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MANUAL TRANSAXLE

1. MANUAL TRANSAXLE OVERHAUL 22B 17 INPUT SHAFT gt gt 8 lt lt BALL BEARING INSTALLATION 1 Using special tool MD998801 support the 2nd speed gear portion of the input shaft and then set them on the press MD998813 2 Using special tools MD998812 MD998813 and MD998818 press install the bearing with the press MD998812 MD998801 MD998818 AK201636AC gt gt C lt lt 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 gt gt D lt lt SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring to the illustrated position of the synchronizer ring and outer synchronizer ring SYNCHRONIZER SPRING AK201638AC SYNCHRONIZER SPRING AKX00951AB TSB Revision 22B 18 MANUAL TRANSAXLE OVERHAUL gt gt INPUT SHAFT E lt lt 3RD 4TH SPEED SYNCHRONIZER HUB INSTALLATION INSTALLATION 1 DIRECTION 2 GROOVE AKX00913AB 5 MD998812 MD998801 MD998813 MD998825 AK201639AC Using special tool MD998801 support the 2nd speed gear portion of the input shaft and then set them on the press Make sure that the inner synchronizer ring has been perfectly matched to the 3rd speed gear cone Check the inst
2. 1 As shown in the figure pull out the transfer shaft lt LH gt from the transaxle using the pry bar As shown in the illustration press a hammer etc against the driveshaft lt RH gt and pull out the driveshaft from the transfer assembly using the pry shaft 2 Cover with cloth to prevent foreign particles from entering the transfer TRANSAXLE SIDE AC207770 AB lt lt D gt gt OUTPUT SHAFT REMOVAL 1 Using the special tool MB991721 remove the output shaft 2 Cover with a cloth to prevent foreign particles from entering the transaxle case AC207771AB TSB Revision 22A 20 ENGINE 22 ja rise TRANSAXLE amp Fen VAT de S ll c SR TRANSFER A WASHER d 226 29 N m 167 x 21 ft Ib AC001151AE MANUAL TRANSAXLE TRANSFER ASSEMBLY lt lt E gt gt TRANSFER ASSEMBLY REMOVAL With the engine mount and transaxle assembly towards the front of the vehicle and remove the transfer assembly from between the engine block and crossmember INSTALLATION SERVICE POINTS gt gt A lt lt OUTPUT SHAFT INSTALLATION N CAUTION When installing the output shaft the drive shaft or the drive shaft and inner shaft assembly be careful that the spline part of the output shaft the drive shaft or the drive shaft and inner shaft assembly do not damage the oil seal gt gt B lt lt DRIVE SHAFT NUT INSTALLAT
3. 22B 35 SERVICE SPECIFICATIONS 228 52 DISASSEMBLY AND ASSEMBLY 22B 35 SEALANTS AND ADHESIVES 22B 52 LUBRICANTS 24 64 0060 0 e 22 52 SELECT LEVER 22B 36 SNAP RINGS SPACERS AND THRUST DISASSEMBLY AND ASSEMBLY _ _ 228 36 PLATE FOR ADJUSTMENT EE 22B 53 228 2 MANUAL TRANSAXLE OVERHAUL GENERAL INFORMATION GENERAL INFORMATION M1222000100078 SECTIONAL VIEW AK203135 TSB Revision MANUAL TRANSAXLE OVERHAUL SPECIAL TOOLS SPECIAL TOOLS 22B 3 M1222000600095 TOOL TOOL NUMBER AND NAME MB990935 Installer adapter W MB990938 Handle B990938 lt Q MD998801 Bearing remover MD998812 Installer cap MD998813 Installer 100 MD998818 Installer adapter 38 MD998825 Installer adapter 52 MD998917 Bearing remover SUPERSESSION APPLICATION MB990935 01 or General service tool Installation of output shaft taper roller bearing outer race and center differential rear taper roller bearing outer race MB990938 01 Use with Installer adapter MD998348 01 or General service tool Installation and removal of gears bearings and sleeves Use with Installer and Installer adapter General service tool General service tool JUse with Installer cap and Installer adapter MD998818 Installation of input shaft bearing
4. 32 2 N m 23 1 ft lb 48 5 35 3 ft lb 70 10 N m 51 7 ft lb TRANSFER ITEMS Transfer clutch housing mounting bolt Transfer cover mounting bolt SPECIFICATIONS 69 9 50 6 ft lb 23 3 N m 17 2 ft lb GENERAL SPECIFICATIONS M1222000200105 ITEMS SPECIFICATIONS Model W5M51 2 X5BB Applicable engine 4G63 Type 5 speed transaxle floor shift Gear ratio 2 928 2nd 1 950 Reverse 3 416 Final reduction ratio 4 529 Speedometer gear ratio 28 36 driven drive Transfer gear ratio 0 3018 TSB Revision 228 52 SERVICE SPECIFICATION MANUAL TRANSAXLE OVERHAUL S SPECIFICATIONS M1222000300083 ITEMS Input shaft end play mm in Input shaft 5th speed gear end p Output shaft preload mm in Output shaft 3rd speed gear end mm in Input shaft front bearing end play mm in Input shaft rear bearing end play mm in lay mm in Output shaft taper roller bearing end play mm in 0 0 09 0 0 0035 plav mm Center differential pinion backlash mm in Center differential case preload mm in Svnchronizer ring back surface to gear clearance gt 0 5 0 020 STANDARD VALUE MINIMUM LIMIT p o 60020 60067 O 6126 oom F oroo EE 0 13 0 18 0 0051 0 0071 0 025 0 150 0 0010 0 0059 0 05 0 11 0 0020 0 0043 _ SEALANTS AND ADHESIVES M122
5. Return to Step 1 NO The procedure is complete TSB Revision MANUAL TRANSAXLE 22A 7 MANUAL TRANSAXLE DIAGNOSIS INSPECTION PROCEDURE 4 Jumps Out of Gear DIAGNOSIS 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 6 STEP 2 Remove and disassemble the transaxle Check the poppet spring for breakage Q Is the poppet spring broken YES Replace the poppet spring Refer to GROUP 228 Transaxle P 22A 9 Then go to Step 6 NO Goto Step 3 STEP 3 Check the control housing Q Is the control housing in good condition YES Go to Step 4 NO Repair or replace the control housing Refer to GROUP 228 Transaxle P 22A 9 Then go to Step 6 STEP 4 Check the gear shift forks for wear Q Is the gear shift forks worn YES Replace the gear shift fork Refer to GROUP 22B Transaxle P 22A 9 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 228 Input Shaft P 22A 9 Output Shaft P 22A 9 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 22
6. 2 THICKNESS mm in 1 59 0 0626 IDENTIFICATION SYMBOL Yellow 2 Snap ring For adjustment of input shaft rear bearing end play THICKNESS mm in 1 44 0 0567 1 51 0 0594 IDENTIFICATION SYMBOL None Blue THICKNESS mm in 1 58 0 0622 IDENTIFICATION SYMBOL Brown Thrust plate For adjustment of input shaft 5th speed gear end play THICKNESS IDENTIFICATION THICKNESS IDENTIFICATION mm in SYMBOL mm in 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 IDENTIFICATION THICKNESS IDENTIFICATION mm in SYMBOL mm in 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 07 0 0421 07 1 40 0 0551 None 10 0 0433 J 1 43 0 0563 Q i 43 0 0445 D 1 46 0 0575 R 1 16 0 0457 K TSB Revision z MANUAL TRANSAXLE OVERHAUL 22B 54 SPECIFICATIONS Snap ring For adjustment of output shaft rear bearing end play THICKNESS IDENTIFICATION THICKNESS IDENTIFICATION mm in SYMBOL mm in SYMBOL 1 36 0 0535 Yellow 1 55 0 0610 White 1 40 0 0551 Gree
7. BALL BEARING REMOVAL MD998801 1 Using special tool MD998801 support the ball bearing and then set them on the press 2 Push down on the input shaft with the press and extract the ball bearing B THRUST PLATE STOPPER REMOVAL Using a screwdriver pry up the position shown in the illustration and remove the thrust plate stopper TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 16 INPUT SHAFT lt lt C gt gt 5TH SPEED GEAR REMOVAL 1 Using special tool MD998801 support the 5th speed gear and then set them on the press 2 Push down on the input shaft with the press and take off the 5th speed gear MD998801 D 0 TG AAN AK201633AC lt lt D gt gt 4TH SPEED GEAR SLEEVE REMOVAL 1 Using special tool MD998801 support the 3rd speed gear and then set them on the press 2 Push down on the input shaft with the press and remove the 4th speed gear sleeve MD998801 AK201634AC lt lt E gt gt BALL BEARING REMOVAL 1 Using special tool MD998801 support the ball bearing and then set them on the press 2 Push down on the input shaft with the press and extract the ball bearing AK201635AC ASSEMBLY SERVICE POINTS gt gt A lt lt OIL SEAL INSTALLATION Install the oil seal into the illustrated position of the input shaft 3 5 mm 0 138 in OIL SEAL AKX00827AB TSB Revision
