22A-4 - Road Race Engineering
Contents
1. AC210558AD 2 Securely fit the tips of the gearshift cable and the select cable 3 Move the shift lever and gearshift lever to all positions and check that the operation is smooth 5 Select cable TSB Revision 22A 12 MANUAL TRANSAXLE TRANSAXLE ASSEMBLY gt gt B lt lt GEARSHIFT CABLE CONNECTION GEARSHIFT LEVER SIDE A CAUTION 4 Gearshift lever assembly Gearshift cable AC607793AB TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION A CAUTION The part indicated by the mark should be temporarily tightened and then fully tightened with the engine and transaxle assembly weight applied on the vehicle body The parts indicated by the are the bolts with friction coefficient stabilizer In removal ensure there is no damage clean dust and soiling from bearing and thread surfaces and tighten them to the specified torque Pre removal and Post installation Operation Engine Cover Removal and Installation Refer to GROUP 11C Engine Assembly P 11C 81 Air Cleaner Assembly Air Intake Hose Removal and Installation Refer to GROUP 15 Air Cleaner P 15 10 Battery and Battery Tray Removal and Installation Water Line Pipe Removal and Installation Refer to GROUP 14 P 14 46 Headlight Support Panel Cover Removal and Installation Refer to GROUP 51 Front Bumper Assembly and Radia tor Grille P 51 5 Starter Motor Assembl2. D Input shaft AC707775AC Transaxle Engine side mounting insulator Transaxle mounting insulator stopper AC505484 AB MANUAL TRANSAXLE TRANSAXLE ASSEMBLY INSTALLATION SERVICE POINTS gt gt A lt lt TRANSAXLE ASSEMBLY INSTALLATION When installing the transaxle assembly apply the specified grease to the spline of clutch disc and input shaft Specified grease Mitsubishi Part No 0101011 or equiv alent gt gt B lt lt TRANSAXLE MOUNTING INSULATOR STOPPER INSTALLATION Install the transaxle mounting insulator stopper as shown in the figure TSB Revision
3. Refer to P 22B 11 Then go to Step 6 STEP 2 Remove and disassemble the transaxle Check the lock ball assembly for breakage Q Is the poppet spring or lock ball assembly broken YES Replace the lock ball assembly Refer to GROUP 22B transaxle P 22B 11 Then go to Step 6 NO Goto Step 3 STEP 3 Check the selecting bell crank assembly and control bell crank dust cover and the gearshift and select lever shaft Q Is the control housing in good condition YES Go to Step 4 NO Repair or replace the selecting bell crank assembly and control bell crank dust cover and the gearshift and select lever shaft Refer to GROUP 22B transaxle 22 11 Then go to Step 6 STEP 4 Check the gearshift forks for wear Q Is the gearshift forks worn YES Replace the gearshift fork Refer to GROUP 22B transaxle P 22B 11 Then go to Step 6 NO Goto Step 5 STEP 5 Check the clearance Q Is the clearance between the synchronizer hub and sleeve excessive YES Replace the synchronizer hub or sleeve Refer to GROUP 22B Output Shaft P 22B 29 Then go to Step 6 NO Goto Step 6 STEP 6 Retest the system Q Does the transaxle still jump out of gear YES Return to Step 1 NO The procedure is complete TSB Revision MANUAL TRANSAXLE 22A 8 ON VEHICLE SERVICE ON VEHICLE SERVICE TRANSMISSION OIL LEVEL CHECK 1 Remove the oil filler plug and gasket 2 Check that the oil level is up to the low
