replacing the transaxle case.

Required Special Tool:

• MD998800: Differential Oil Seal Installer

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22B-46 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSMISSION CASE

ASSEMBLY SERVICE POINTS

.

>>A<< BUSHING INSTALLATION

1. Press fit the bushing so the seam is away from the air vent.

AIR VENT SEAM OF

BUSHING

AK201672AC

2. Be sure the bushing is fully seated as shown. It must be 3

mm (0.12 inch) below the housing surface.

3 mm (0.12 in)

AK204304AD

>>B<< OIL GUIDE INSTALLATION

1. Evenly press the oil guide so it is fully seated and at an
angle.
OIL GUIDE

AK500016 AC

>>C<< NEEDLE BEARING INSTALLATION

1. Check the installation direction of the needle bearing.
2. Press fit the needle bearing until it is flush with the case.
MODEL NUMBER
STAMPED SIDE

AK204287 AC

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSMISSION CASE
22B-47
>>D<<OIL SEAL INSTALLATION
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W
conforming to API classification GL-4).

1.5 mm (0.59 in)

AK204286AF

2. Using special tool MD998800, press fit the oil seal into the
transaxle case.
MD998800

AK201673 AC

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22B-48 MANUAL TRANSAXLE OVERHAUL <W5M51>
CENTER DIFFERENTIAL

CENTER DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY
M1222002800103

1 3
APPLY GEAR OIL
TO ALL MOVING 2
PARTS BEFORE
INSTALLATION.
5
12 4
6
11
12

17 133 ± 4 N·m
14
98 ± 3 ft-lb
9 10 3.9 ± 1.0 N·m
34 ± 8 in-lb
12

13 11
8 12

9
16
15
7

AK302821AC

DISASSEMBLY STEPS DISASSEMBLY STEPS

>>D<< 1. CENTER DIFFERENTIAL DRIVE >>C<< 9. PINION SHAFT
GEAR >>C<< 10. PINION SHAFT HOLDER
>>C<< 2. CENTER DIFFERENTIAL FLANGE >>C<< 11. PINIONS
<<A>> >>B<< 3. TAPERED ROLLER BEARING >>C<< 12. WASHERS
>>C<< 4. SPACER >>C<< 13. SIDE GEAR
>>C<< 5. SNAP RING >>C<< 14. SPACER
>>C<< 6. SIDE GEAR <<B>> >>A<< 15. TAPERED ROLLER BEARING
>>C<< 7. FRONT OUTPUT SHAFT 16. SPEEDOMETER DRIVEN GEAR
>>C<< 8. LOCK PIN 17. DIFFERENTIAL CASE

Required Special Tools:

• MD998812: Installer Cap • MD998823: Installer Adapter (48)
• MD998917: Bearing Remover • MB990937: Installer Adapter
• MB990930: Installer Adapter

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
CENTER DIFFERENTIAL
22B-49
DISASSEMBLY SERVICE POINTS
.

<<A>> TAPERED ROLLER BEARING REMOVAL

1. Support the tapered roller bearing with special tool
MD998917, and then set them on the press.
MD998917 2. Push down on the differential case with the press to remove
the bearing.

AK103658AB

<<B>> TAPER ROLLER BEARING REMOVAL

1. Support the taper roller bearing with special tools
MD998917 and MB990930, and then set them on the press.
MD998917 MB990930
2. Push down on the differential case with the press to remove
the bearing.

AK103659AC

ASSEMBLY SERVICE POINTS

.

>>A<< TAPERED ROLLER BEARING INSTALLA-

TION
Using special tool MB990937, press install the taper roller bear-
ing.
MB990937

AK103663AC

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22B-50 MANUAL TRANSAXLE OVERHAUL <W5M51>
CENTER DIFFERENTIAL

>>B<< TAPERED ROLLER BEARING

INSTALLATION
Using special tools MD998812 and MD998823, press install
the taper roller bearing.
MD998823 MD998812