8. MB990767 01 Fixing of the hub MB990241 01 or Removal of the drive shaft General service tool General service tool TRANSAXLE OIL ON VEHICLE SERVICE FILLER PLUG HOLE FILLER PLUG AC102278AC TRANSAXLE OIL LEVEL CHECK 1 Remove the filler plug 2 Check that the oil level is up to the lower edge of the filler plug hole 3 Check that the oil is not noticeably dirty 4 Tighten the filler plug to the specified torque Tightening torque 32 2 N m 23 2 ft Ib M1221000900435 TRANSAXLE OIL REPLACEMENT 1 Remove the filler plug 2 Remove the drain plug and drain the oil 3 Tighten the drain plug to the specified torque Tightening torque 32 2 M 23 2 ft Ib 4 Fill with gear oil API classification GL 4 SAE 75W 85W or 75W 90 until the level comes to the lower portion of filler plug hole Quantity 2 8 dm 2 9 quart 5 Tighten the filler plug to the specified torque Tightening torque 32 2 M 23 2 ft Ib M1221001000349 TSB Revision 22A 10 FILLER PLUG FILLER PLUG HOLE AC102278AM TRANSFER OIL 7 DRAIN PLUG T N X AC209273AB Woch NA FILLER PLUG Bn i l MANUAL TRANSAXLE ON VEHICLE SERVICE TRANSFER OIL CHECK 1 Remove the filler plug 2 Check that the oil level is up to the lower edge of the filler plug hole 3 Check that the oil is not noticeably dirty 4 Tighten the filler plug to the spe
9. 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 Insert the pinion shaft Install the lock pin so that it will be oriented in the direction shown Install the front output shaft on the side gear and install the snap ring Mount a spacer on the back surface of the side gear and then install the side gear in the differential case NOTE When new side gear is to be installed use medium thickness spacer 0 93 to 1 00 mm 0 0366 to 0 0395 inch Install the center differential flange by aligning the matching marks and temporarily tighten the four machine screws TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 48 CENTER DIFFERENTIAL 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 86 NOTE Adjust until the backlash on both sides are equal bu gt AK103657 NR gt gt D lt lt DIFFERENTIAL DRIVE GEAR INSTALLATION 1 Apply sealant aM VAAD Part Number 8730 or 8731 or equivalent to the entire threaded portion of the bolt AKX00955 2 Tighten to the specified torque in the illustrated sequence Tightening torque 1
10. 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 transaxle oil Q Is the oil dirty YES Replace the transaxle oil Refer to P 22A 9 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 22A 9 Then go to Step 7 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 Go 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 housing Q Is the control housing in good condition YES Go to Step 5 NO Repairor replace the control housing Refer to GROUP 228 Transaxle P 22A 9 Then go to Step 7 STEP 5 Check for poor meshing of worn svnchronizer ring and gear cone Q Is poor meshing or worn svnchronizer ring and gear cone found VES Repair or replace the svnchronizer 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 Go to Step 7 STEP 7 Retest the system Q Is the shifting of the gears still hard YES
11. lt lt D gt gt 39 5N m 29 3 ft lb 39 5 N m 29 3 ft lb 11 gt gt A lt lt 12 13 158 Revision AC207756AB REMOVAL STEPS Continued LOWER ARM BALL JOINT CONNECTION TIE ROD END CONNECTION DRIVESHAFT LH CONNECTION DRIVESHAFT RH CONNECTION OUTPUT SHAFT CIRCLIP MANUAL TRANSAXLE TRANSFER ASSEMBLV gt KE L 29 MG INK pp 7N m 52 7 N m 39 5 ft Ib 69 9 N m 51 7 ft lb 1 69 9 N m 51 7 ft lb 14 FRONT PROPELLER SHAFT 15 REAR ROLL STOPPER lt lt E gt gt CONNECTION BOLT 16 CENTERMEMBER ASSEMBLY Required Special Tools e MB990767 End Yoke Holder MB991897 Ball Joint Remover e MB990241 Axle Shaft Puller MB991354 Puller Body e MB991721 Slide Hammer 22A 17 69 9 N m 51 7 ft lb Gear oil Hypoid gear oil API classification GL 5 SAE90 51 7 ft lb AC207766AB 17 DUST SEAL GUARD 18 TRANSFER ASSEMBLY 19 O RING TSB Revision 22A 18 D 1 gt MB990767 AC102462 AC CORD BALL JOINT MB991897 AC106820 AB 4 B BOLT e KNOB lt p GOOD PARALLEL BAD Ac106821AB MB990244 THREE MB990242 MB991354 AC102550AC MANUAL TRANSAXLE TRANSFER ASSEMBLY REMOVAL SERVICE POINTS lt lt A gt gt DRIVE SHAFT NUT REMOVAL N CAUTION Do not apply pressure to the wheel bearing
12. 22B 14 INPUT SHAFT BACKUP LIGHT SWITCH Check for continuity between terminals SWITCH CONDITION CONTINUITY Pressed Open Released Conductive AK201630 INPUT SHAFT DISASSEMBLY AND ASSEMBLY M1222001600087 APPLY GEAR OIL TO ALL MOVING PARTS BEFORE INSTALLATION AKX00877AB DISASSEMBLY STEPS DISASSEMBLY STEPS gt gt L lt lt 1 SNAP RING gt gt l lt lt 4 THRUST PLATE lt A gt gt gt gt K lt lt 2 BALL BEARING lt C gt gt gt gt H lt lt 5 5TH SPEED GEAR lt lt gt gt gt gt J lt lt 3 THRUST PLATE STOPPER 6 4TH SPEED GEAR TSB Revision MANUAL TRANSAXLE OVERHAUL INPUT SHAFT 22B 15 DISASSEMBLV STEPS 7 NEEDLE ROLLER BEARING D gt gt G lt lt 8 4TH SPEED GEAR SLEEVE 9 SYNCHRONIZER RING gt gt D lt lt 10 SYNCHRONIZER SPRING gt gt F lt lt 11 SYNCHRONIZER SLEEVE gt gt E lt lt 12 3RD 4TH SPEED SYNCHRONIZER HUB 13 OUTER SYNCHRONIZER RING gt gt D lt lt 14 SYNCHRONIZER SPRING 15 SYNCHRONIZER CONE 16 INNER SYNCHRONIZER RING 17 3RD SPEED GEAR 18 NEEDLE ROLLER BEARING gt gt C lt lt 19 SNAP RING lt lt E gt gt gt gt lt lt 20 BALL BEAR gt gt A lt lt 21 OIL SEAL 22 INPUT SHAFT Required Special Tools e MD998801 Bearing Remover e MD998812 Installer Cap e MD998813 Installer 100 e MD998818 Installer Adapter 38 e MD998825 Installer Adapter 52 DISASSEMBLY SERVICE POINTS A
13. General service tool jInstallation of 1st speed gear sleeve 3rd 4th speed svnchronizer hub 4th speed gear sleeve 5th speed gear and thrust plate stopper Installation and removal of gears bearing and sleeves General service tool TSB Revision 2 MANUAL TRANSAXLE OVERHAUL 22B 4 SPECIAL TOOLS TOOL TOOL NUMBER AND SUPERSESSION APPLICATION NAME MD998819 General service tool Installation of output shaft taper roller bearing MD998814 MIT304180 Use with Installer cap and Installer 200 Installer adapter MD998824 General service tool Installation of 1st 2nd speed Installer adapter 50 svnchronizer hub 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 Ge Claw outer race PF MB991445 MB991445 Installation of differential front Bushing remover and taper roller bearing outer race installer base Installer adapter 40 TSB Revision MANUAL TRANSAXLE OVERHAUL SPECIAL TOOLS 22B 5 TOOL TOOL NUMBER AND SUPERSESSION APPLICATION NAME MB990928 MB990928 01 Installation of input shaft o
14. MB990938 and MB990928 press fit the NS oil seal into the clutch housing MB990928 MB990938 C ie TRANSMISSION CASE DISASSEMBLV AND ASSEMBLV 3 AK203131AC DISASSEMBLY STEPS Continued gt gt lt lt 5 BUSHING 6 TRANSAXLE DISASSEMBLY STEPS gt gt C lt lt 1 OIL SEAL gt gt B lt lt 2 NEEDLE BEARING 3 OIL GUIDE NOTE Refer to the needle bearing and bushing instal 4 OIL GUIDE lation procedures only when replacing the transaxle case TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 44 TRANSMISSION CASE Required Special Tools e MD998800 Differential Oil Seal Installer ASSEMBLY SERVICE POINTS gt gt A lt lt BUSHING INSTALLATION 1 Press fit the bushing so the seam is away from the air vent gt XENI 2 Be sure the bushing is fullv seated as shown It must be 3 mm 0 12 inch below the housing surface 3 mm 0 12 in i AKX00924AB gt gt B lt lt 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 AKX00871AB gt gt C lt lt OIL SEAL INSTALLATION 1 Apply gear oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 AKX00870 TSB Revision MANUAL TRANSAXLE OVERHAUL CEN
15. by the vehicle weight to avoid possible damage when the drive shaft nut is loosened Use special tool MB990767 to fix the hub and remove the drive shaft nut lt lt B gt gt LOWER ARM BALL JOINT TIE ROD END DISCONNECTION N CAUTION e Do not remove the nut from ball joint Loosen it and use special tool MB991897 to avoid possible damage to ball joint threads e Hang special tool MB991897 with cord to prevent it from falling 1 Install the special tool MB991897 as shown in the figure 2 Tum the bolt and knob as necessary to make the jaws of special tool MB991897 parallel tighten the bolt by hand and confirm that the jaws are still parallel NOTE When adjusting the jaws in parallel make sure the knob is in the position shown in the figure 3 Tighten the bolt with a wrench to disconnect the tie rod end lt lt C gt gt DRIVE SHAFT lt LH gt DRIVE SHAFT lt RH gt DISCONNECTION 1 lt Removal of the disc brake side gt 1 Use special tools MB990241 MB990242 and MB990244 MB991354 and MB990767 to push out the drive shaft or the drive shaft and inner shaft assembly from the hub TSB Revision MANUAL TRANSAXLE 22A 19 TRANSFER ASSEMBLV 2 Remove the drive shaft from the hub V pulling the bottom of the brake disc towards vou 2 lt Removal of the transaxle side A CAUTION As the TJ may damage when the driveshaft is pulled out from the BJ side be sure to use the lever