4. disconnect the joint lt lt C gt gt ENGINE ASSEMBLY SUPPORTING 1 Remove the vacuum pipe assembly Refer to GROUP 14 Water Hose and Water Pipe P 14 46 and install the engine hanger plate special tool MB992201 to the position as shown in the figure 2 When engine hanger Special tool MB991928 is used 1 Assemble the engine hanger Special tool MB991928 Set the components below to the base hanger Slide bracket HI Foot x 4 standard MB991932 Joint x 2 90 MB991930 TSB Revision MANUAL TRANSAXLE TRANSAXLE ASSEMBLY 22A 1 5 2 Set the feet of the special tool as shown in the figure NOTE Adjust the engine hanger balance by sliding the slide bracket HI AC611565AB 3 Remove the garage jack and then remove the transaxle assembly upper part coupling bolts that have been loosened previously 3 lt When using engine mechanical hanger Special tool MB991895 gt 1 Set the foot of the engine mechanical hanger Special tool MB991895 as shown in the figure NOTE Slide the front foot of the engine mechanical hanger Special tool MB991895 to balance the engine hanger 2 Remove the garage jack and then remove the transaxle assembly upper part coupling bolts that have been loosened previously ale 991895 TSB Revision 22A 16 Clutch disc
5. 22A 1 GENERAL INFORMATION LUBRICANT s ku rS SPECIAL TOOLS MANUAL TRANSAXLE DIAGNOSIS TROUBLESHOOTING STRATEGY SYMPTOM SYMPTOM PROCEDURES GROUP 22A MANUAL TRANSAXLE CONTENTS 22A 2 ON VEHICLE SERVICE 22A 8 TRANSMISSION OIL LEVEL CHECK 22A 8 22A 2 TRANSMISSION OIL REPLACEMENT 224 8 22 3 TRANSAXLE CONTROL 22A 9 REMOVAL AND INSTALLATION 22A 9 22A 4 22A 4 TRANSAXLE ASSEMBLY 22A 12 22A 4 REMOVAL AND INSTALLATION 22A 12 22 4 22 4 E MANUAL TRANSAXLE GENERALINFORMATON SSS o o GENERAL INFORMATION These manual transaxles come in the models namely F5MBB M1221000101197 Item Specification Transaxle model F5MBB Transaxle type 5 speed forward 1 speed reverse constant mesh Transaxle gear ratio 3 538 1 913 1 333 4th 5th Reverse Final gear ratio Differential gear ratio LUBRICANT Specified lubricant Quantity GL 3 SAE 75W 80 Transaxle The spline area of No 0101011 or equivalent Adequate assembly input shaft and clutch disc TSB Revision MANUAL TRANSAXLE 22A 3 SPECIAL TOOLS SPECIAL TOOLS Tool number and Supersession Application name M1221000601244 MB992277 Clip remover Disconnect the joint between the gearshift cable and select cable assembly B
6. 992277 MB991895 Tool not available When the engine hanger is used Engine hanger Supporting the engine assembly during removal and installation of the transaxle assembly MB991928 Tool not available Engine hanger a MB991929 Joint 50 x 2 b MB991930 Joint 90 x 2 c MB991931 Joint 140 x 2 d MB991932 Foot standard x4 e MB991933 Foot short x 2 f MB991934 Chain and hook assembly MB992201 Engine hanger plate B991928 B992201 TSB Revision E MANUAL TRANSAXLE 22 4 MANUAL TRANSAXLE DIAGNOSIS MANUAL TRANSAXLE DIAGNOSIS INTRODUCTION M1221006900778 The manual transaxle can exhibit any of the following causes of these symptoms could come from symptoms noise or vibration is generated oil leaks incorrect mounting the oil level may be low or a shifting gears is hard or troublesome or the tran component of the transaxle may be faulty saxle jumps out of gear TROUBLESHOOTING STRATEGY M1221007000712 Use these steps to plan your diagnostic strategy If 2 Verify that the condition described by the you follow them carefully you will be sure that you customer exists have exhausted most of the possible ways to find a 3 Find the malfunction by following the Symptom manual transaxle fault Chart 1 Gather information from the customer 4 Verify malfunction is eliminated SYMPTOM CHART M1221007100720 Symptom Inspection Reference page procedure Noise Vibr