AK103661AE

>>C<< SPACER, SIDE GEAR, WASHER, PINION

AND PINION SHAFT, PINION SHAFT HOLDER,
LOCK PIN, FRONT OUTPUT SHAFT, SNAP RING,
CENTER DIFFERENTIAL FLANGE,
INSTALLATION
1. Mount a spacer on the back surface of the side gear, and
then install the side gear in the differential case.
NOTE: When a new side gear is to be installed, use a
medium thickness spacer [0.93 to 1.00 mm (0.0366 to
0.0395 inch)].
2. Place the washers on the back of the pinions, and
simultaneously mesh the four pieces with the side gears.
Place them into position while rotating them. Then, install
the pinion shaft holder.
AK103656
3. Insert the pinion shaft.
4. Install the lock pin so that it will be oriented in the direction
DIFFERENTIAL CASE shown.
LOCK PIN 5. Install the front output shaft on the side gear, and install the
PINION SHAFT snap ring.
6. Mount a spacer on the back surface of the side gear, and
then install the side gear in the differential case.
NOTE: When a new side gear is to be installed, use a
medium thickness spacer [0.93 to 1.00 mm (0.0366 to
0.0395 inch)].
AK103660AB
7. Install the center differential flange by aligning the matching
marks, and temporarily tighten the four machine screws.
8. Measure the backlash between the side gear and pinion.
Standard value:
0.025 − 0.150 mm (0.0010 − 0.0059 inch)
9. If the backlash is out of the standard value, select a spacer
and re-measure the backlash.
NOTE: Adjust until the backlash on both sides are equal.

AK103657

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
CENTER DIFFERENTIAL
22B-51
>>D<< DIFFERENTIAL DRIVE GEAR
INSTALLATION
1. Apply sealant (3MTMSTUD Locking No.4170 or equivalent)
to the entire threaded portion of the bolt.

AK204320AC

2. Tighten to the specified torque in the illustrated sequence.

3
1 10 Tightening torque: 133 ± 4 N⋅ m (98 ± 3 ft-lb)
8
5 6

7 4
9 2

AK103662AB

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22B-52 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSFER

TRANSFER
DISASSEMBLY AND ASSEMBLY
M1222004000158

1
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
2 INSTALLATION.

3
4

AK402153AB

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. DUST SEAL GUIDE >>B<< 4. O-RING
>>D<< 2. OIL SEAL >>A<< 5. OIL SEAL
>>C<< 3. OIL SEAL

Required Special Tools:

• MD998800: Oil Seal Installer
• MD999506: Crankshaft Installer
• MB990936: Installer Adapter

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
TRANSFER
22B-53
ASSEMBLY SERVICE POINTS
.

>>A<< OIL SEAL INSTALLATION

1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE
90).
MD998800
2. Using special tool MD998800, press fit the oil seal into the
transfer cover.

AK302772AD

>>B<< O-RING INSTALLATION

Install a O-ring to the transfer, and apply gear oil (Hypoid gear
oil API classification GL-5 SAE 90) to the O-ring.
.

>>C<< OIL SEAL INSTALLATION

1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE
90).
2. Using special tool MD999506, press fit the oil seal into the
MD999506 transfer.

AK302773AC

>>D<< OIL SEAL INSTALLATION

1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE
90).
MB990936
2. Using special tool MB990936, press fit the oil seal into the
transfer.

AK101417 AC

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22B-54 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIFICATIONS

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1222012100332

TRANSAXLE
ITEM SPECIFICATION
Transfer-clutch housing mounting bolt 69 ± 9 N⋅ m (51 ± 7 ft-lb)
Under cover mounting bolt 6.9 ± 0.9 N⋅ m (61 ± 7 in-lb)
Interlock plate bolt 30 ± 3 N⋅ m (22 ± 2 ft-lb)
Clutch housing-transaxle case mounting bolt 44 ± 5 N⋅ m (32 ± 3 ft-lb)
Clutch release bearing retainer mounting bolt 9.8 ± 2.0 N⋅ m (86 ± 17 in-lb)
Control housing mounting bolt 18 ± 3 N⋅ m (13 ± 2 ft-lb)
Shift cable bracket mounting bolt 18 ± 3 N⋅ m (13 ± 2 ft-lb)
Vehicle speed sensor mounting bolt 3.9 ± 1.0 N⋅ m (34 ± 8 in-lb)
Stopper bracket mounting bolt 21.7 ± 0.3 N⋅ m (16.1 ± 0.2 ft-lb)
Select lever mounting bolt 18 ± 3 N⋅ m (13 ± 2 ft-lb)
Select lever mounting nut 11 ± 1 N⋅ m (97 ± 8 in-lb)
Differential drive gear mounting bolt 133 ± 4 N⋅ m (98 ± 3 ft-lb)
Center differential flange to differential case mounting bolt 3.9 ± 1.0 N⋅ m (34 ± 8 in-lb)
Backup light switch 32 ± 2 N⋅ m (23 ± 1 ft-lb)
Poppet spring 32 ± 2 N⋅ m (23 ± 1 ft-lb)
Reverse idler gear shaft mounting bolt 48 ± 6 N⋅ m (35 ± 4 ft-lb)
Roll stopper bracket mounting bolt 70 ± 10 N⋅ m (52 ± 7 ft-lb)