16. gt ENGINE AND TRANSAXLE 4 CLUTCH RELEASE CYLINDER ASSEMBLY SUPPORTING AND CLUTCH OIL PIPE TSB Revision 22A 22 MANUAL TRANSAXLE TRANSAXLE ASSEMBLV UN MU 48 5 BIES Mp 35 5 ft Ib 36 3 ft lb o 48 5 N m 8 48 5 36 3 ft Ib 8 36 3 ft Ib 48 5N m 36 3 ft lb 13 cp 9 0 1 0 N m d 80 9 in Ib 26 5N m 19 4 ft lb AC207692AB REMOVAL STEPS REMOVAL STEPS Continued 8 TRANSAXLE ASSEMBLY UPPER lt lt C gt gt e CLUTCH RELEASE BEARING PART COUPLING BOLTS CONNECTION lt lt A gt gt 9 TRANSAXLE MOUNT 12 BELL HOUSING COVER ASSEMBLY 13 TRANSAXLE ASSEMBLY gt gt A lt lt 10 TRANSAXLE MOUNT STOPPER LOWER PART COUPLING 11 TRANSAXLE MOUNT BRACKET BOLTS lt lt B gt gt ENGINE ASSEMBLV 14 TRANSAXLE ASSEMBLY SUPPORTING Required Special Tools e MB991453 Engine Hanger Assembly e MB991454 Engine Hanger Balancer MZ203827 Engine Lifter e MB991895 Engine Hanger MB991928 Engine Hanger REMOVAL SERVICE POINTS lt lt A gt gt ENGINE AND TRANSAXLE ASSEMBLY SUPPORT ING TRANSAXLE MOUNT ASSEMBLY REMOVAL While supporting the engine and transaxle assembly with a garage jack remove the transaxle mount assembly ENGINE AND U 1 TRANSAXLE ASSEMBLY DERE LENE Ad RR 3 JACK AC207720 AB TSB Revision MANUAL TRANSAXLE 22A 23 TRANSAXLE ASSEMBLV lt lt 8 gt gt ENGINE ASSEMBLV SUPP
17. oil API classification GL 5 SAE90 Transfer oil YES Go to Step 5 NO Ifin doubt replace the oil Refer to P 22A 9 Then go to Step 7 STEP 5 Remove the transaxle and transfer assembly 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 and transfer assembly Check the gears for wear and damage Q Are the gears worn or damaged YES Replace the gears Go to Step 7 NO Goto 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 utes Then check the leak again Q Is the oil leak s found YES Go to Step 2 NO Check for the oil leak s around the engine Then go to Step 4 transfer assembly and drive the vehicle for at 10 min TSB Revision 22A 6 MANUAL TRANSAXLE MANUAL TRANSAXLE DIAGNOSIS 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 and transfer assembly Check the input shaft oil seal and replace if necessary Then go to Step 4 NO Goto Step 3 INSPECTION PROCEDURE 3 Hard Shifting DIAGNOSIS STEP 1 Check the transaxle control Q Are the shift cable and the select cable in good
18. rail and fork and 5th SHIFT FORK reverse speed shift rail and fork 5TH REVERSE SPEED SHIFT SPEED SHIFT FORK 3RD 4TH SPEED SHIFT RAIL l ji omes 77777723 p TG y Sat 2 Fit each shift fork in the groove of synchronizer sleeve and install the shift fork and rail assembiv 3 Insert the 3rd 4th speed shift rail and 5th speed reverse shift rail into the rail hole in the clutch housing 3RD 4TH SPEED SHIFT RAIL 5TH REVERSE SPEED SHIFT lt EKE IN AN Za n SH 46 MAN NL fe AK201626AC gt gt C lt lt SPRING PIN INSTALLATION CSHFTFORK O o 1 Align the pin holes in the shift rail and shift fork SHIFT RAIL J Zamin H EN 2 Insert the new spring pin Push it in so that the slit and center axis of the rail are aligned I C SPRING PIN AKX00920AB TSB Revision 228 12 MANUAL TRANSAXLE OVERHAUL b eae Lae REN AKX00886 AK201627 TRANSAXLE gt gt D lt lt 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 gt gt E lt lt TRANSAXLE CASE INSTALLATION A CAUTION Squeeze out the sealant uniformly while making sure that it is not
19. spring pin from the shift fork and rail TSB Revision MANUAL TRANSAXLE OVERHAUL TRANSAXLE 22B 9 lt lt B gt gt 3RD 4TH SPEED SHIFT RAIL 3RD 4TH SPEED SHIFT FORK 5TH REVERSE SPEED SHIFT RAIL 5TH REVERSE SPEED SHIFT FORK REMOVAL 1 Pull out the shift rails from the shift rail holes in the clutch housing 2 Remover the shift rails together with the shift forks 3RD 4TH SPEED pz SHIFT RAIL eg rN 27777772 7 A LN FI Z Ce 4 B NNN q TF 5TH REVERS SHIFT RAIL lt lt C gt gt CENTER DIFFERENTIAL OUTPUT SHAFT INPUT SHAFT REMOVAL Remove the input and output shafts together CENTER DIFFERENTIAL DM SEE GWEN AN AP AR O I 4 Q Ss K TG AK201620AC ADJUSTMENT BEFORE ASSEMBLY SPACER SELECTION FOR ADJUSTING INPUT SHAFT END PLAV OUTPUT SHAFT PRELOAD CENTER DIFFERENTIAL PRELOAD 1 Install the input shaft output shaft and center differential as a set to the clutch housing NOTE If necessatrv replace the input shaft output shaft center differential case and or bearings before carrving out these adjustments I amp am S E lt 2 Sy 158 Revision 228 10 MANUAL TRANSAXLE OVERHAUL SOLDERS SZ AK201622AC AK201624 TRANSAXLE Put solders 1 6 mm 0 063 inch diameter a
20. support stand 2 Using special tools MD998812 MD998814 MD998824 and MD998364 press install the 1st speed gear sleeve with the press gt gt D lt lt SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring to the illustrated position of the outer synchronizer ring TSB Revision MANUAL TRANSAXLE OVERHAUL _ INSTALLATION DIRECTION AKX00930AC MD998812 MD998814 1ST 2ND SPEED SYNCHRONIZER HUB MD998824 MD998364 AK201655AC GROOVE yd C d INSTALLATION DIRECTION AK201687AC TEETH WITH RAISED TIPS DEEP GROOVES BETWEEN THE TEETH AKX00928AB 22B 27 OUTPUT SHAET gt gt E lt lt 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 3 Using special tools MD998812 MD998814 MD998824 and MD998364 press install the 1st 2nd speed synchronizer hub with the press 4 Make sure that the outer synchronizer ring on the 1st speed gear side can rotate freely gt gt F lt lt SYNCHRONIZER SLEEVE INSTALLATION 1 Check that the synchronizer sleeve is in the correct direction for installation and install it on the 1st 2nd speed synchronizer hub 2 Install the synchronizer sleeve so that the areas with teeth that have raised tips three areas total are aligned with t
21. the press gt gt H lt lt 5TH SPEED GEAR INSTALLATION 1 Using special tool MD998801 support the 2nd speed gear portion of the input shaft and then set them on the press 2 Using special tools MD998812 MD998813 and MD998825 press install the 5th speed gear in the input shaft gt gt 1 lt lt THRUST PLATE INSTALLATION 1 Install the thickest thrust plates that can be fitted in the groove of input shaft Install the thrust plate so the surface stamped with the identification mark is facing up 2 Make sure that the 5th speed gear end play meets the standard value Standard value 0 0 09 mm 0 0 0035 inch gt gt J lt lt THRUST PLATE STOPPER INSTALLATION Install the thrust plate stopper by pressing special tools MD998812 MD998813 and MD998825 by hand Make sure that it is not tilted TSB Revision 228 20 MANUAL TRANSAXLE OVERHAUL INPUT SHAFT gt gt K lt lt BALL BEARING INSTALLATION MD998801 1 Using special tool MD998801 support the 2nd speed gear MD998812 portion of the input shaft and then set them on the press AK201644 AC 2 Using special tools MD998812 and MD998818 press install M0998818 the ball bearing in the input shaft gt gt L lt lt 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 plav meet the standard value Standard valu
22. 1 TRANSFER CASE 3RD 4TH SPEED 12 HYPOID PINION SYNCHRONIZER HUB 13 CENTER DIFFERENTIAL 3RD SPEED GEAR 14 1ST SPEED GEAR TRANSAXLE CASE 15 1ST 2ND SPEED CLUTCH HOUSING SYNCHRONIZER HUB CLUTCH RELEASE BEARING 16 2ND SPEED GEAR RETAINER 17 5TH SPEED GEAR INPUT SHAFT 18 5TH REVERSE SPEED OUTPUT SHAFT SYNCHRONIZER HUB FRONT DIFFERENTIAL 19 REVERSE SPEED GEAR VISCOUS COUPLING UNIT VCU 20 REVERSE IDLER GEAR TSB Revision MANUAL TRANSAXLE 22A 4 MANUAL TRANSAXLE DIAGNOSIS MANUAL TRANSAXLE DIAGNOSIS INTRODUCTION The manual transaxle can exhibit anv of the following svmptoms noise or vibration is generated oil leaks shifting gears is hard or troublesome or the tran saxle jumps out of gear TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy II you follow them carefully you will be sure that you have exhausted most of the possible ways to find a manual transaxle fault 1 Gather information from the customer SYMPTOM CHART M1221006900659 The causes of these symptoms could come from incorrect mounting the oil level may be low or component of the transaxle may be faulty M1221007000563 2 Verify that the condition described by the customer exists 3 Find the malfunction by following the Symptom Chart 4 Verify malfunction is eliminated M1221007100548 SYMPTOMS Noise vibration Oil leaks Hard shifting Jumps out of gear INSPECT
