GR00002700-22B - Evo X Service Manuals
Contents
1. MANUAL TRANSAXLE OVERHAUL lt TRANSAXLE 22 17 gt gt lt lt SPRING INSTALLATION Shift rail Install the spring pin to the shift rail so that the slit of the spring aligns with the center axis of the rail as shown 2 5 e 0 0984 inch AR AK703408AC Spring pin gt gt C lt lt REVERSE IDLER GEAR ASSEMBLY INSTALLATION Install reverse idler gear assembly so that the notch of the reverse idler gear shaft and 1st 2nd speed synchronizer sleeve meet at the illustrated position gear assembly AK703681AC gt gt D lt lt SPRING PIN INSTALLATION e 2 5 mm Install the spring pin to the shift rail so that the slit of the spring Shift rail Shift fork 0 0984 inch pin aligns with the center axis of the rail as shown Lo o Spring pin AK703409AC gt gt E lt lt 5TH REVERSE SPEED SHIFT RALL INSTALLATION Install the 5th reverse speed shift rail with its identification groove groove to the clutch housing side I Installation direction 5th reverse speed shift rail AK703410AC TSB Revision 22 18 703819 Back up light switch Control shaft 1st 2nd speed rail switch rU 4 LIS AK703332AC MANUAL TRANSAXLE OVERHAUL TRANSAXLE gt gt F lt lt REVERSE SHIFT LEVER INSTALLATION Install the reverse shift lever2. B SPRING PIN REMOVAL Knock the spring pin out of the 3rd 4th speed shift fork from the illustrated direction C REVERSE IDLER GEAR ASSEMBLY REMOVAL Pull up the input shaft and output shaft together and remove the reverse idler gear assembly TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 16 TRANSAXLE lt lt D gt gt 3RD 4TH SPEED SHIFT FORK 5TH SPEED SHIFT FORK SHIFT LUG 5TH SPEED SHIFT RALL ASSEMBLY INPUT SHAFT ASSEMBLY OUTPUT SHAFT ASSEMBLY 1ST 2ND SPEED SHIFT FORK 1ST 2ND SPEED SHIFT RAIL ASSEMBLY REMOVAL With the differential assembly raised a little remove the 3rd 4th speed shift fork 5th speed shift fork shift lug 5th speed shift rail assembly output shaft assembly 1st 2nd speed shift fork 1st 2nd speed shift rail assembly and input shaft assembly as a set lt lt E gt gt SPRING PIN REMOVAL Knock the spring pin out of the 1st 2nd speed shift fork from the illustrated direction AK703324 ASSEMBLY SERVICE POINTS gt gt A lt lt 3RD 4TH SPEED SHIFT FORK 5TH SPEED SHIFT FORK SHIFT LUG 5TH SPEED SHIFT RALL ASSEMBLY INPUT SHAFT ASSEM BLY OUTPUT SHAFT ASSEMBLY REMOVAL With the differential assembly raised a little install the 3rd 4th speed shift fork 5th speed shift fork shift lug 5th speed shift rail assembly input shaft assembly and output shaft assembly as a set TSB Revision
3. Thickness mm in MANUAL TRANSAXLE OVERHAUL 22B 7 ADJUSTMENT SNAP RING AND SPACERS Snap ring For adjustment of output shaft rear bearing end play Thickness mm in Thickness mm in 1 31 0 0561 1 55 0 0610 1 35 0 0531 1 59 0 0626 1 39 0 0547 1 63 0 0642 1 43 0 0563 1 67 0 0657 1 47 0 0579 1 71 0 0673 1 51 0 0594 Spacer For adjustment of output shaft end play Thickness mm in Thickness mm in 0 86 0 0339 1 19 0 0469 0 89 0 0350 1 22 0 0480 0 92 0 0362 1 25 0 0492 0 95 0 0374 1 28 0 0504 0 98 0 0386 1 31 0 0516 1 01 0 0398 1 34 0 0528 1 04 0 0409 1 37 0 0539 1 07 0 0421 1 40 0 0551 1 10 0 0433 1 43 0 0563 1 13 0 0445 1 46 0 0575 1 16 0 0457 Snap ring For adjustment of reverse idler gear thrust washer end play Thickness mm in 1 49 0 0587 Thickness mm in 1 77 0 0697 2 12 0 0835 1 82 0 0717 2 17 0 0854 1 87 0 0736 2 22 0 0874 1 97 0 0776 2 32 0 0913 2 02 0 0795 2 37 0 0933 1 92 0 0756 2 07 0 0815 2 27 0 0894 2 42 0 0953 TSB Revision 22 8 MANUAL TRANSAXLE OVERHAUL SPECIAL TOOLS Spacer For adjustment of center differential case end play Thickness mm in Thickness
4. 703414 TSB Revision MANUAL TRANSAXLE OVERHAUL OUTPUT SHAFT 22 35 gt gt M lt lt OIL SEAL INSTALLATION Using special tool MD999601 drive the oil seal as deep as 3 5 shown into place 0 1378 inch Oil seal i N rf AK702519AD MD999601 ea AK703176AC INSPECTION M1222002300294 OUTPUT SHAFT e Check the needle bearing mounting portion of the shaft for damage wear and seizure e Check the splines for damage and wear AK702518AC NEEDLE BEARING e Combine the needle bearing with the input shaft and gears and check that it smoothly rotates without noise or play e Check the needle bearing retaining sleeve for deformation TSB Revision 22 36 MANUAL TRANSAXLE OVERHAUL AK204169AD Outer A AK703376AC Inner ring I AK703160AC AK703375 OUTPUT SHAFT SPEED GEARS 1 2 Check that the helical and clutch gears of each speed gear are not damaged or worn in the tooth surface Check that the synchronizer cones of the 1st and 2nd speed gears are not roughened damaged or worn in the surface heck that the inner front and rear surfaces of each speed gear are not damaged or worn SYNCHRONIZER RING 1 2 Check that the outer synchronizer ring clutch gear is free of damage Check that the synchronizer rings and synchronizer cones are free of damage or w
5. MB991946 Pry bar Removal of oil guide d do SP p d MB990883 MB990883 Rear suspension bushing arbor MB990883 01 or general service tool Removal of slide ball bearing Installation of slide ball bearing 8 0999547 Oil seal installer TSB Revision Installation of oil guide Installation of center differential taper roller bearing MANUAL TRANSAXLE OVERHAUL SPECIAL TOOLS 22 1 1 Tool number Supersession Application and name MB992075 Installation of oil seal Handle MB992271 Installation of oil seal Oil seal installer MB991115 MB991015 01 Installation of center differential Oil seal installer oil seal MB990938 MB990938 01 Installation of center differential Installer bar oil seal MB992272 Installation of center differential Bearing installer taper roller bearing MB990847 MB990847 Installation of center differential Rear taper roller bearing suspension bushing remover and MB990847 installer base TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 12 TRANSAXLE TRANSAXLE DISASSEMBLY AND ASSEMBLY M1222016500042 Apply gear oil to WD all moving parts before installation 24 4N m 17 2 ft lb 9 AK703151AC Removal steps Removal steps Continued 1 Transfer assembly 6 Gasket gt gt J lt lt 2 Shift cable bracket gt lt lt 7 Back up light switch 3 Stud adapter 8 Gasket 4 Han