7. ERVICE POINTS lt lt A gt gt GEARSHIFT CABLE DISCONNECTION GEARSHIFT LEVER SIDE N CAUTION When removing the gearshift cable be careful not to deform it because the clip is opened forcibly lt lt B gt gt SELECT CABLE DISCONNECTION TRANSAXLE SIDE GEARSHIFT CABLE DISCONNECTION TRANSAXLE SIDE GEARSHIFT LINK CLIP REMOVAL A CAUTION Be careful not to pull out the cable directly to disconnect the joint because the cable could be broken 1 Use the clip remover special tool MB992277 and disconnect the joint 2 Push up the claws of the gearshift link clip using a screwdriver etc and then remove the gearshift link clip from the bracket together with the cables TSB Revision MANUAL TRANSAXLE 22 11 TRANSAXLE CONTROL INSTALLATION SERVICE POINTS gt gt A lt lt GEARSHIFT CABLE AND SELECT CABLE ASSEMBLY GEARSHIFT CABLE CONNECTION TRANSAXLE SIDE SELECT CABLE CONNEC TION TRANSAXLE SIDE GEARSHIFT LINK CLIP INSTALLATION A CAUTION Insert thoroughly the gearshift link clip gearshift cable and select cable until they click in place N New gearshift 1 After installing the new gearshift link clip to the cable bracket 4 nk clip of the transaxle install the gearshift cable and select cable to the cable bracket 4 NOTE The clip is reversible bracket A CAUTION Check that the clip is securely installed Gearshift cable Select cable i
8. STEP 3 Check the oil seal or O ring for damage Q Is the oil seal or O ring damaged YES Replace the oil seal or the O ring Then go to Step 4 NO to Step 4 STEP 4 Retest the system Q Is the oil still leaking YES Return to Step 1 NO The procedure is complete STEP 4 Remove and disassemble the transaxle Check the control bell crank dust cover and the shift and select lever shaft Q Is the control housing in good condition YES Go to Step 5 NO Repair or replace the control housing Refer to GROUP 22B transaxle P 22B 11 Then go to Step 7 STEP 5 Check for poor meshing or worn synchronizer ring and gear cone Q Is poor meshing or worn synchronizer ring and gear cone found YES Repair or replace the synchronizer ring and gear cone Then go to Step 7 NO Goto Step 6 STEP 6 Check the synchronizer spring for weakness Q Is the synchronizer spring weak YES Replace the synchronizer spring Then go to Step 7 NO Goto Step 7 TSB Revision MANUAL TRANSAXLE 22A 7 MANUAL TRANSAXLE DIAGNOSIS STEP 7 Retest the system Q Is the shifting of the gears still hard YES Return to Step 1 NO The procedure is complete Inspection Procedure 4 Jumps Out of Gear DIAGNOSIS PROCEDURE STEP 1 Check the transaxle control Q Are the gearshift cable and the select cable in good condition YES Go to Step 2 NO Repair or replace the gearshift cable and the select cable
9. Step 7 NO Go to Step 7 STEP 7 Retest the systems Q Is the noise or vibration still there YES Return to Step 1 NO The procedure is complete TSB Revision 22A 6 MANUAL TRANSAXLE MANUAL TRANSAXLE DIAGNOSIS Inspection Procedure 2 Oil Leaks DIAGNOSIS PROCEDURE STEP 1 Visual check Raise the vehicle and check for oil leaks If oil leak is difficult to locate steam clean the transaxle and drive the vehicle for at 10 minutes Then check the leak again Q Is the oil leak s found YES Go to Step 2 NO Check for the oil leaks around the engine Then go to Step 4 Inspection Procedure 3 Hard Shifting DIAGNOSIS PROCEDURE STEP 1 Check the transaxle control Q Are the shift cable and the select cable in good condition YES Go to Step 2 NO Repair or replace the shift