23. 1 or equivalent to the inserting portion of air breather 2 Install the air breather so that the embossed mark is in the direction shown in the figure gt gt D lt lt SPRING PIN INSTALLATION Drive in the spring pin so that the slit is in the direction shown in the figure gt gt E lt lt LOCK PIN INSTALLATION Drive the lock pin in from the direction shown in the figure TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 40 CLUTCH HOUSING CLUTCH HOUSING DISASSEMBLV AND ASSEMBLV M1222003700080 4 AK201683AC DISASSEMBLY STEPS DISASSEMBLY STEPS 1 CLUTCH RELEASE BEARING gt gt A lt lt 6 COVER A RETAINER gt gt A lt lt 7 COVER B gt gt E lt lt 2 OIL SEAL 8 CLUTCH HOUSING lt lt gt gt gt gt D lt lt 3 OUTER RACE NOTE Refer to the needle bearing and bushing instal lt lt B gt gt gt gt C lt lt 4 OUTER RACE lation procedures only when replacing the transaxle case gt gt B lt lt 5 BUSHING Required Special Tools e MB990928 Installer Adapter e MB991445 Bushing Remover and Installer Base e MB990935 Installer Adapter MD999566 Claw e MB990938 Handle TSB Revision MANUAL TRANSAXLE OVERHAUL CLUTCH HOUSING X OUTER RACE I ES Ak201665AC MD999566 AK201666AC COVER B COVER A t AK201668AC 22B 41 DISASSEMBLY SERVICE POINT lt lt A gt gt OUTER RACE REMOVAL Using special tool M
24. 101414 AC gt gt D lt lt OIL SEAL INSTALLATION 1 Apply gear oil Hypoid gear oil API classification GL 5 SAE MB990891 90 MB990887 2 Using special tools MB990887 and MB990891 press fit the oil seal into the transfer gt gt E lt lt OIL SEAL INSTALLATION 1 Apply gear oil Hypoid gear oil API classification GL 5 SAE 90 2 Using special tool MB990936 press fit the oil seal into the transfer MB990936 AK101417 AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 51 SPECIFICATIONS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS M1222012100086 TRANSAXLE ITEMS SPECIFICATIONS Under cover mounting bolt Interlock plate bolt Clutch housing transaxle case mounting bolt Clutch release bearing retainer mounting bolt Control housing mounting bolt Shift cable bracket mounting bolt Speedometer gear mounting bolt Stopper bracket mounting bolt Select lever mounting bolt Select lever mounting nut Differential drive gear mounting bolt Backup light switch Poppet spring Reverse idler gear shaft mounting bolt Roll stopper bracket mounting bolt 6 9 0 9 61 7 in Ib 30 3 Num 22 2 ft lb 44 5 32 3 ft lb 9 8 2 0 Nm 86 17 in Ib 18 3 Nm 13 2 ft lb 18 3 13 2 ft lb 3 9 1 0 N m 34 8 in lb 22 3 0 3 16 1 0 2 ft lb 18 3 13 2 ft lb 12 1 N m 104 9 in Ib 133 4 N m 98 3 ft lb 32 2 N m 23 1 ft lb
25. 2000500087 ITEM Clutch housing transaxle case m ating surface Control housing transaxle case mating surface Under cover transaxle case mating surface SPECIFIED SEALANT MITSUBISHI Genuine sealant part No MD997740 or equivalent Air breather 3M AAD Part No 8001 or equivalent Center differential drive gear bolt 3M AAD Part No 8730 or 8731 or equivalent LUBRICANTS M1222000400057 TRANSAXLE ITEMS SPECIFIED SEALANTS Speedometer gear O ring Control shaft oil seal lip gear oil Input shaft oil seal lip gear oil Driveshaft oil seal lip gear oil Each O ring Select lever shoe Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 MITSUBISHI genuine grease part No 0101011 or equivalent TRANSFER ITEMS SPECIFIED SEALANTS Each O ring Hypoid gear oil API classification GL 5 SAE 90 Each oil seal TSB Revision Spacer MANUAL TRANSAXLE OVERHAUL SPECIFICATIONS SNAP RINGS SPACERS AND THRUST PLATE FOR ADJUSTMENT For adjustment of input shaft end plav 22B 53 M1222012000108 THICKNESS mm in 1 34 0 0528 1 43 0 0563 1 52 0 0598 IDENTIFICATION SYMBOL 34 43 52 THICKNESS mm in 1 61 0 0634 1 70 0 0669 1 79 0 0705 IDENTIFICATION SYMBOL Snap ring For adjustment of input shaft front bearing end play THICKNESS mm in 1 43 0 0563 1 51 0 0594 IDENTIFICATION SYMBOL Green 2 White
26. 22 1 GROUP 22 MANUAL TRANSAXLE CONTENTS MANUAL TRANSAXLE 22A MANUAL TRANSAXLE OVERHAUL 22B NOTES 22A 1 GENERAL DESCRIPTION MANUAL TRANSAXLE DIAGNOSIS INTRODUCTION TROUBLESHOOTING STRATEGY SYMPTOM CHART SYMPTOM PROCEDURES SPECIAL TOOLS ON VEHICLE SERVICE TRANSAXLE OIL LEVEL CHECK TRANSAXLE OIL REPLACEMENT TRANSFER OIL CHECK TRANSFER OIL REPLACEMENT GROUP 22A MANUAL TRANSAXLE CONTENTS 22A 2 TRANSAXLE CONTROL 22A 11 REMOVAL AND INSTALLATION 22A 11 22A 4 SHIFT LEVER 22A 14 22A 4 DISASSEMBLY AND ASSEMBLY 22A 14 22A 4 22A 4 TRANSFER ASSEMBLY 22A 15 22A 4 REMOVAL AND INSTALLATION 22A 15 22A 8 TRANSAXLE ASSEMBLY 22A 21 REMOVAL AND INSTALLATION 22A 21 22A 9 22A 9 SPECIFICATIONS 22A 25 22A 9 FASTENER TIGHTENING 22A 10 SPECIFICATIONS 22A 25 22A 10 LUBRICANT 22A 25 A WARNING authorized MITSUBISHI dealer related component NOTE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to se
27. 33 4 N m 98 3 ft Ib AK103662AB TSB Revision MANUAL TRANSAXLE OVERHAUL TRANSEER 22B 49 TRANSFER DISASSEMBLY AND ASSEMBLY M1222004000039 APPLV GEAR OIL l TO ALL MOVING PARTS BEFORE INSTALLATION AK101413AE DISASSEMBLY STEPS DISASSEMBLY STEPS 1 DUST SEAL GUIDE gt gt C lt lt 6 OIL SEAL gt gt E lt lt 2 OIL SEAL gt gt B lt lt 7 OIL SEAL gt gt D lt lt 3 OIL SEAL gt gt A lt lt 8 O RING gt gt A lt lt 4 O RING 9 TRANSFER COVER gt gt A lt lt 5 O RING 10 TRANSFER Required Special Tools e MD998800 Oil Seal Installer e MB990887 Ring e MB990938 Handle e MB990891 Bushing Remover Installer Base e MB990937 Installer Adapter e MB990936 Installer Adapter ASSEMBLY SERVICE POINT gt gt A lt lt O RING INSTALLATION Install 8 O ring to the transfer and apply gear oil Hypoid gear oil API classification GL 5 SAE 90 to the O ring TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 90 TRANSFER gt gt B lt lt OIL SEAL INSTALLATION 1 Apply gear oil Hypoid gear oil API classification GL 5 SAE 90 2 Using special tools MB990937 and MB990938 press fit the oil seal into the transfer cover AK101415AC gt gt C lt lt OIL SEAL INSTALLATION 1 Apply gear oil Hypoid gear oil API classification GL 5 SAE 90 2 Using special tool MD998800 press fit the oil seal into the transfer cover MD998800 AK
28. A 8 MANUAL TRANSAXLE SPECIAL TOOLS SPECIAL TOOLS M1221000600616 TOOL B991453 TE MZ203827 B991454 AC106827 TOOL NUMBER AND NAME MB991453 Engine hanger assembly GENERAL SERVICE TOOL MZ203827 Engine lifter MB991454 Engine hanger balancer MB991895 Engine hanger MB991928 Engine hanger A MB991929 Joint 50 x2 B MB991930 Joint 90 x2 C MB991931 Joint 140 x2 D MB991932 Foot standard x4 E MB991933 Foot short x2 F MB991934 Chain and hook assembly MB991897 Ball joint remover MB991721 Slide hammer SUPERSESSION APPLICATION MZ203827 01 When the engine hanger is used Supporting the engine assembly during removal and installation of the transaxle assembly MZ203827 01 NOTE Special tool MB991454 is a part of engine hanger attachment set MB991453 MZ203827 01 MB991113 01 Knuckle and tie rod end ball joint MB990635 01 or breakaway torque check general service tool NOTE Steering linkage puller MB990635 or MB991113 is also used to disconnect knuckle and tie rod end ball joint Removal of the output shaft TSB Revision MANUAL TRANSAXLE ON VEHICLE SERVICE TOOL B990767 br Le B 1211 Y MB990241AB A MB991354 TOOL NUMBER AND NAME MB990767 End yoke holder MB990241 Axle shaft puller A MB990242 Puller shaft B MB990244 Puller bar MB991354 Puller body SUPERSESSION APPLICATION