6. 1 Apply specified sealant to the periphery of the air breather insertion part Specified sealant Three bond 1501 or equivalemt 2 Install the air breather to the transaxle case in accordance with the illustrated identification mark gt gt B lt lt STEEL BALL INSTALLATION 1 Apply specified sealant to the periphery of the transaxle case where the steel ball is installed then install the steel ball onto the transaxle case Specified sealant 3M STUD Locking 4710 or equivalent 2 Using special tool MB990883 install the steel ball TSB Revision 2 MANUAL TRANSAXLE OVERHAUL 22B 50 TRANSAXLE CASE gt gt lt lt OIL SEAL INSTALLATION 1 Using the special tools MB991115 and MB990938 indicated below install the seal to the transaxle case MB990938 IU MB991115 Jens 2 Apply specified transaxle oil to the oil seal lip area Specified transaxle oil Mitsubishi Genuine DiaQueen New Multi Gear Oil SAE 75W 80 GL 3 gt gt D lt lt SLIDE BALL BEARING FOR CONTROL SHAFT INSTALLATION N CAUTION e Normally it is not necessary to disassemble the slide ball bearing Install it only when the transaxle case is replaced with a new one e Install the bearing with the stamped mark facing upward Using special tool MB990883 install the slide ball bearing for control shaft to the new transaxle case AK703405 AC zu
7. l AK703306AC gt gt G lt lt SNAP RING INSTALLATION Select and install appropriate snap ring onto the output shaft so that the clearance of the output shaft 3rd speed gear meets the standard value Standard value 0 01 0 09 mm 0 0004 0 0035 inch gt gt H lt lt 4TH SPEED GEAR INSTALLATION m Using the special tools MD998812 MD998813 and S di MD998821 indicated below install the 4th speed gear AK703307AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 34 OUTPUT SHAFT gt gt lt lt 5TH SPEED GEAR INSTALLATION MD998812 Using the special tools MD998812 MD998813 and Se MD998819 indicated below install the 5th speed gear MD998813 L AK703308AC gt gt J lt lt TAPER ROLLER BEARING INSTALLATION Using the special tools MD998812 MD998813 and J 0998812 MD998819 indicated below press fit the taper roller bearing MD998813 1 _ MD998819 AK703309AC gt gt K lt lt SNAP RING INSTALLATION Select and install appropriate snap ring onto the output shaft so that the clearance of the taper roller bearing meets the stan Snap ring dard value Standard value 0 01 0 09 mm 0 0004 0 0035 inch AK703380 AC gt gt L lt lt TAPER ROLLER BEARING INSTALLATION Using the special tools MD998812 and MD998819 indicated MD998812 below install the taper roller bearing MD998819
8. AK703370AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 51 TRANSAXLE CASE gt gt E lt lt SLIDE BALL BEARING FOR SHIFT RAIL INSTALLATION A CAUTION e Normally it is not necessary to disassemble the slide ball bearing Install it only when the transaxle case is replaced with a new one e Install the bearing with the stamped mark facing upward Using special tool MB990883 install the slide ball bearing ror shift rail to the new transaxle case zz S gm gt gt F lt lt OIL GUIDE A INSTALLATION A CAUTION Normally it is not necessary to disassemble the oil guide A Install the oil guide only when the transaxle case is replaced with a new one Install the oil guide A to the new transaxle case Stake at the illustrated point to secure the oil guide in position gt gt G lt lt OIL TANK COVER INSTALLATION N CAUTION Normally it is not necessary to disassemble the oil tank cover Install the cover only when the transaxle case is replaced with a new one Install the oil tank cover onto the new transaxle case Stake at the illustrated six points to secure the cover in position TSB Revision T MANUAL TRANSAXLE OVERHAUL 22B 52 TRANSAXLE CASE gt gt H lt lt OIL GUIDE INSTALLATION N CAUTION Install the oil guide squarely Using special tool MD999547 drive the oil guide all the way into p
9. Apply specified grease to the oil seal lip area Specified grease Retinax A TSB Revision 22 48 MANUAL TRANSAXLE OVERHAUL TRANSAXLE CASE TRANSAXLE CASE DISASSEMBLY AND ASSEMBLY 1 10 2N m v Removal steps lt lt A gt gt gt gt H lt lt 1 Oil guide gt gt G lt lt 2 Oil tank cover gt gt F lt lt 3 Oil guide A 4 Oil guide B gt gt E lt lt 5 Slide ball bearing for shift rail gt gt D lt lt 6 Slide ball bearing for control shaft gt gt lt lt 7 Oil seal Required Special Tools MB991946 Ply bar e MB990883 Rear suspension bushing arbor e MB991115 Oil seal installer UV M1222016300048 AK702516 AC Removal steps Continued 8 Steel ball 9 Air breather 10 Transaxle case NOTE Refer to the assembly service points only when the transaxle case is replaced gt gt B lt lt gt gt A lt lt MB990938 Installer bar e MD999547 Oil seal installer TSB Revision MANUAL TRANSAXLE OVERHAUL Q N A x MB991946 CAT SL Identification mark Clutch housing AK703373AC d Steel ball AK703371AC ANI AC 22B 49 TRANSAXLE CASE DISASSEMBLY SERVICE POINTS lt lt A gt gt OIL GUIDE REMOVAL Using special tool MB991946 remove the oil guides from the transaxle case ASSEMBLY SERVICE POINTS gt gt A lt lt AIR BREATHER INSTALLATION
10. AK703311 AC lt lt C gt gt SLIDE BALL BEARING REMOVAL Using special tool MB990947 remove the slide ball bearing Slide ball bearing AK703384AC ASSEMBLY SERVICE POINTS gt gt A lt lt SLIDE BALL BEARING INSTALLATION Toe Using special tool MB990984 install the slide ball bearing in alignment with the control housing end face taking care not to let the bearing protrude to the oil seal installing surface AK703367 AC TSB Revision 22 42 MANUAL TRANSAXLE OVERHAUL AK703312 AC AK703385 AC CONTROL HOUSING gt gt lt lt OIL SEAL INSTALLATION 1 Using special tool MB991246 install the oil seal 2 Apply specified transmission oil to the oil seal lip area Specified transaxle oil Mitsubishi Genuine DiaQueen New Multi Gear oil SAE 75W 80 GL 3 gt gt C lt lt LOCK PIN INSTALLATION Drive the lock pin all the way into place to the end face from the illustrated direction gt gt D lt lt STOPPER BRACKET INSTALLATION Tighten the stopper bracket mounting bolts to the specified torque in the illustrated order TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 43 SELECT LEVER SELECT LEVER DISASSEMBLY AND ASSEMBLY Removal steps Dust cover Nut Spring washer Washer Select lever bushing Select lever shoe lt ce 703386 1222012800320 10 703152 R