cable and the select cable Refer to P 22A 9 Then go to Step 7 STEP 2 Check the transmission oil Q Is the oil dirty YES Replace the oil Refer to P 22A 8 Then go to Step 7 NO Goto Step 3 STEP 3 Check the clutch system Q Is the clutch system normal YES Go to Step 4 NO Repair or replace the clutch system Refer to P 21B 3 Then go to Step 7 STEP 2 Visual check at the clutch housing Q Do oil leaks appear around the joint between the engine and the clutch housing YES Remove the transaxle Check the input shaft oil seal and replace if necessary Then go to Step 4 NO Goto Step 3
10. ation 1 P 22A 4 Oil Leaks Hard Shifting Jumps Out of Gear SYMPTOM PROCEDURES Inspection Procedure 1 Noise Vibration DIAGNOSIS STEP 1 Check the idle speed Q Does the idle speed meet the standard values YES Go to Step 2 NO Refer to GROUP 11C On vehicle Service Idle Speed Check P 11C 13 STEP 2 Check whether the transaxle and engine mount are loose or damaged Q Is the check result normal YES Tighten or replace the part Then go to Step 7 NO Goto Step 3 TSB Revision MANUAL TRANSAXLE 22A 5 MANUAL TRANSAXLE DIAGNOSIS STEP 3 Check that the oil level is up to the lower edge of the filler plug hole Q Is the check result normal YES Go to Step 4 Filler plug hole NO Refill DiaQueen NEW MULTI GEAR OIL API classification GL 3 SAE 75W 80 Then go to Step 7 Transmission oil Filler plug 102278 STEP 4 Check for the specified oil Q Is the check result normal YES Go to Step 5 doubt replace the oil Refer to P 22A 8 Then go to Step 7 STEP 5 Remove the transaxle Check the end play of the input and output shafts Q Does the end play of the input and output shafts meet the standard value YES Go to Step 6 NO Adjust the end play of the input and output shafts Then go to Step 7 STEP 6 Disassemble the transaxle Check the gears for wear and damage Q Are the gears worn or damaged YES Replace the gears Go to
11. ble assembly removal steps Gearshift lever knob Sleeve SRS ECU Removal and Installation Refer to GROUP 52B SRS ECU 52 411 Select cable connection Gearshift lever side Gearshift cable connection Gearshift lever side Air Cleaner Assembly Removal and Installation Refer to GROUP 15 Air Cleaner P 15 10 Battery and Battery Tray Removal and Installation Refer to GROUP 54A Battery 54 10 Gearshift cable connection Transaxle side Select cable connection Transaxle side lt lt B gt gt gt gt lt lt gt gt A lt lt gt gt B lt lt Required Special Tools 992277 Clip remover 62 0 27 0 in Ib TSB Revision AC609225AB Gearshift cable and select cable assembly removal steps Gearshift link clip Gearshift cable and select cable assembly Gearshift lever assembly removal steps Gearshift lever knob Sleeve Floor Console Bracket A Removal and Installation Refer to GROUP 52A P 52A 9 Select cable connection Gearshift lever side Gearshift cable connection Gearshift lever side Harness clamp connector connection Gearshift lever assembly 22A 10 Gearshift lever assembly 97 Clip Gearshift cable AC800736AD Gearshift or select cable it MB992277 AC800730AD Gearshift cable Claws Select cable Gearshift link clip AC210556 AB MANUAL TRANSAXLE TRANSAXLE CONTROL REMOVAL S