29. D SPEED GEAR SLEEVE 6 INNER SVNCHRONIZER RING 23 INNER SYNCHRONIZER RING 7 SYNCHRONIZER CONE 24 SYNCHRONIZER CONE 8 OUTER SYNCHRONIZER RING 25 OUTER SYNCHRONIZER RING gt gt L lt lt 9 SVNCHRONIZER SPRING gt gt D lt lt 26 SYNCHRONIZER SPRING gt gt F lt lt 10 SYNCHRONIZER SLEEVE gt gt F lt lt 27 SYNCHRONIZER SLEEVE lt C gt gt gt gt M lt lt 11 5TH SPEED REVERSE gt gt E lt lt 28 1ST 2ND SPEED SYNCHRONIZER HUB SYNCHRONIZER HUB 12 SYNCHRONIZER RING 29 OUTER SYNCHRONIZER RING L 13 SYNCHRONIZER SPRING gt gt D lt lt 30 SYNCHRONIZER SPRING 14 5TH SPEED GEAR 31 INNER SYNCHRONIZER RING 15 NEEDLE ROLLER BEARING 32 SYNCHRONIZER CONE gt gt K lt lt 16 5TH SPEED GEAR SLEEVE 33 18T SPEED GEAR 34 NEEDLE ROLLER BEARING TSB Revision 228 24 MANUAL TRANSAXLE OVERHAUL OUTPUT SHAFT DISASSEMBLV STEPS lt lt F gt gt gt gt C lt lt 35 IST SPEED GEAR SLEEVE lt G gt gt gt gt B lt lt 36 TAPER ROLLER BEARING gt gt A lt lt 37 OIL SEAL 38 OUTPUT SHAFT Required Special Tools e MD998364 Camshaft Oil Seal Installer e MD998820 Installer Adapter 42 e MD998801 Bearing Remover e MD998821 Installer Adapter 44 e MD998812 Installer Cap e MD998824 Installer Adapter 50 e MD998814 Installer 200 e MD998917 Bearing Remover e MD998819 Installer Adapter 40 DISASSEMBLY SERVICE POINTS lt lt A gt gt TAPER ROLLER BEARING REMOVAL MD998801 TAPER ROLLER 1 Using s
30. D999566 remove the outer race from the clutch housing lt lt B gt gt OUTER RACE REMOVAL Using special tool MD999566 remove the outer race from the clutch housing ASSEMBLY SERVICE POINTS gt gt A lt lt COVER B COVER A INSTALLATION Install the covers directed as shown in the illustration gt gt B lt lt BUSHING INSTALLATION 1 Press fit the bushing so the seam is away from the air vent TSB Revision 228 42 1 mm 0 04 in AKX00875AB MB990938 rt PE AK201669AC Z MB991445 yf Ss p cr O 1 AK201670AC AKX00868 MANUAL TRANSAXLE OVERHAUL _ O CLUTCHHOUSING __ 2 Be sure the bushing is fullv seated as shown It must be 1 mm 0 04 inch below the housing surface gt gt C lt lt OUTER RACE INSTALLATION Using special tools MB990938 and MB990935 press fit the outer race into the clutch housing gt gt D lt lt OUTER RACE INSTALLATION 1 Check the installation direction of the outer race 2 Using special tools MB990938 and MB991445 press fit the outer race into the clutch housing gt gt E lt lt OIL SEAL INSTALLATION 1 Apply transmission oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 to the oil seal lip TSB Revision MANUAL TRANSAXLE OVERHAUL 1 TRANSMISSION CASE 22B 43 2 Using special tools
31. ION 1 Be sure to install the drive shaft washer in the specified direction N CAUTION Before securely tightening the drive shaft nuts make sure there is no load on the wheel bearings Otherwise the wheel bearing will be damaged 2 Using special tool MB990767 tighten the drive shaft nut to the specified torgue Tightening torque 226 29 N m 167 21 ft Ib TSB Revision MANUAL TRANSAXLE _ TRANSAXLE ASSEMBLY 22A 21 TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION CAUTION Indicates parts which should be temporarily tightened and then fully tightened after installing the engine into the vehicle M1221002700211 Pre removal and Post installation Operation e Transfer Assembly Removal and Installation Refer to P 22A 15 e Starter Motor Removal and Installation Refer to GROUP 16 P 16 24 Air Cleaner Bracket Removal and Installation Refer to GROUP 15 Air Cleaner P 15 7 Rear Roll Rod Assembly and Rear Roll Rod Bracket Removal and Installation Refer to GROUP 32 Engine Roll Stopper and Center member P 32 6 18 3 N m 13 2 ft Ib 18 3 Nm 18z3Nm 4342 ft lb 13 2 ft lb 1 70 10N m e ft lb AC207691AB REMOVAL STEPS REMOVAL STEPS Continued 1 TRANSAXLE HARNESS CLAMP 5 SNAP PIN 2 BACK UP LAMP SWITCH 6 CABLE BRACKET AND CABLE CONNECTOR ASSEMBLY lt TRANSAXLE SIDE gt 3 VEHICLE SPEED SENSOR 7 REAR ROLL MOUNT BRACKET CONNECTOR lt lt A gt
32. ION REFERENCE PROCEDURE PAGE 2 P 22A 5 4 P 22A 7 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 11A P 11A 13 On vehicle Service Curb Idle Speed Check STEP 2 Check whether the transaxle and transfer assembly and engine mount is loose or damaged Q Are the transaxle and transfer assembly and engine mount loose or damaged YES Tighten or replace the part Then 90 to Step 7 NO Goto Step 3 TSB Revision MANUAL TRANSAXLE 22A 5 MANUAL TRANSAXLE DIAGNOSIS TRANSAXLE OIL lt TRANSAXLE gt OR TRANSFER OIL lt TRANSFER gt FILLER PLUG FILLER PLUG HOLE AC102278AN INSPECTION PROCEDURE 2 Oil Leaks DIAGNOSIS STEP 1 Visual check Raise the vehicle and check for oil leaks II oil leak is difficult to locate steam clean the transaxle and STEP 3 Check that the oil level is up to the lower edge of the filler plug hole Q Is the oil level up to the lower edge of the filler plug hole YES Go to Step 4 NO Refill gear oil API classification GL 4 SAE 75W 85W or 75W 90 Transaxle oil e Refill hypoid gear oil API classification GL 5 SAE90 Transfer oil e Then go to Step 7 STEP 4 Check for the specified oil Q Is the specified oil gear oil GL 4 SAE 75W 85W or 75W 90 Transaxle oil and the hypoid gear
33. Ib AK203128AC DISASSEMBLY STEPS DISASSEMBLY STEPS 12 INTERLOCK PLATE BOLT 19 REVERSE IDLER GEAR 13 GASKET gt gt E lt lt 20 TRANSAXLE CASE gt gt lt lt 14 CONTROL HOUSING gt gt D lt lt 21 OUTER RACE 15 NEUTRAL RETURN SPRING gt gt D lt lt 22 OUTER RACE gt gt F lt lt 16 UNDER COVER gt gt D lt lt 23 SPACER 17 REVERSE IDLER GEAR SHAFT gt gt D lt lt 24 SPACER BOLT gt gt D lt lt 25 SPACER 18 GASKET TSB Revision a MANUAL TRANSAXLE OVERHAUL 228 8 TRANSAXLE N29 4 TO ALL MOVING 32 Ib PARTS BEFORE MU II 30 7 INSTALLATION 34 33 AK201617AC DISASSEMBLY STEPS DISASSEMBLY STEPS gt gt C lt lt 26 SPRING PIN lt lt gt gt gt gt B lt lt 33 5TH REVERSE SPEED SHIFT 27 1ST 2ND SPEED SHIFT RAIL RAIL 28 1ST 2ND SPEED SHIFT FORK lt lt B gt gt gt gt B lt lt 34 5TH REVERSE SPEED SHIFT gt gt C lt lt 29 SPRING PIN FORK lt lt A gt gt gt gt C lt lt 30 SPRING PIN C gt gt lt lt 35 CENTER DIFFERENTIAL lt lt gt gt gt gt B lt lt 31 3RD 4TH SPEED SHIFT RAIL C gt gt lt lt 36 OUTPUT SHAFT lt lt B gt gt gt gt B lt lt 32 3RD 4TH SPEED SHIFT FORK C gt gt A lt lt 37 INPUT SHAFT 38 CLUTCH HOUSING DISASSEMBLY SERVICE POINTS A SPRING PIN REMOVAL 1 Shift the 5th reverse shift fork in the direction shown in the 5TH REVERS SHIFT FORK illustration 2 Using a pin punch remove the
34. NNECTION TRANSAXLE SIDEN GEARSHIFT LINK CLIP 1 Set the transaxle side shift lever and the passenger compartment side shift lever to the neutral position 2 Install the painted part of the shift cable end transaxle side and painted part of the select cable transmission side facing the snap pin TSB Revision MANUAL TRANSAXLE kl TRANSAXLE CONTROL 22A 13 CAUTION Insert thoroughly the gearshift link clip shift cable and select cable until they click in place NEW GEARSHIFT 3 After installing the new gearshift link clip to the cable bracket LINK CLIP of the transaxle install the shift cable and select cable to the cable bracket NOTE The clip is reversible CABLE 4 Move the shift lever to all positions and check that the BRACKET operation is smooth SHIFT CABLE SELECT CABLE AC209411 AB gt gt B lt lt SHIFT CABLE CONNECTION SHIFT LEVER SIDE INSTALLATION 1 Make sure that there is no excessive play at the shift cable end gearshift cable clip If there is excessive play or the gearshift cable clip is disengaged from the shift cable end check the clip opening gap II the gap is more than 9 5 mm 0 37 inch squeeze the gearshift cable clip until the relaxed gap reaches 5 to 8 mm 0 20 to 0 31 inch Ss 5 8 0 20 0 31 AC001661 AB 2 Engage the gearshift cable clip with the shift cable hook securely and push the gearshift cable clip with your thumbs unti
35. ORT 1 lt Engine lifter special tool MZ203827 is used gt 1 Set the special tools MB991453 and MZ203827 to the vehicle to support the engine assembiv 2 Set special tools MB991453 to hold the engine transaxle assembiv 2 sEngine hanger special tool MB991895 is used gt 1 Set special tool MB991895 to the strut mounting nuts and the radiator support upper insulator mounting bolts which are located in the engine compartment as shown 2 Set special tools MB991454 to hold the engine transaxle assembiv 3 lt Engine hanger special tool MB991928 is used gt 1 Assemble the engine hanger special tool MB991928 Set following parts to the base hanger e Slide bracket HI e Foot standard MB991932 e Joint 90 MB991930 FOOT STADARD MB991932 2 Set the engine hanger special tool MB991928 to the strut mounting nuts and the radiator support upper insulator mounting bolts which are located in the engine compartment as shown NOTE Adjust the engine hanger balance V sliding the slide bracket HI 3 Set special tools MB991454 to hold the engine transaxle assembiv TSB Revision 22A 24 RELEASE BEARING AC207722 AB dam ENGINE SIDE TRANSAXLE ARROW TRANSAXLE MOUNT BRACKET MOUNT GN AC207723 AB MANUAL TRANSAXLE TRANSAXLE ASSEMBLY C CLUTCH RELEASE BEARING SEPARATION CAUTION If it is hard to turn th