11. 22 MANUAL TRANSAXLE OVERHAUL INPUT SHAFT INPUT SHAFT DISASSEMBLY AND ASSEMBLY lt lt A gt gt lt lt A gt gt lt lt A gt gt lt lt A gt gt lt lt A gt gt gt gt lt lt gt gt H lt lt gt gt G lt lt gt gt F lt lt gt gt F lt lt Removal steps Oil seal Snap ring Taper roller bearing Synchronizer key stopper plate 5th speed synchronizer sleeve 5th speed synchronizer hub Synchronizer key lt lt A gt gt lt lt A gt gt lt lt A gt gt lt lt A gt gt lt lt B gt gt lt lt B gt gt gt gt E lt lt M1222001600667 Apply gear oil to all moving parts before installation AK702340AD Removal steps Continued 8 Synchronizer outer ring 9 Synchronizer cone 10 Synchronizer inner ring 11 5th speed gear 12 Needle roller bearing 13 5th speed gear sleeve 14 4th speed gear TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 23 INPUT SHAFT Removal steps Continued lt lt B gt gt 15 Needle roller bearing lt lt B gt gt gt gt D lt lt 16 4th speed gear sleeve lt lt B gt gt 17 Synchronizer outer ring lt lt B gt gt 18 Synchronizer cone lt lt B gt gt 19 Synchronizer inner ring lt lt B gt gt gt gt lt lt 20 3 4 speed synchronizer sleeve lt lt B gt gt gt gt lt lt 21 3rd 4th speed synchronizer hub lt lt B gt gt 22 Synchronizer key lt lt B gt gt 23 Synchronizer outer ri
12. BEARING INSTALLATION Install the thrust bearings as shown Thrust bearing Tsbspaod gear sleeve gf 7 Needle roller bearing AK703377AC gt gt C lt lt 1ST 2ND SPEED SYNCHRONIZER HUB INSTALLATION 1 Install the 1st 2nd speed synchronizer hub in the illustrated direction Installation direction AK703378AC 2 Using the special tools MD998812 MD998814 and Pe MD998824 indicated below install the 1st 2nd speed MD998812 synchronizer hub MD998814 1 gt gt D lt lt 1ST 2ND SPEED SYNCHRONIZER SLEEVE INSTALLATION 1 Install the 1st 2nd speed synchronizer sleeve in the illustrated direction 2 Install the synchronizer outer ring synchronizer cone and synchronizer inner ring 3 After installation check that the 1st 2nd speed gears rotate smoothly Identification aw d groove Installation direction AK703379AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 33 OUTPUT SHAFT gt gt E lt lt 2ND SPEED GEAR SLEEVE INSTALLATION Using the special tools MD998812 MD998814 M MD998824 indicated below install the 2nd speed gear sleeve MD998814 l MD998812 2 w d 703305 gt gt F lt lt 3RD SPEED GEAR INSTALLATION Using the special tools MD998812 MD998814 and MD998822 indicated below install the 3rd speed gear TT 12 MD998814
13. mm in 1 07 0 0421 1 34 0 0528 1 10 0 0433 1 37 0 0539 1 13 0 0445 1 40 0 0551 1 16 0 0457 1 43 0 0563 1 19 0 0469 1 49 0 0587 1 25 0 0492 1 52 0 0598 1 28 0 0504 1 46 0 0575 1 55 0 0610 1 22 0 0480 1 31 0 0516 SPECIAL TOOLS Tool number and name Supersession M1222000600750 Application MD998917 Bearing remover General service tool Removal of gears and bearings MB990560 MB990560 Rear axle shaft bearing remover Removal of output shaft taper roller bearing 990842 Drag link bushing remover and installer B Removal of input shaft 5th speed gear Removal of output shaft taper roller bearing Removal of output shaft 5th and 4th speed gears MD999601 Valve stem seal installer Installation of input shaft and output shaft oil seal e MD998812 Installer cap General service tool TSB Revision Use with installer and installer adapter MANUAL TRANSAXLE OVERHAUL SPECIAL TOOLS Tool number and name Supersession 22B 9 Application MD998813 Installer 100 General service tool Use with installer cap and installer adapter MD998814 Installer 200 MIT304180 Use with installer cap and installer adapter MD998819 Installer adapter 40 General service tool e Installati
14. so that its identification mark is located at the illustrated position gt gt G lt lt TRANSAXLE CASE INSTALLATION Apply a bead approximately 2 mm 0 0787 inch thick of spec ified sealant to the transaxle case as shown Specified sealant Mitsubishi Part No MD997740 or equivalent gt gt H lt lt CONTROL HOUSING INSTALLATION Apply a bead approximately 3 5 mm 0 1378 inch thick of specified sealant to the control housing as shown Specified sealant Mitsubishi Part No MD997740 or equivalent gt gt I lt lt BACK UP LIGHT SWITCH 1ST 2ND SPEED RAIL SWITCH INSTALLATION Install the back up light switch and 1st 2nd speed rail switch at the illustrated positions TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 19 Shift cable Control 139 141 mm bracket shaft 5 4724 5 5512 inch AK703153AC 139 2 i Select lever 2 14 Shift cable 5 4803 8mm 5 433 inch bracket Select lever bracket AK703154AC AK201630 TRANSAXLE gt gt J lt lt SHIFT CABLE BRACKET INSTALLATION Install the shift cable bracket loosely Put the control shaft into neutral Position the shift cable bracket so that the distance between the control shaft and shift cable bracket is within the standard value Then fix the bracket securely Standard value 139 141 mm 5 48 5 55 inch Install the select lever bracket loosely Put the select lever into the 3rd 4th spee
15. the tooth surfaces of the clutch gear of the reverse gear A free of damage or wear gt y 2 Check that the synchronizer ring of the reverse idler gear A P is not roughened damaged or worn in the surface 3 Check that the helical gear of the reverse idler gear is free of damage or wear AK703383AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 40 CONTROL HOUSING CONTROL HOUSING DISASSEMBLY AND ASSEMBLY M1222013100391 702514 Removal steps Removal steps Continued 1 Stopper bracket mounting bolt 9 Washer 2 Spring washer 10 Interlock plate gt gt D lt lt 3 Stopper bracket 11 Neutral return spring lt lt A gt gt gt gt C lt lt 4 Lock pin 12 Control shaft 5 Snap ring 13 Control shaft boot 6 Return spring holder B lt lt B gt gt gt gt lt lt 14 seal 7 Return spring lt lt C gt gt gt gt lt lt 15 Slide ball bearing 8 Return spring holder A 16 Control housing Required Special Tools MD999566 Claw MB990984 Mount bushing remover and installer MB990947 Lower arm bushing arbor arbor MB991246 Lower arm bushing arbor TSB Revision MANUAL TRANSAXLE OVERHAUL 2 CONTROL HOUSING 22B 41 DISASSEMBLY SERVICE POINTS lt lt A gt gt LOCK PIN REMOVAL Drive out the lock pin in the direction shown lt lt B gt gt OIL SEAL REMOVAL Using special tool MD999566 remove the oil seal