12. er edge of the filler plug hole 3 Check that the oil is not noticeably dirty 4 Tighten the filler plug and new gasket to the specified torque Tightening torque 49 19 N m 37 14 ft lb M1221000900963 Filler plug hole Gasket lm pou E Oil filler plug Transfer oil AC700330 AF TRANSMISSION OIL REPLACEMENT 1 Remove the filler plug and gasket 2 Remove the drain plug and drain the oil 3 Tighten the drain plug to the specified torque Tightening torque 49 19 N m 37 14 ft lb 4 Fill with DiaQueen NEW MULTI GEAR OIL API classification GL 3 SAE 75W 80 until the level comes to the lower portion of filler plug hole Quantity 2 5 dm 2 6 quarts 5 Tighten the filler plug and new gasket to the specified torque Tightening torque 49 19 m 37 14 ft lb 1221001000985 Filler plug hole Gasket ut P y Oil filler plug Transfer oil AC700330 AF TSB Revision MANUAL TRANSAXLE TRANSAXLE CONTROL TRANSAXLE CONTROL REMOVAL AND INSTALLATION WARNING 22A 9 M1221003801333 Be careful not to subject the SRS ECU to any shocks during removal and installation of the gearshift cable and select cable assembly lt lt gt gt gt gt lt lt A lt lt B gt gt gt gt lt lt 5 lt lt gt gt gt gt lt lt 6 7 0 3 0 N m Gearshift cable and select ca
13. racket lt lt B gt gt 5 Cable bracket and transaxle gt gt B lt lt 11 Transaxle mounting insulator control cable assembly stopper lt Transaxle side gt 12 Transaxle mounting insulator 6 Transaxle assembly upper part lt lt C gt gt e Engine assembly supporting coupling bolts 13 Transaxle assembly lower part 7 Center member assembly coupling bolts 8 Rear roll stopper gt gt A lt lt 14 Transaxle assembly Required Special Tools MB991895 Engine Hanger MB991932 Foot standard MB991928 Engine Hanger MB992201 Engine hanger plate MB991930 Joint 90 MB992277 Clip remover TSB Revision 22A 14 Clutch tube assembly yr Clip Concentric slave cylinder adapter AC701311AE Gearshift or select cable imm MB992277 AC800730AD MANUAL TRANSAXLE TRANSAXLE ASSEMBLY REMOVAL SERVICE POINTS lt lt A gt gt CLUTCH TUBE REMOVAL ZA CAUTION Do not remove the O rings and the clips from the clutch tube and the concentric slave cylinder adapter If the O rings or the clips of the clutch tube and the con centric slave cylinder adapter are damaged replace each assembly lt lt B gt gt CABLE BRACKET AND TRANSAXLE CONTROL CABLE ASSEMBLY REMOVAL lt TRANSAXLE SIDE gt A CAUTION Be careful not to pull out the cable directly to disconnect the joint because the cable could be broken Use the clip remover special tool MB992277 and
14. y Removal and Installation Refer to GROUP 16 Stator Motor Assembly P 16 36 Clutch Fluid Draining and Bleeding Engine Room Under Front A B and Engine Room Side Cover Removal and Installation Refer to GROUP 51 Under Cover P 51 5 Transmission Oil Draining and Refilling Refer to 22 8 Drive Shaft Removal and Installation Refer to GROUP 26 P 26 21 After the installation slightly pull the joint to down direc tion to check that it is connected securely Insert the tip of the gearshift cable to the gearshift lever assem bly thoroughly as shown until it clicks in place n TSB Revision MANUAL TRANSAXLE 22A 13 TRANSAXLE ASSEMBLY 3 17 0 6 8 N m 50 5N m 47 27Nm X 50 5 N m P uiis 37 4 ft lb 35 5 ft lb 37 4 ft lb 10 Ih 1 EN 48 6 N m E e 36 4 ft lb P 11 12 11 J 50 5 N m 2 3724 ftlb 2 53 8 N ni 1 39 6 ft Ib 53 8 N m 9 Q Ib t gt 90 10N m x iS 67 x 7 ft lb 48 6 0 36 4 ft lb 1 24 5 50 5 N m 0 37 4 ft Ib ALLE AC610012AB Removal steps Removal steps Continued 1 Speed sensor connector 9 Transaxle case rear roll stopper connection bracket 2 Back up light switch connector e While supporting the engine and connection transaxle assembly with a garage lt lt A gt gt 3 Clutch tube connection jack 4 Harness bracket 10 Transaxle mounting b
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