36. RSHIFT CABLE CLIP 5 GEARSHIFT CABLE CONNECTION GEARSHIFT LEVER SIDE e SRS ECU REFER TO GROUP 528 P 52B 182 6 SNAP PIN GEARSHIFT LINK CLIP SELECT CABLE CONNECTION TRANSAXLE SIDE 12 2 N m 102 22 in Ib lt lt A gt gt A 9 gt gt A lt lt 10 gt gt B lt lt 4 11 TSB Revision 6 0 1 5 N m 53 14 in Ib AC207681AB GEARSHIFT CABLE AND SELECT CABLE ASSEMBLY REMOVAL STEPS Continued GEARSHIFT CABLE CONNECTION TRANSAXLE SIDE GEARSHIFT CABLE AND SELECT CABLE ASSEMBLY GEARSHIFT LEVER ASSEMBLY REMOVAL STEPS GEARSHIFT LEVER KNOB FRONT FLOOR CONSOLE REFER TO GROUP 52A P 52A 7 NAP PIN SELECT CABLE CONNECTION GEARSHIFT LEVER SIDE GEARSHIFT CABLE CLIP GEARSHIFT CABLE CONNECTION GEARSHIFT LEVER SIDE GEARSHIFT LEVER ASSEMBLY 22A 12 GEARSHIFT LINK CLIP GEARSHIFT CABLE SELECT CABLE AC207686AB NEUTRAL POSITION AC207689 AB MANUAL TRANSAXLE TRANSAXLE CONTROL REMOVAL SERVICE POINT lt lt A gt gt GEARSHIFT LINK CLIP SELECT CABLE CONNEC TION TRANSAXLE SIDE GEAR SHIFT CABLE CONNEC TION TRANSAXLE SIDE INSTALLATION Push up the claws of the gearshift link clip using 8 screwdriver etc and then remove the gearshift link clip from the bracket together with the cables INSTALLATION SERVICE POINT gt gt A lt lt GEARSHIFT CABLE AND SELECT CABLE ASSEM BLY GEARSHIFT CABLE CONNECTION TRANSAXLE SIDE SELECT CABLE CO
37. TER DIFFERENTIAL 22B 45 2 Using special tool MD998800 press fit the oil seal into the transaxle case MD998800 SH KU CENTER DIFFERENTIAL DISASSEMBLY AND ASSEMBLY M1222002800039 APPLY GEAR OIL Sb TO ALL MOVING PARTS BEFORE INSTALLATION AK203701AC DISASSEMBLV STEPS DISASSEMBLV STEPS gt gt D lt lt 1 CENTER DIFFERENTIAL DRIVE gt gt C lt lt 4 SPACER GEAR gt gt C lt lt 5 SNAP RING gt gt C lt lt 2 CENTER DIFFERENTIAL FLANGE gt gt C lt lt 6 SIDE GEAR lt lt A gt gt gt gt B lt lt 3 TAPER ROLLER BEARING gt gt C lt lt 7 FRONT OUTPUT SHAFT TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 46 CENTER DIFFERENTIAL DISASSEMBLV STEPS gt gt C lt lt 8 LOCK PIN gt gt C lt lt 9 PINION SHAFT gt gt C lt lt 10 PINION SHAFT HOLDER gt gt C lt lt 11 PINIONS gt gt C lt lt 12 WASHERS gt gt C lt lt 13 SIDE GEAR gt gt C lt lt 14 SPACER lt lt gt gt gt gt A lt lt 15 TAPER ROLLER BEARING 16 SPEED METER DRIVE GEAR 17 DIFFERENTIAL CASE Required Special Tools e MD998812 Installer Cap e MD998824 Installer Adapter 50 e MD998917 Bearing Remover MB990937 Installer Adapter e MB990930 Installer Adapter DISASSEMBLY SERVICE POINT lt lt A gt gt TAPER ROLLER BEARING REMOVAL 1 Support the taper roller bearing with special tool MD998917 and then set them on the press MD998917 2 Push down on the differential ca
38. TER GEAR 22B 35 SPEEDOMETER GEAR DISASSEMBLV AND ASSEMBLV APPLV GEAR OIL TO ALL MOVING PARTS BEFORE INSTALLATION M1222003400056 AKX00804AB DISASSEMBLY STEPS DISASSEMBLY STEPS 1 E CLIP 3 O RING 2 SPEEDOMETER DRIVEN GEAR 4 SLEEVE TSB Revision e MANUAL TRANSAXLE OVERHAUL 22B 36 SELECT LEVER SELECT LEVER DISASSEMBLV AND ASSEMBLV M1222012800052 1 12 1N m 104 9 in Ib OG 3 O AKX00801AC DISASSEMBLY STEPS DISASSEMBLY STEPS 1 DUST COVER 6 SELECT LEVER SHOE 2 NUT 7 SELECT LEVER 3 SPRING WASHER gt gt A lt lt 8 SELECT LEVER BUSHING 4 WASHER gt gt A lt lt 9 DUST COVER gt gt A lt lt 5 SELECT LEVER BUSHING 10 SELECT LEVER SHAFT TSB Revision MANUAL TRANSAXLE OVERHAUL E CONTROL HOUSING 22B 37 ASSEMBLY SERVICE POINT gt gt A lt lt DUST COVER AND SELECT LEVER BUSHING INSTALLATION SELECT LEVER Use the figure to make sure the dust cover and select lever BUSHING bushing installation direction is correct and the distinguished FI parts are correctiv assembled DUST COVER AKX00939AB CONTROL HOUSING DISASSEMBLY AND ASSEMBLY M1222013100120 AK100967AC TSB Revision DISASSEMBLY STEPS Continued SPACER CONTROL SHAFT AIR BREATHER CONTROL SHAFT BOOT OIL SEAL NEEDLE BEARING CONTROL HOUSING Driv
39. allation direction of the 3rd 4th speed synchronizer hub and put it on the input shaft Using special tools MD998812 MD998813 and MD998825 press install the 3rd 4th speed synchronizer hub with the press Make sure that the outer synchronizer ring can rotate freely gt gt F lt lt SYNCHRONIZER SLEEVE INSTALLATION 1 GROOVE yd KR E d INSTALLATION DIRECTION AKX00914AB TEETH WITH RAISED TIPS DEEP GROOVES BETWEEN THE TEETH AKX00928AB Check the installation direction of the synchronizer sleeve and install it onto the 3rd 4th speed synchronizer hub Install the synchronizer sleeve so that the areas with teeth that have raised tips three areas total are aligned with the areas on the synchronizer hub that have deep grooves between the teeth three areas total TSB Revision MANUAL TRANSAXLE OVERHAUL MD998812 MD998801 MD998813 MD998825 AK201640AC MD998812 MD998813 MD998825 MD998801 AK201641AC STAMPED WITH IDENTIFICATION AK201642AC MD998812 MD998813 MD998825 AK201643AC 22B 19 INPUT SHAET gt gt G lt lt 4TH SPEED GEAR SLEEVE INSTALLATION 1 Using special tool MD998801 support the 2nd speed gear portion of the input shaft and then set them on the press 2 Using special tools MD998812 MD998813 and MD998825 press install the 4th speed gear sleeve with
40. and then set them on the press 2 Push down on the output shaft with the press and remove the 2nd speed gear sleeve lt lt F gt gt 1ST SPEED GEAR SLEEVE REMOVAL 1 Using special tool MD998801 support the 1st speed gear sleeve and then set them on the press 2 Push down on the output shaft with the press and remove the 1st speed gear sleeve lt lt G gt gt TAPER ROLLER BEARING REMOVAL 1 Using special tool MD998801 support the taper roller bearing and then set them on the press 2 Push down on the output shaft with the press and remove the taper roller bearing TSB Revision 228 26 3 5 mm 0 138 in OIL SEAL AKX00827AB MD998812 MD998819 TAPER ROLLER BEARING AK201653AC MD998812 MD998814 1ST SPEED GEAR SLEEVE MD998824 MD998364 AK201654AC SYNCHRONIZER SPRING AK201638AC MANUAL TRANSAXLE OVERHAUL OUTPUT SHAFT ASSEMBLY SERVICE POINTS gt gt A lt lt OIL SEAL INSTALLATION Make sure that the oil seal is pressed into the position shown in the illustration gt gt B lt lt TAPER ROLLER BEARING INSTALLATION 1 Using special tool MD998801 support the output shaft gear and then set them on the press 2 Using special tools MD998812 and MD998819 press install the taper roller bearing with the press gt gt C lt lt 1ST SPEED GEAR SLEEVE INSTALLATION 1 Set the output shaft on the press
41. axle mount stopper attaching nut 82 7 Nm 61 5 ft lb Transaxle oil drain plug 32 2 N m 23 2 ft lb Transaxle oil filler plug 32 2 N m 23 2 ft lb LUBRICANT M1221000400140 ITEM SPECIFIED LUBRICANTS QUANTITY Gear oil API classification GL 4 SAE 2 8 2 9 75W 85W or 75W 90 0 55 0 58 TSB Revision NOTES 228 1 GROUP 228 MANUAL TRANSAXLE OVERHAUL CONTENTS GENERAL INFORMATION 228 2 CONTROL HOUSING 22B 37 DISASSEMBLV AND ASSEMBLY 22B 37 SPECIAL TOOLS 22B 3 CLUTCH HOUSING 22B 40 TRANSAXLE 22B 6 DISASSEMBLY AND ASSEMBLY 22B 40 DISASSEMBLY AND ASSEMBLY 22B 6 INSPECTION 22B 13 TRANSMISSION CASE 228 43 DISASSEMBLV AND ASSEMBLY 22B 43 INPUT SHAFT 22B 14 DISASSEMBLY AND ASSEMBLY 22B 14 CENTER DIFFERENTIAL 22B 45 INSPECTION 22B 21 DISASSEMBLV AND ASSEMBLY 22B 45 OUTPUT SHAFT 228 23 TRANSFER 22B 49 DISASSEMBLY AND ASSEMBLY 22B 23 DISASSEMBLY AND ASSEMBLY 22B 49 INSPECTION 228 31 SPECIFICATIONS 22B 51 REVERSE IDLER GEAR 22B 34 FASTENER TIGHTENING DISASSEMBLY AND ASSEMBLY 22B 34 SPECIFICATIONS 22B 51 GENERAL SPECIFICATIONS 22B 51 SPEEDOMETER GEAR