16. 2 6 MANUAL TRANSAXLE OVERHAUL ADJUSTMENT SNAP RING AND SPACERS ADJUSTMENT SNAP RING AND SPACERS M1222012000799 Snap ring For adjustment of input shaft rear bearing end play Thickness mm in Thickness mm in 1 23 0 0484 1 55 0 0610 1 27 0 0500 1 59 0 0626 1 31 0 0516 1 63 0 0642 1 35 0 0531 1 71 0 0673 1 43 0 0563 1 75 0 0689 1 47 0 0579 1 67 0 0657 1 79 0 0705 1 39 0 0547 1 51 0 0594 Spacer For adjustment of input shaft end play Thickness mm in 0 80 0 0315 1 16 0 0457 0 83 0 0327 1 19 0 0469 0 86 0 0339 1 22 0 0480 0 89 0 0350 1 25 0 0492 0 92 0 0362 1 28 0 0504 0 95 0 0374 1 31 0 0516 1 01 0 0398 1 37 0 0539 1 04 0 0409 1 40 0 0551 1 07 0 0421 1 43 0 0563 1 10 0 0433 1 46 0 0575 0 98 0 0386 1 13 0 0445 Snap ring For adjustment of output shaft 3rd speed gear end play Thickness mm in 1 34 0 0528 1 49 0 0587 Thickness mm in 2 23 0 0878 2 27 0 0894 2 47 0 0972 2 51 0 0988 2 31 0 0909 2 55 0 1004 2 39 0 0941 2 63 0 1035 2 35 0 0925 2 43 0 0957 2 59 0 1020 2 67 0 1051 TSB Revision
17. 8813 and MD998822 indicated below install the 3rd 4th speed synchronizer sleeve 3rd 4th speed synchronizer hub synchronizer outer ring synchronizer inner ring and synchronizer cone 3 After installation check that the 3rd speed gear rotates smoothly gt gt D lt lt 4TH SPEED GEAR SLEEVE INSTALLATION Using the special tools MD998812 MD998813 and MD998822 indicated below install the 4th speed gear sleeve TSB Revision 22 26 MANUAL TRANSAXLE OVERHAUL uno AK703171AC Identification Installation X direction Identification groove AK703158AC AK703172AC MD998822 AK703173AC INPUT SHAFT gt gt E lt lt 5TH SPEED GEAR SLEEVE INSTALLATION Using the special tools MD998812 MD998813 and MD998822 indicated below install the 5th speed gear sleeve gt gt F lt lt 5TH SPEED SYNCHRONIZER HUB 5 SYNCHRONIZER SLEEVE INSTALLATION 1 Install the 5th speed synchronizer hub and synchronizer sleeve in the illustrated direction 2 Using the special tools MD998812 MD998813 and MD998822 indicated below install the 5th speed synchronizer hub and synchronizer sleeve 3 After installation check that the 5th speed gear rotates smoothly gt gt G lt lt TAPER ROLLER BEARING INSTALLATION Using the special tools MD998812 MD998813 and MD998822 indicated below press fit the taper roller bearing TSB Revision MANUAL TRAN
18. ED GEAR SLEEVE SYNCHRONIZER OUTER RING SYNCHRONIZER CONE SYNCHRONIZER INNER RING 3RD 4TH SPEED SYNCHRONIZER SLEEVE 3RD 4TH SPEED SYNCHRONIZER HUB THRUST BEARING 3RD SPEED GEAR REMOVAL Using special tool MD998917 support the 3rd speed gear and then remove the 3rd seed gear thrust bearings 3rd 4th speed synchronizer sleeve 3rd 4th speed synchronizer hub synchro nizer outer ring synchronizer inner ring synchronizer cone 4th speed gear needle roller bearing 4th speed gear sleeve and 5th speed gear sleeve lt lt C gt gt TAPER ROLLER BEARING REMOVAL Using special tool MD998917 remove the taper roller bearing ASSEMBLY SERVICE POINTS gt gt A lt lt TAPER ROLLER BEARING INSTALLATION Using the special tools MD998812 MD998813 and MD998819 indicated below install the taper roller bearing TSB Revision MANUAL TRANSAXLE OVERHAUL Colorless Colorless thin thin Black 1 3rd speed gear thick AK703374AC Installation direction AK703159AC AK703169AC Identification groove AK703170AC 22B 25 INPUT SHAFT gt gt B lt lt THRUST BEARING INSTALLATION Install the thrust bearings as shown gt gt C lt lt 3RD 4TH SPEED SYNCHRONIZER HUB 3RD 4TH SPEED SYNCHRONIZER SLEEVE INSTALLATION 1 Install the 3rd 4th speed synchronizer hub and synchronizer sleeve in the illustrated direction 2 Using the special tools MD998812 MD99
19. NER TIGHTENING SPECIFICATIONS M1222013900342 TRANSAXLE Item Specification Reverse shift lever 24 4 m 17 2 ft lb Clutch housing transaxle case mounting bolt 50 5 m 37 3 ft lb Reverse idler gear shaft mounting bolt 78 7 N m 57 4 ft lb Poppet spring 32 2 N m 24 1 ft Id Control housing mounting bolt 24 A N m 17 2 ft lb Select lever 24 A N m 17 2 ft lb Harness bracket 24 A N m 17 2 ft lb Back up light switch 32 2 N m 24 1 ft Id 1st 2nd speed rail switch 32 2 N m 24 1 ft Id Hanger bracket 24 A N m 17 2 ft lb Stud adapter 50 5 N m 37 3 ft lb Shift cable bracket 24 A N m 17 2 ft lb Transaxle transfer mounting bolt 69 9 m 51 6 ft lb Stopper bracket mounting bolt 19 3N m 14 2 ft lb Select lever select lever bracket connecting nut 11 2 N m 97 17 in Ib Clutch release bearing retainer mounting bolt 10 2 m 88 17 in Ib Oil guide B 10 2 m 88 17 in Ib Center differential drive gear mounting bolt 133 4 m 98 2 ft Ib TRANSFER Item Specification Transfer heat protector 10 2 N m 88 17 in Ib Drive shaft heat protector 9 0 1 0 m 79 8 in Ib SEALANTS AND ADHESIVES Item Specified sealant Mating face for transaxle case and clutch housing Mitsubishi Part No MD997740 or equivalent M1222000500720 Mating face for transaxle case and control h
20. NG INSTALLATION Install the thrust bearing as shown Lew Thrust pearing AK703381 AC gt gt B lt lt SYNCHRONIZER SLEEVE INSTALLATION Install the synchronizer sleeve in the illustrated direction Identification groove Installation direction AK703156AC gt gt C lt lt SNAP RING INSTALLATION Select and install appropriate snap ring onto the reverse idler gear shaft so that the clearance of the thrust washer A meets the standard value Standard Value 0 0 11 mm 0 0 0043 inch AK703318 AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 39 REVERSE IDLER GEAR INSPECTION M1222012400117 REVERSE IDLER GEAR 1 Check that the synchronizer ring clutch gear teeth are free of damage 2 Check that the inside surface of the synchronizer ring cone is free of damage and wear 3 Check that the synchronizer ring and synchronizer key are not damaged or worn in the contact surface 4 Press the synchronizer ring against the gear and check clearance A If A is less than the limit value replace the synchronizer ring Limit 0 5 mm 0 02 inch AK204103AD NEEDLE BEARING 1 Assemble the needle bearing with the reverse idler shaft and gear and check that the bearing rotates smoothly without noise or play 2 Check that needle bearing retaining sleeve for deformation REVERSE IDLER GEAR 1 Check that the helical gear and