GENERAL SPECIFICATIONS
M1222000200451

ITEM SPECIFICATION
Model W5M51-2-X5BH
Applicable engine 4G63
Type 5-speed transaxle floor shift
Gear ratio 1st 2.928
2nd 1.950
3rd 1.407
4th 1.031
5th 0.761
Reverse 3.416
Final reduction ratio 4.529
Speedometer gear ratio 28/36
(driven/drive)

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIFICATIONS
22B-55
SERVICE SPECIFICATIONS
M1222000300243

ITEM STANDARD VALUE MINIMUM

LIMIT
Input shaft end play mm (in) 0.05 − 0.17 (0.0020 − 0.0067) −
Input shaft front bearing end play mm (in) 0 − 0.12 (0 − 0.0047) −
Input shaft rear bearing end play mm (in) 0 − 0.12 (0 − 0.0047) −
Input shaft 5th speed gear end play mm (in) 0 − 0.09 (0 − 0.0035) −
Output shaft preload mm (in) 0.13 − 0.18 (0.0051 − 0.0071) −
Output shaft taper roller bearing end play mm (in) 0 − 0.09 (0 − 0.0035) −
Output shaft 3rd speed gear end play mm (in) 0 − 0.09 (0 − 0.0035) −
Center differential pinion backlash mm (in) 0.025 − 0.150 (0.0010 − 0.0059) −
Center differential case preload mm (in) 0.05 − 0.11 (0.0020 − 0.0043) −
Synchronizer ring back surface to gear clearance − 0.5 (0.020)
mm (in)

SEALANTS AND ADHESIVES

M1222000500247

ITEM SPECIFIED SEALANT

Clutch housing-transaxle case mating surface Mitsubishi genuine sealant part No. MD997740 or
Control housing-transaxle case mating surface equivalent
Under cover-transaxle case mating surface
Air breather 3M™AAD Part No.8001 or equivalent
Center differential drive gear bolt 3M™STUD Locking No.4710 or equivalent

LUBRICANTS
M1222000400303

TRANSAXLE
ITEM SPECIFIED SEALANT
Speedometer gear O-ring Hypoid gear oil SAE 75W-90 or 75W-85W conforming to
Control shaft oil seal lip gear oil API classification GL-4
Driveshaft oil seal lip gear oil
Each O-ring
Select lever shoe Mitsubishi part No. 0101011 or equivalent
Input shaft oil seal
TRANSFER
ITEM SPECIFIED SEALANT
Each O-ring Hypoid gear oil API classification GL-5 SAE 90
Each oil seal

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22B-56 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIFICATIONS

SNAP RINGS, SPACERS AND THRUST PLATE FOR ADJUSTMENT

M1222012000357

Spacer
(For adjustment of input shaft end play)
THICKNESS mm (in) IDENTIFICATION SYMBOL THICKNESS mm (in) IDENTIFICATION SYMBOL
0.98 (0.0386) 98 1.43 (0.0563) 43
1.07 (0.0421) 07 1.52 (0.0598) 52
1.16 (0.0457) 16 1.61 (0.0634) 61
1.25 (0.0492) 25 1.70 (0.0669) 70
1.34 (0.0528) 34 1.79 (0.0705) 79
Snap ring
(For adjustment of input shaft front bearing end play)
THICKNESS mm (in) IDENTIFICATION COLOR THICKNESS mm (in) IDENTIFICATION COLOR
1.43 (0.0563) Green (2) 1.59 (0.0626) Yellow (2)
1.51 (0.0594) White (2)
Snap ring
(For adjustment of input shaft rear bearing end play)
THICKNESS mm (in) IDENTIFICATION COLOR THICKNESS mm (in) IDENTIFICATION COLOR
1.44 (0.0567) None 1.58 (0.0622) Brown
1.51 (0.0594) Blue
Thrust plate
(For adjustment of input shaft 5th speed gear end play)
THICKNESS mm (in) IDENTIFICATION SYMBOL THICKNESS mm (in) IDENTIFICATION SYMBOL
3.82 (0.1504) 0 3.98 (0.1567) 6
3.86 (0.1520) 2 4.02 (0.1583) 7
3.90 (0.1535) 3 4.06 (0.1598) 8
3.94 (0.1551) 5 4.10 (0.1614) 9
Spacer
(For adjustment of output shaft preload)
THICKNESS mm (in) IDENTIFICATION SYMBOL THICKNESS mm (in) IDENTIFICATION SYMBOL
0.86 (0.0339) 86 1.19 (0.0469) L
0.89 (0.0350) 89 1.22 (0.0480) G
0.92 (0.0362) 92 1.25 (0.0492) M
0.95 (0.0374) 95 1.28 (0.0504) N
0.98 (0.0386) 98 1.31 (0.0516) E
1.01 (0.0398) 01 1.34 (0.0528) O
1.04 (0.0409) 04 1.37 (0.0539) P
1.07 (0.0421) 07 1.40 (0.0551) None
1.10 (0.0433) J 1.43 (0.0563) Q
1.13 (0.0445) D 1.46 (0.0575) R
1.16 (0.0457) K

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 MANUAL TRANSAXLE OVERHAUL <W5M51>
SPECIFICATIONS
22B-57
Snap ring
(For adjustment of output shaft rear bearing end play)
THICKNESS mm (in) IDENTIFICATION COLOR THICKNESS mm (in) IDENTIFICATION COLOR
1.36 (0.0535) Yellow 1.55 (0.0610) White
1.40 (0.0551) Green 1.58 (0.0622) Brown
1.44 (0.0567) None 1.63 (0.0642) Orange
1.48 (0.0583) Black 1.68 (0.0661)
1.51 (0.0594) Blue
Snap ring
(For adjustment of output shaft 3rd speed gear end play)
THICKNESS mm (in) IDENTIFICATION COLOR THICKNESS mm (in) IDENTIFICATION COLOR
2.81 (0.1106) None 2.97 (0.1169) Green
2.85 (0.1122) Blue 3.01 (0.1185) Black
2.89 (0.1138) Brown 3.05 (0.1201) White
2.93 (0.1154) Yellow 3.09 (0.1217) Orange
Spacer
(For adjustment of center differential case preload)
THICKNESS mm (in) IDENTIFICATION SYMBOL THICKNESS mm (in) IDENTIFICATION SYMBOL
0.74 (0.0292) 74 1.04 (0.0409) 04
0.77 (0.0303) 77 1.07 (0.0421) 07
0.80 (0.0315) 80 1.10 (0.0433) J
0.83 (0.0327) 83 1.13 (0.0445) D
0.86 (0.0339) 86 1.16 (0.0457) K
0.89 (0.0350) 89 1.19 (0.0469) L
0.92 (0.0362) 92 1.22 (0.0480) G
0.95 (0.0374) 95 1.25 (0.0492) M
0.98 (0.0386) 98 1.28 (0.0504) N
1.01 (0.0398) 01 1.31 (0.0516) E
Spacer
(For adjustment of center differential case backlash)
THICKNESS mm (in) IDENTIFICATION SYMBOL THICKNESS mm (in) IDENTIFICATION SYMBOL
0.6 (0.0236) − 0.9 (0.0354) −
0.7 (0.0276) − 1.0 (0.0394) −
0.8 (0.0315) − 1.1 (0.0433) −

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NOTES