42. bout 10 mm 0 39 inch long on the input shaft rear bearing at the positions shown in the illustration Put solders 1 6 mm 0 063 inch diameter about 10 mm 0 39 inch long on the transaxle case at the positions shown in the illustration Install the bearing outer races of the center differential and output shaft Install the transaxle case and tighten the bolts to the specified torque Tightening torque 44 5 M 32 3 ft Ib Remove the transaxle case Remove the outer races and take out the crushed solders Measure the thickness of the crushed solder with a micrometer and select spacers that will provide the standard end play preload value 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 TSB Revision MANUAL TRANSAXLE OVERHAUL TRANSAXLE 22B 11 ASSEMBLY SERVICE POINTS gt gt A lt lt INPUT SHAFT OUTPUT SHAFT CENTER DIFFEREN TIAL INSTALLATION Install the input shaft output shaft and center differential as a set CENTER DIFFERENTIAL a Ee C MEN gt AK201620AC gt gt B lt lt 5TH REVERSE SPEED SHIFT FORK 5TH REVERSE SPEED SHIFT RAIL 3RD 4TH SPEED SHIFT FORK 3RD 4TH SPEED SHIFT RAIL INSTALLATION A 3RD 4THSPEED 1 Assemble the Srd 4th speed shift
43. 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 Install the transaxle case Tighten the transaxle case mounting bolts to the specified torque Tightening torque 44 5 M 32 3 ft Ib NOTE After installation keep the sealed area away from the oil for approximately one hour gt gt F lt lt UNDER COVER INSTALLATION A CAUTION Squeeze out the sealant uniformly while making sure that it is not broken or excessively applied 1 Applv 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 quickiv while the sealant is wet within 15 minutes Install the under cover to the transaxle case and tighten the bolts to specified torque Tightening torque 6 9 0 9 N m 61 7 in Ib NOTE After installation keep the sealed area away from the oil for approximately one hour TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 13 AK201628 CONTROL SHAFT SELECT O LEVER SHOE AKX00822AB TRANSAXLE gt gt G l
44. cified torque Tightening torque 32 2 N m 23 2 ft Ib M1221001100067 TRANSFER OIL REPLACEMENT 1 Remove the filler plug 2 Remove the drain plug and drain the oil 3 Tighten the drain plug to the specified torque Tightening torque 32 2 N m 23 2 ft Ib 4 Fill with hvpoid gear oil API classification GL 5 SAE90 until the level comes to the lower portion of filler plug hole Quantity 0 55 dm 0 58 quart 5 Tighten the filler plug to the specified torque Tightening torque 32 2 N m 23 2 ft Ib M1221001200042 TSB Revision MANUAL TRANSAXLE TRANSAXLE CONTROL TRANSAXLE CONTROL REMOVAL AND INSTALLATION A WARNING 22A 11 M1221003800512 Be careful not to subject the SRS ECU to anv shocks during removal and installation of the shift cable and select cable assembiv Pre removal and Post installation Operation Air Cleaner Assembly Removal and Installation Refer to GROUP 15 Air Cleaner P 15 7 Air Hose E Air Hose C Air Hose D Removal and Installa tion Refer to GROUP 15 Charge Air Cooler P 15 8 Battery and Battery Tray Removal and Installation lt lt A gt gt gt gt lt lt 7 lt lt A gt gt gt gt lt lt 8 10 GEARSHIFT CABLE AND SELECT CABLE ASSEMBLV REMOVAL STEPS 1 GEARSHIFT LEVER KNOB e FRONT FLOOR CONSOLE REFER TO GROUP 524A P 52A 7 2 SNAP PIN 3 SELECT CABLE CONNECTION GEARSHIFT LEVER SIDE gt gt B lt lt 4 GEA
45. e 0 0 12 mm 0 0 0047 inch TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 21 INPUT SHAFT INSPECTION M1222001700062 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 and broken 2 Check internal surface for damage wear and broken threads AKX00915 3 Force the synchronizer ring toward the clutch gear and A ht check clearance A If A is less than the limit replace SE SYNCHRO Minimum limit 0 5 mm 0 020 inch NIZER RING AKX00927AB TSB Revision 228 22 AKX00933 A OUTER RING SE p CONE AKX00888AB INNER RIN ii und AK201697AC AKX00916 MANUAL TRANSAXLE OVERHAUL INPUT SHAFT 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 cl
46. e 5th speed gear side can rotate freely TSB Revision E MANUAL TRANSAXLE OVERHAUL 22B 30 OUTPUT SHAFT gt gt M lt lt REVERSE GEAR BEARING SLEEVE INSTALLATION 1 Make sure the synchronizer ring reverse gear and needle MD998812 roller bearing have been correctiv installed MD998820 2 Using special tools MD998812 MD998820 and MD998364 REB IEEE press fit the reverse gear sleeve Make sure that the reverse KI gear and the svnchronizer ring can rotate freelv during the pressing process MD998364 AK201662AC gt gt 0 lt lt TAPER ROLLER BEARING INSTALLATION Using special tools MD998812 MD998819 and MD998364 press install the taper roller bearing MD998812 TAPER ROLLER MD998819 MD998364 AK201663AC gt gt P lt lt SNAP RING INSTALLATION 1 Install the thickest snap ring that can be fitted in the groove STANDARD VALUE of output shaft 2 Make sure that the taper roller bearing end play meets the APER ROLLER standard value BEARING Standard value 0 0 09 mm 0 0 0035 inch SNAP RING LA AKX00934AC TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 31 AKX00938 AKX00915 GEAR lt SYNCHRO NIZER RING AKX00927AB OUTPUT SHAFT INSPECTION M1222002300067 OUTPUT SHAFT 1 Check the splines for damage and wear 2 Check that the helical gear teeth surfaces are n
47. e out the lock pin from the direction shown x MANUAL TRANSAXLE OVERHAUL 22B 38 CONTROL HOUSING DISASSEMBLY STEPS 1 SPRING WASHER 9 2 STOPPER BRACKET 10 lt lt A gt gt gt gt E lt 3 LOCKPIN gt gt C lt lt 11 4 INTERLOCK PLATE 12 5 CONTROL FINGER gt gt B lt lt 13 gt gt D lt lt 6 SPRING PIN gt gt A lt lt 14 7 STOPPER BODY 15 8 SPRING DISASSEMBLY SERVICE POINT lt lt A gt gt LOCK PIN REMOVAL LOCK PIN PV senn AKX00856AB ASSEMBLY SERVICE POINTS gt gt A lt lt NEEDLE BEARING INSTALLATION CONTROL HOUSING shown Press fit the needle bearing into the control housing side as NEEDLE Make sure that the side with the model number stamped on it BEARING MODEL NUMBER STAMPED SIDE 0 0 5 mm 0 0 02 in AK100980AB faces the end of the control housing as shown gt gt B lt lt OIL SEAL INSTALLATION AKX00921 TSB Revision 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 MANUAL TRANSAXLE OVERHAUL 22B 39 AKX00858 CONTROL SHAFT STOPPER BODV gt SLIT SPRING PIN INSTALLATION DIRECTION AK100981AB E AKX00859 CONTROL HOUSING gt gt C lt lt AIR BREATHER INSTALLATION 1 Apply sealant 3M AAD Part Number 800
48. e screwdriver to pry off the release bearing remove the screwdriver once and repeat the above procedure after pushing the release fork fully in the direction a two to three times Forcibly prying can cause the release bearing to be damaged 1 Remove the cover from the service hole in the clutch housing 2 While pushing the release fork by hand in the direction A insert a flap tip screwdriver between the release bearing and the wedge collar CAUTION Be sure to push the release fork in the direction A before inserting a screwdriver 3 Separate the release bearing from the wedge collar by prying with the screwdriver turning the screwdriver grip 90 NOTE The release fork is forced to move fully in the direc tion B by the return spring as soon as if is separated from the wedge collar INSTALLATION SERVICE POINTS gt gt A lt lt TRANSAXLE MOUNT STOPPER INSTALLATION Install the transaxle mount stopper so that the arrow points as shown in the illustration TSB Revision MANUAL TRANSAXLE SPECIFICATIONS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS 22A 25 M1221006600142 Transaxle control Gearshift lever base bracket attaching bolt Shift lever assembly Gearshift select lever retainer nut Gearshift lever retainer nut Transfer assembly Centermember attaching bolt Crossmember bar attaching bolt Driveshaft connecting nut Front roll stopper bracket retainer nut L
49. er installing the engine into the vehicle M1221003200026 Pre removal and Post installation Operation e Under Cover Removal and Installation Refer to GROUP 51 Front Bumper P 51 2 e Side Under Cover Removal and Installation Refer to GROUP 51 Front Bumper P 51 2 e Transaxle Oil Draining and Supplying Refer to P 22A 9 e Engine Coolant Draining and Supplying Refer to Group 14 On vehicle Service P 14 18 e Crossmember Bar Removal and Installation Refer to GROUP 32 Engine Roll Stopper Centermember P 32 6 e Front Exhaust Pipe Removal and Installation Refer to GROUP 15 Exhaust Pipe and Main Muffler P 15 23 e Air Cleaner Air Intake Hose Removal and Installation Refer to GROUP 15 Air Cleaner P 15 7 e Strut Tower Bar Removal and Installation Refer to GROUP 42 P 42 12 e Air Hose E Air By pass Hose and Turbocharger Bypass Valve Air Pipe C Air Hose D Air Pipe B Air Hose A Removal and Installation Refer to GROUP 15 Charge Air Cooler P 15 8 e Radiator Removal and Installation Refer to GROUP14 P 14 22 TSB Revision 22A 16 lt lt A gt gt gt gt B lt lt ONS NO MANUAL TRANSAXLE TRANSFER ASSEMBLY REMOVAL STEPS SPLIT PIN DRIVE SHAFT NUT FRONT SPEED SENSOR FRONT SPEED SENSOR HARNESS BRACKET BRAKE HOSE BRACKET STABILIZER BAR CONNECTION STABILIZER LINK lt lt B gt gt lt lt B gt gt lt lt C gt gt lt lt C gt gt