21. RING REMOVAL Using the special tools MD998917 and MB990842 indicated below remove the taper roller bearing lt lt C gt gt 5TH SPEED GEAR 4TH SPEED GEAR REMOVAL Using the special tools MD998917 and MB990842 indicated below remove the 5th speed gear and 4th speed gear TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 31 K703301AC MD998814 4 0998812 MD998824 AK703303AC OUTPUT SHAFT lt lt D gt gt 3RD SPEED GEAR REMOVAL Using special tool MD998917 remove the 3rd speed gear lt lt E gt gt NEEDLE ROLLER BEARING SYNCHRONIZER CONE SYNCHRONIZER OUTER RING SYNCHRONIZER INNER RING THRUST BEARING 2ND SPEED GEAR SLEEVE 1ST 2ND SPEED SYNCHRONIZER HUB 1ST SPEED GEAR 1ST SPEED GEAR SLEEVE REMOVAL Using special tool MD998917 support the 1st speed gear sleeve and then remove the 2nd speed gear sleeve 1st 2nd speed synchronizer hub synchronizer cones synchronizer outer rings synchronizer inner rings thrust bearings 1st speed gear needle roller bearing and 1st speed gear sleeve ASSEMBLY SERVICE POINTS gt gt A lt lt 1ST SPEED GEAR SLEEVE INSTALLATION Using the special tools MD998812 MD998814 and MD998824 indicated below install the 1st speed gear sleeve TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 32 OUTPUT SHAFT gt gt B lt lt THRUST
22. SAXLE OVERHAUL 22B 27 3 5mm 0 1378 inch Oil seal MD999601 AK702519AD AK703175AC AK702517AC INPUT SHAFT gt gt H lt lt SNAP RING INSTALLATION Select and install appropriate snap ring onto the input shaft so that the clearance of the taper roller bearing meets the stan dard value Standard value 0 01 0 09 mm 0 0004 0 0035 inch gt gt 1 lt lt OIL SEAL INSTALLATION Using special tool MD999601 drive the oil seal as deep as shown into place INSPECTION M1222001700330 INPUT SHAFT e Check the needle bearing mounting portion of the shaft for damage wear and seizure e Check the splines for damage and wear TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 28 INPUT SHAFT NEEDLE BEARING e Combine the needle bearing with the input shaft and gears and check that it smoothly rotates without noise or play e Check the needle bearing retaining sleeve for deformation SPEED GEARS 1 Check that the helical and clutch gears of each speed gear are not damaged or worn in the tooth surface 2 Check that the synchronizer cone of each speed gear is not roughened damaged or worn in the surface 3 Check that the inner front and rear surfaces of each speed gear are not damaged or worn AK204169AD SYNCHRONIZER RING 1 Check that the outer synchronizer ring clutch gear is free of damage 2 Check that the synchronizer rings and sync
23. SPECIFICATIONS LUBRICANTS 228 5 SELECT LEVER DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS INPUT SHAFT 22B 22 TRANSFER DISASSEMBLY AND ASSEMBLY 22B 22 DISASSEMBLY AND ASSEMBLY 22 27 GROUP 22B MANUAL TRANSAXLE OVERHAUL CONTENTS GENERAL INFORMATION 22B 2 OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY GENERAL SPECIFICATIONS 22B 3 INSPECTION SERVICE SPECIFICATIONS 22B 3 REVERSE IDLER GEAR DISASSEMBLY AND ASSEMBLY FASTENER TIGHTENING 22 4 CONTROL HOUSING SEALANTS AND ADHESIVES dd DISASSEMBLY AND ASSEMBLY ADJUSTMENT SNAP RING AND DEER 22 6 CLUTCH HOUSING DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY 22B 12 gua eee a a Ros 22B 8 TRANSAXLE CASE liana p rea 22B 12 DISASSEMBLY AND ASSEMBLY 22B 19 CENTER DIFFERENTIAL TRANSAXLE ADJUSTMENT 22B 19 DISASSEMBLY AND ASSEMBLY 22B 1 22 2 MANUAL TRANSAXLE OVERHAUL GENERAL INFORMATION GENERAL INFORMATION M1222000100874 TRANSAXLE MODEL Transaxle model Engine model Vehicle model W5M6A 1 A1ZA 4 11 CZ4A SECTIONAL VIEW AK703412 TSB Revision MANUAL TRANSAXLE OVERHAUL GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS GEAR RATIO TABLE Item Specification 22B 3 M1222000201056 Transaxle model W5M6A Tran
24. Y SERVICE POINTS gt gt A lt lt SLIDE BALL BEARING FOR SHIFT RAIL INSTALLATION A CAUTION e Normally it is not necessary to disassemble the slide ball bearings Install them only when the clutch hous ing is replaced with a new one e Install the bearing with the stamped mark facing upward Using special tool MB990883 install the slide ball bearings on the new clutch housing TSB Revision 22 46 MANUAL TRANSAXLE OVERHAUL O CI AK703335 AC CLUTCH HOUSING gt gt B lt lt OIL TANK COVER REV OIL TANK COVER CHG INSTALLATION N CAUTION Normally it is not necessary to disassemble the oil tank covers Install them only when the clutch housing is replaced with a new one Install the oil tank covers to the new clutch housing Stake the projections at the illustrated positions of the clutch housing to secure the covers in position gt gt C lt lt OUTPUT FRONT OIL GUIDE INSTALLATION A CAUTION Make sure that the output front oil guide is installed squarely Using special tool MD999547 drive the oil guide all the way into place to the end face of the clutch housing TSB Revision MANUAL TRANSAXLE OVERHAUL CLUTCH HOUSING 22B 47 gt gt D lt lt OIL SEAL INSTALLATION 1 2 Using special tool MB992271 MB992075 drive the oil seal squarely into the clutch housing
25. d position Position the select lever bracket so that the distance between the select lever and shift cable bracket is within the standard value Then fix the bracket securely Standard value 139 2 140 8 mm 5 481 5 543 inch INSPECTION M1222016600049 BACKUP LIGHT SWITCH 1 2 speed rall switch Check for continuity between terminals Switch Condition Continuity Pressed Open Released Conductive TRANSAXLE ADJUSTMENT M1222013800129 ADJUSTMENT BEFORE ASSEMBLY SPACER SELECTION FOR INPUT SHAFT PRE LOAD OUTPUT SHAFT PRELOAD CENTER DIF FERENTIAL PRELOAD ADJUSTMENT lt Measurement using solder gt e If soft solder is not available select the spacer in accor dance with Plastigage method e spacer appropriate for the standard value cannot be selected using soft solder select the spacer in accordance with Plastigage method TSB Revision 22 20 MANUAL TRANSAXLE OVERHAUL TRANSAXLE Install the input shaft output shaft and center differential as a set to the clutch housing Solders KE Put a piece of solder 1 6 mm 0 06 in diameter 10 mm 0 39 in long on the transaxle case at the positions shown in the illustration Install the bearing outer races on the pieces of solder Install the clutch housing to the transaxle case and tighten the bolts to the specified torque Remove the clutch housing then remove the bea
26. ear in the contact surface and broken screw threads Check that the outer synchronizer ring and synchronizer key contact surface is free of damage and wear Join the outer and inner synchronizer rings and synchronizer cone together and check clearance A shown If A is less than the limit value replace them Limit A from back of outer ring to clutch gear 0 5 mm 0 02 inch SYNCHRONIZER SLEEVE AND HUB e Combine the synchronizer sleeve and hub and check that they slide smoothly e Check that the sleeve is free of damage at its inside spline ends TSB Revision MANUAL TRANSAXLE OVERHAUL REVERSE IDLER GEAR 22B 37 REVERSE IDLER GEAR DISASSEMBLY AND ASSEMBLY Removal steps Snap ring Thrust washer A Thrust bearing Reverse idler gear A Needle bearing Needle bearing Synchronizer sleeve Synchronizer ring Synchronizer key gt gt C lt lt gt gt B lt lt gt gt A lt lt gt gt A lt lt M1222012500299 gear oil to all moving parts before installation AK702513AC Removal steps Continued 10 Thrust bearing 11 Thrust washer B 12 Steel ball 13 Thrust bearing 14 Reverse idler gear B 15 Needle bearing 16 Needle bearing 17 Thrust bearing 18 Reverse idler gear shaft TSB Revision E MANUAL TRANSAXLE OVERHAUL 22B 38 REVERSE IDLER GEAR DISASSEMBLY SERVICE POINTS gt gt lt lt THRUST BEARI
27. emoval steps Continued 6 Select lever bracket 7 Select lever bushing 8 Dust cover 9 Select lever 1 gt gt A lt lt 0 Select lever shoe ASSEMBLY SERVICE POINTS gt gt A lt lt SELECT LEVER SHOE INSTALLATION Apply specified grease to the sliding contact surface of the select lever shoe Specified grease Mitsubishi Part No 0101011 or equivalent TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 44 CLUTCH HOUSING CLUTCH HOUSING DISASSEMBLY AND ASSEMBLY M1222003700596 10 2 N m 88 17 in Ib 702515 Removal steps Removal steps Continued 1 Clutch release bearing retainer gt gt B lt lt 8 Oil tank cover REV gt gt D lt lt 2 Oil seal gt gt A lt lt 9 Slide ball bearing for shift rail 3 Maintenance hole cover 10 Clutch housing 4 Cover A NOTE Refer to the assembly service points only 5 Cover B when the clutch housing is replaced lt lt A gt gt gt gt C lt lt 6 Output front oil guide gt gt lt lt 7 tank cover Required Special Tools e MB991946 Ply bar e MB992271 Oil seal installer MB990883 Rear suspension bushing arbor e MB992075 Hamdle e MD999547 Oil seal installer TSB Revision MANUAL TRANSAXLE OVERHAUL AK703336AC CLUTCH HOUSING 22B 45 DISASSEMBLY SERVICE POINTS lt lt A gt gt OUTPUT FRONT OIL GUIDE REMOVAL Using special tool MB991946 remove the output front oil guide ASSEMBL
28. ger bracket 9 Harness bracket gt gt lt lt 5 1st 2nd speed rail switch 10 Select lever TSB Revision MANUAL TRANSAXLE OVERHAUL TRANSAXLE 22B 1 3 Apply gear oil to all moving parts before installation Removal steps AK703162AC Removal steps Continued 17 Outer race for center differential gt gt H lt lt 11 Control housing 12 Poppet spring 18 Spacer for center differential 13 Gasket 19 Outer race for output shaft 14 Reverse idler gear shaft mounting 20 Spacer for output shaft bolt 21 Outer race for input shaft 15 Gasket 22 Spacer for input shaft gt gt G lt lt 16 case TSB Revision 22 14 lt lt gt gt lt lt gt gt lt lt gt gt lt lt gt gt lt lt D gt gt lt lt D gt gt lt lt D gt gt lt lt D gt gt lt lt D gt gt lt lt D gt gt lt lt D gt gt lt lt D gt gt lt lt E gt gt MANUAL TRANSAXLE OVERHAUL TRANSAXLE Removal steps 23 Reverse shift lever 24 Reverse shift rail 25 Reverse shift fork 26 5th reverse speed shift rail 27 Steel ball 28 Steel ball 29 Spring pin 30 3rd 4th speed shift rail 31 Reverse idler gear assembly 32 3rd 4th speed shift fork 33 Snap ring 34 Shift lug 35 5th speed shift fork 36 5th speed shift rail assembly 37 Input shaft assembly 38 Output shaft assembly 39 1st 2nd speed shift fork 40 1st 2nd speed shift rail as
29. hronizer cones are free of damage or wear in the contact surface and broken screw threads 3 Check that the outer synchronizer ring and synchronizer key contact surface is free of damage and wear AK703376AC 4 Join the outer and inner synchronizer rings and synchronizer cone together and check clearance A shown If A is less than the limit value replace them Limit A from back of outer ring to clutch gear 0 5 mm 0 02 inch Outer ring Inner ring AK703161AC SYNCHRONIZER SLEEVE AND HUB e Combine the synchronizer sleeve and hub and check that they slide smoothly e Check that the sleeve is free of damage at its inside spline ends AK703375 TSB Revision MANUAL TRANSAXLE OVERHAUL OUTPUT 5 22 29 5 DISASSEMBLY AND ASSEMBLY M1222002200598 Apply gear to all moving parts before installation AK702341AC Removal steps Removal steps Continued gt gt M lt lt 1 Oil seal gt gt D lt lt 15 1st 2nd speed synchronizer lt lt A gt gt gt gt L lt lt 2 Taper roller bearing sleeve gt gt lt lt 3 Snap ring lt lt E gt gt gt gt E lt lt 16 2nd speed gear sleeve lt lt B gt gt gt gt J lt lt 4 Taper roller bearing lt lt E gt gt gt gt C lt lt 17 1st 2nd speed synchronizer 5 Collar hub lt lt C gt gt gt gt lt lt 6 5th speed gear lt lt E gt gt 18 Synchronizer key lt lt g
30. lace to end face of the transaxle case lt Input shaft side gt a 0999547 AK703368AC 2 T side Ei Z 69 TSB Revision MANUAL TRANSAXLE OVERHAUL CENTER DIFFERENTIAL 22B 53 CENTER DIFFERENTIAL DISASSEMBLY AND ASSEMBLY M1222010600074 98 2 ft Ib AK703150 AC Removal steps Removal steps Continued gt gt C lt lt 1 Center differential drive gear lt lt B gt gt gt gt A lt lt 3 Taper roller bearing lt lt A gt gt gt gt B lt lt 2 Taper roller bearing 4 Center differential assembly Required Special Tools e MD998917 Bearing remover e MD998830 Installer adapter 66 e MD999547 Oil seal installer MD992272 Bearing installer e MD998812 Installer cap MB990847 Rear suspension bushing remover MD998813 Installer 100 and installer base DISASSEMBLY SERVICE POINTS A TAPER ROLLER BEARING REMOVAL 1 Using a chisel or the like knock off the roller cage of the taper roller bearing 2 Using the special tools MD998917 and MD999547 indicated below remove the taper roller bearing MD999547 MD998917 AK703314AC TSB Revision 22 54 MANUAL TRANSAXLE OVERHAUL ees 0998812 0998917 4 AK703317 AC S e STE E 703315 CENTER DIFFERENTIAL lt
31. lt B gt gt TAPER ROLLER BEARING REMOVAL 1 Using a chisel or the like knock off the roller cage of the taper roller bearing 2 Using the special tools MD998917 MD998812 MD998813 and MD998830 indicated below remove the taper roller bearing ASSEMBLY SERVICE POINTS gt gt A lt lt TAPER ROLLER BEARING INSTALLATION Using special tool 992272 install the taper roller bearing gt gt B lt lt TAPER ROLLER BEARING INSTALLATION Using special tool MB990847 install the taper roller bearing TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 55 CENTER DIFFERENTIAL gt gt C lt lt CENTER DIFFERENTIAL DRIVE GEAR INSTALLATION 1 Apply specified sealant to the entire threaded portion of the bolt Specified sealant Gui 3M STUD Locking No 4710 or equivalent AK204150AD 2 Tighten the bolts to the specified torque of 133 4 98 2 ft lb in fthe illustrated order AK204149AD TSB Revision 2 MANUAL TRANSAXLE OVERHAUL 22B 56 5 TRANSFER DISASSEMBLY AND ASSEMBLY M1222004000385 10 2 N m 704422 Removal steps 1 Drive shaft heat protector 2 Transfer heat protector TSB Revision
32. ng lt lt B gt gt 24 Synchronizer cone lt lt B gt gt 25 Synchronizer inner ring lt lt B gt gt gt gt lt lt 26 Thrust bearing lt lt B gt gt 27 3rd speed gear 28 Needle roller bearing gt gt B lt lt 29 Thrust bearing lt lt C gt gt gt gt lt lt 30 roller bearing 31 Input shaft Required Special Tools MD998813 Installer 100 MD998819 Installer adapter 40 MD998822 Installer adapter 46 MD999601 Valve stem seal installer e MD998917 Bearing remover e MB990842 Drag link bushing remover and installer B MD998812 Installer cap DISASSEMBLY SERVICE POINTS lt lt A gt gt 5TH SPEED GEAR SYNCHRONIZER INNER RING SYNCHRONIZER CONE SYN CHRONIZER OUTER RING 5TH SPEED SYN CHRONIZER HUB TAPER ROLLER BEARING SYNCHRONIZER KEY STOPPER PLATE 5TH SPEED SYNCHRONIZER SLEEVE REMOVAL Using the special tools MD998917 and MB990842 indicated below remove the 5th speed gear 5th speed synchronizer sleeve 5th speed synchronizer hub synchronizer inner ring synchronizer outer ring synchronizer cone synchronizer key stopper plate and taper roller bearing A AK703165AC TSB Revision 22 24 MANUAL TRANSAXLE OVERHAUL AK703166AC MD998812 TX MD998813 L MD998819 kh AK703168AC INPUT SHAFT lt lt B gt gt 3RD SPEED GEAR 5TH SPEED GEAR SLEEVE 4TH SPEED GEAR NEEDLE ROLLER BEARING 4TH SPE
33. nts 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 surfaces 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 installa tion Avoid operating the transaxle 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 Item M1222000400660 Specified sealant Transaxle oil Control shaft oil seal lip gear oil Oil seal transaxle case Mitsubishi Genuine DiaQueen NEW MULTI GEAR OIL API classification GL 3 SAE 75W 80 Select lever shoe Mitsubishi Part No 0101011 or equivalent Input shaft oil seal lip gear oil Retinax A TSB Revision 2
34. on of taper roller bearing e Installation of output shaft 5th speed gear MD998821 Installer adapter 44 MD998821 Installation of output shaft 4th speed gear MD998822 Installer adapter 46 MD998824 Installer adapter 50 General service tool TSB Revision Installation of input shaft 3rd 4th speed synchronizer sleeve and 3rd 4th speed synchronizer hub Installation of input shaft 5th speed synchronizer sleeve 5th speed synchronizer hub Installation of input shaft 4th speed gear sleeve Installation of input shaft 5th speed gear sleeve Installation of input shaft taper roller bearing Installation of output shaft 3rd speed gear Installation of output shaft 1st gear sleeve Installation of output 1st 2nd speed synchronizer hub Installation of output 2nd speed gear sleeve MANUAL TRANSAXLE OVERHAUL Tool number and name SPECIAL TOOLS Supersession Application MD998830 Installer adapter 66 Removal of center differential taper roller bearing MD999566 Claw General service tool Removal of control housing oil seal MB990947 MB990947 Lower arm push arbor MB990947 01 or general service tool Removal of control housing slide ball bearing MB990984 Mount bushing remover and installer arbor Installation of control housing slide ball bearing MB991246 Lower arm bushing arbor Installation of control housing oil seal
35. ousing Steel ball 3M STUD Locking No 4710 or equivalent Center differential drive gear bolt Air breather bracket Three bond 1501 or equivalent TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 5 LUBRICANTS FORM IN PLACE GASKET FIPG This transaxle has several areas where the form in place gasket FIPG is used for sealing To ensure that the FIPG fully serves its purpose it is necessary to observe some precautions when apply ing it Bead size continuity and location are of para mount 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 with out 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 A CAUTION When re applying liquid gasket FIPG be sure that 1 Residues of FIPG are cleared from all the ins and outs of parts 2 Surfaces to be coated with FIPG are wiped clean carefully with a quick drying degreaser like isopropyl alcohol 3 FIPG is correctly applied in accordance with FIPG Application 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 joi
36. ring outer races and take out crushed pieces of solder NOTE If the pieces of solder have not crushed use thicker solders and repeat steps 2 to 3 AK703329AC Measure the thickness of crushed solder with a micrometer select the spacers that provide the standard preload values and install them e Input shaft Input shaft preload Spacer thickness 0 10 mm 0 0039 inch T 0 17 mm 0 0067 inch T Thickness of crushed solder mm inch Standard value 0 10 0 17 mm 0 0039 0 0067 inch e Output shaft Output shaft preload Spacer thickness 0 15 mm 0 0059 inch T 0 21 mm 0 0083 inch T Thickness of crushed solder mm inch Standard value 0 15 0 21 mm 0 0059 0 0083 inch e Center differential Center differential preload Spacer thickness T 0 06 0 0024 inch T 0 12 mm 0 0047 inch T Thickness of crushed solder mm inch Standard value 0 06 0 12 mm 0 0024 0 0047 inch TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 21 TRANSAXLE lt Measurement using plastigage gt 1 Install the input shaft output shaft and center differential as a set to the clutch housing 2 Install the thinnest spacers in position for measurement 3 Put a piece of Plastigage about 10 mm 0 39 in long on the transaxle case at the positions shown in the illustration 4 Install the bearing outer races 5 Install the clutch housing to the transaxle case and tigh
37. saxle type 5 speed Transaxle gear ratio 1st 2 857 2nd 1 950 3rd 1 444 Ath 1 096 Sth 0 761 Reverse 2 892 Final reduction ratio 4 687 SERVICE SPECIFICATIONS Item Standard value M1222000300685 Transaxle Distance between the control shaft in neural and shift cable bracket mm in 139 141 5 48 5 55 Distance between the select lever 3rd 4th speed position and shift cable bracket mm in 139 2 140 8 5 481 5 543 Input shaft preload mm in 0 10 0 17 0 0039 0 0067 Output shaft preload mm in 0 15 0 21 0 0059 0 0083 Center differential preload mm in 0 06 0 12 0 0024 0 0047 Input shaft Input shaft taper roller bearing end play mm in Synchronizer inner ring rear end to outer ring rear end clearance mm in 0 01 0 09 0 0004 0 0035 0 5 0 02 Output shaft Output shaft 3rd speed gear end play mm in 0 01 0 09 0 0004 0 0035 Output shaft taper roller bearing end play mm in 0 01 0 09 0 0004 0 0035 Synchronizer inner ring rear end to outer ring rear end clearance mm in 0 5 0 02 Reverse idler gear Reverse idler gear thrust washer end play mm in 00 11 0 0 0043 Synchronizer ring back surface to gear clearance mm in TSB Revision 0 5 0 02 22B 4 MANUAL TRANSAXLE OVERHAUL FASTENER TIGHTENING SPECIFICATIONS FASTE
38. sembly 41 Spring pin gt gt A lt lt gt gt A lt lt gt gt A lt lt gt gt A lt lt gt gt A lt lt gt gt A lt lt Apply gear oil to d all moving parts before installation 45 AK703164AC Removal steps Continued 42 Center differential assembly 43 Outer race for center differential 44 Outer race for output shaft 45 Outer race for input shaft 46 Clutch housing Installation steps 46 Clutch housing 45 Outer race for input shaft 44 Outer race for output shaft 43 Outer race for center differential 42 Center differential assembly 38 Output shaft assembly 37 Input shaft assembly 36 5th speed shift rail assembly 35 5th speed shift fork 34 Shift lug 33 Snap ring 32 3rd 4th speed shift fork 39 1st 2nd speed shift fork 40 1st 2nd speed shift rail assembly TSB Revision gt gt B lt lt gt gt C lt lt gt gt D lt lt gt gt E lt lt gt gt F lt lt MANUAL TRANSAXLE OVERHAUL TRANSAXLE 22 1 5 Installation steps Continued 41 Spring pin 31 Reverse idler gear assembly 30 3rd 4th speed shift rail 29 Spring pin 28 Steel ball 27 Steel ball 26 speed shift rail 25 Reverse shift fork 24 Reverse shift rail 23 Reverse shift lever DISASSEMBLY SERVICE POINTS A STEEL BALL REMOVAL Remove the steel balls at the illustrated positions from the shift lug and 5th speed shift fork
39. t gt gt gt H lt lt 7 4th speed gear lt lt E gt gt 19 Synchronizer outer ring gt gt G lt lt 8 Snap ring lt lt E gt gt 20 Synchronizer cone lt lt D gt gt gt gt F lt lt 9 3rd speed gear lt lt gt gt 21 Synchronizer inner ring 10 2nd speed gear lt lt E gt gt gt gt B lt lt 22 Thrust bearing 11 Needle roller bearing lt lt E gt gt 23 1st speed gear 12 Synchronizer outer ring lt lt E gt gt 24 Needle roller bearing 13 Synchronizer cone lt lt E gt gt gt gt B lt lt 25 Thrust bearing 14 Synchronizer inner ring lt lt E gt gt gt gt lt lt 26 1st speed gear sleeve 27 Output shaft TSB Revision 22 30 5 Required Special Tools MANUAL TRANSAXLE OVERHAUL MB990560 Rear axle shaft bearing remover e MB990842 Drag link bushing remover and installer B e MD998917 Bearing remover e MD998812 Installer cap e MD998814 Installer 200 MD998824 Installer adapter 50 MD998822 Installer adapter 46 MD998813 Installer 100 MD998821 Installer adapter 44 MD998819 Installer adapter 40 MD999601 Valve stem seal installer DISASSEMBLY SERVICE POINTS lt lt A gt gt TAPER ROLLER BEARING REMOVAL 1 Using a chisel or the like knock off the roller cage of the MB990560 taper roller bearing 2 Using the special tools MB990842 and MB990560 indicated below remove the taper roller bearing lt lt B gt gt TAPER ROLLER BEA
40. ten the bolts to the specified torque 6 Remove the clutch housing then remove the bearing outer races and take out crushed pieces of Plastigage 7 If the pieces of Plastigage have not crushed and clearance measurement is impossible replace them with thicker ones and repeat steps 3 to 5 8 Using the scale printed on the Plastigage package measure the width of crushed pieces of Plastigage at their widest part select the spacers that provide the standard preload values and install them e Input shaft Input shaft preload Spacer thickness T1 2 0 10 mm 0 0039 inch T1 T2 0 17 mm 0 0067 inch T1 Thickness of crushed Plastigage mm inch T2 Thickness of spacer used for measurement mm inch Standard value 0 10 0 17 mm 0 0039 0 0067 inch e Output shaft Output shaft preload Spacer thickness T1 T2 0 15 mm 0 0059 inch T1 T2 0 21 mm 0 0083 inch T1 Thickness of crushed Plastigage mm inch T2 Thickness of spacer used for measurement mm inch Standard value 0 15 0 21 mm 0 0059 0 0083 inch e Center differential Center differential preload Spacer thickness T1 T2 0 06 mm 0 0024 inch T1 T2 0 12 mm 0 0047 inch T1 Thickness of crushed Plastigage mm inch T2 Thickness of spacer used for measurement mm inch Standard value 0 06 0 12 mm 0 0024 0 0047 inch AK703329AD Plastigage TSB Revision 22
Download Pdf Manuals
Related Search