50. he areas on the synchronizer hub that have deep grooves between the teeth three areas total TSB Revision 228 28 MD998812 MD998814 2ND SPEED GEAR SLEEVE MD998824 MD998364 AK201656AC MD998812 MD998814 AS MD998824 MD998364 AK201657AC MD998812 MD998813 AER MD998821 MD998364 AK201659AC MANUAL TRANSAXLE OVERHAUL OUTPUT SHAFT gt gt G lt lt 2ND SPEED GEAR SLEEVE INSTALLATION 1 Set the output shaft on the press support stand 2 Using special tools MD998812 MD998813 MD998824 and MD998364 press install the 2nd speed sleeve onto the output shaft gt gt H lt lt 3RD SPEED GEAR INSTALLATION 1 Check that the 2nd speed gear and the outer synchronizer ring have been properly installed Also make sure the claws on the synchronizer cone four places are correctly fitted into the holes in the 2nd speed gear four places 2 Using special tools MD998812 MD998814 MD998824 and MD998364 press install the 3rd speed gear onto the output shaft 3 Make sure that the 2nd speed gear and the outer synchronizer ring can rotate freely gt gt I lt lt 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 standard value Standard value 0 0 09 mm 0 0 0035 inch gt gt J lt lt 4TH SPEED GEAR INSTALLATION 1 Se
51. il seal Installer adapter MD998800 General service tool Installation of differential oil seal Oil seal installer and transfer oil seal MB990930 MB990930 01 Installation 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 MD998824 General service tool jInstallation of center differential Installer adapter 50 rear taper roller bearing MB990887 EE Installation of transfer oil seal Ring ec MB990891 Installation of transfer oil seal Bushing remover installer base MB990936 MB990936 01 or Installation of transfer oil seal Installer adapter General service tool A TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 6 TRANSAXLE TRANSAXLE DISASSEMBLV AND ASSEMBLV M1222001000096 AK203132AC DISASSEMBLV STEPS DISASSEMBLV STEPS 1 TRANSFER ASSEMBLY gt gt l lt lt 6 SELECT LEVER gt gt 2 O RING gt gt H lt lt 7 SPEEDOMETER GEAR 3 ROLL STOPPER BRACKET 8 BACKUP LIGHT SWITCH FRONT 9 GASKET 4 ROLL STOPPER BRACKET 10 POPPET REAR 11 GASKET 5 SHIFT CABLE BRACKET Required Special Tools e MB990935 Installer Adapter e MB990938 Handle TSB Revision MANUAL TRANSAXLE OVERHAUL TRANSAXLE 22B 7 APPLV GEAR OIL TO ALL MOVING PARTS BEFORE INSTALLATION 35 3 ft Ib 61 7 in
52. l it clicks in place 3 Install the shift cable to the shift lever AC001662 TSB Revision _ MANUAL TRANSAXLE 22A 14 TRANSAXLE CONTROL SHIFT LEVER ASSEMBLY DISASSEMBLY AND ASSEMBLY M1221004000155 7 ESN x lt 9 w 1422N m Y Gp 9 _ G 12 6 L Tus D 6 Q yes eg LS Mi N m 11 84 13 in Ib SST AC208687AB DISASSEMBLY STEPS DISASSEMBLY STEPS 1 GEARSHIFT LINK BOLT 8 GEARSHIFT LEVER 2 GEARSHIFT SELECT LEVER 9 GEARSHIFT LINK BUSHING 3 GEARSHIFT LINK BUSHING 10 GEARSHIFT LEVER BRACKET 4 GEARSHIFT LEVER SPRING DISTANCE PIECE 5 GEARSHIFT LINK COLLAR 11 GEARSHIFT LINK BUSHING 6 BOLT 12 GEARSHIFT LEVER BRACKET T GEARSHIFT LEVER RETAINER TSB Revision MANUAL TRANSAXLE TRANSFER ASSEMBLY 22A 15 TRANSFER ASSEMBLY REMOVAL AND INSTALLATION CAUTION e If the vehicle is equipped with the Brembo disc brake during maintenance take care not to con tact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe out quickly For vehicles with ABS do not strike the rotor for wheel speed sensor installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft Otherwise the rotor for wheel speed sensor will be damaged ndicates parts which should be temporarily tightened and then fully tightened aft
53. n 1 58 0 0622 Brown 1 44 0 0567 None 1 63 0 0642 Orange 1 48 0 0583 Black 1 68 0 0661 Blue 1 51 0 0594 Blue Snap ring For adjustment of output shaft 3rd speed gear end play THICKNESS IDENTIFICATION THICKNESS IDENTIFICATION mm in SYMBOL mm in SYMBOL 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 IDENTIFICATION THICKNESS IDENTIFICATION mm in SYMBOL mm in 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 IDENTIFICATION THICKNESS IDENTIFICATION mm in SYMBOL mm in SYMBOL 0 6 0 0236 0 9 0 0354 0 7 0 0276 1 0 0 0394 Es 0 8 0 0315 SS 1 1 0 0433 Revision
54. ot damaged or worn NEEDLE ROLLER BEARING 1 Combine the needle roller bearing with the bearing sleeve and gear and check that it rotates smoothiv without noise or plav 2 Check the needle roller bearing cage for deformation SYNCHRONIZER RING FOR 5TH SPEED 1 Check if the clutch gear teeth are damaged or broken 2 Check internal surface for damage wear and broken threads 3 Force the synchronizer ring toward the clutch gear and check clearance A If A is less than the limit replace the synchronizer ring Minimum limit 0 5 mm 0 020 inch TSB Revision 228 32 MANUAL TRANSAXLE OVERHAUL AKX00933 de OUTER RING INNER RING AKX00843AB AK203129AC AK203130AC OUTPUT SHAFT OUTER SYNCHRONIZER RING INNER SYNCHRONIZER RING SYNCHRONIZER CONE sFOR REVERSE gt CAUTION When replacing replace the outer ring inner ring and cone as set 1 Check that the clutch gear tooth surfaces and cone surfaces are not damaged or broken 2 Install the outer ring inner ring and cone force them toward the gear and check clearance A If A is less than the limit replace them as set Minimum limit 0 5 mm 0 020 inch OUTER SYNCHRONIZER RING INNER SYNCHRONIZER RING SYNCHRONIZER CONE lt FOR 1 ST SPEED AND 2 ND SPEED gt CAUTION When replacing replace the outer ring inner ring and cone as a set 1 Check
55. ower arm connecting nut Rear roll stopper bracket retainer nut Stabilizer link connecting nut Tie rod end connecting nut Transfer assembly part coupling bolt Transfer oil drain plug Transfer oil filler plug Transaxle assembly Bell housing cover attaching bolt transaxle side Bell housing cover attaching bolt engine side Clutch release cylinder and clutch oil pipe attaching bolt Rear roll mount bracket attaching bolt Gearshift cable and select cable assembly attaching bolt ITEM SPECIFICATION 12 2 N m 102 22 in Ib 12 2 N m 102 22 in lb 10 1 N m 84 13 in Ib 14 2 N m 120 22 in Ib 69 9 N m 51 7 ft lb 49 10 37 7 ft lb 226 29 N m 167 21 ft Ib 52 7 N m 39 5 ft lb 108 10 N m 80 7 ft Ib 52 7 N m 39 5 ft lb 39 5 N m 29 3 ft lb 25 5 19 3 ft lb 69 9 N m 51 7 ft lb 32 2 N m 23 2 ft lb 32 2 N m 23 2 ft Ib 9 0 1 0 N m 80 9 in Ib 26 5 Nm 19 4 ft lb 18 3 N m 13 2 ft lb 70 10 N m 52 7 ft Ib Transaxle oil dm qt Transfer oil dm qt Hypoid gear oil API classification GL 5 SAE90 Shift cable and select cable assembly attaching bolt 18 3 N m 13 2 ft lb Transaxle assembly lower part coupling bolt 48 5 N m 36 3 ft lb Transaxle assembly upper part coupling bolt 48 5 N m 36 3 ft lb Transaxle mount bracket attaching nut 47 7 N m 35 5 ft lb Trans
56. pecial 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 AK201646AC lt lt B gt gt REVERSE GEAR BEARING SLEEVE REMOVAL 1 Using special tool MD998801 support the reverse gear and then set them on the press 2 Push down on the output shaft with the press and remove the reverse gear bearing sleeve REVERS GEAR BEARING lt lt C gt gt 5TH SPEED REVERSE SYNCHRONIZER HUB REMOVAL 1 Using special tool MD998801 support the 4th speed gear 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 MD998801 AK201648AC TSB Revision MD998917 MANUAL TRANSAXLE OVERHAUL 3RD SPEED GEAR AK201649AC MD998917 N 2ND SPEED GEAR SLEEVE 1 n 201650 MD998801 1ST SPEED GEAR SLEEVE MD998801 22B 25 OUTPUT SHAET lt lt D gt gt 3RD SPEED GEAR REMOVAL 1 Using special tool MD998917 support the 2nd speed gear and then set them on the press 2 Push down on the output shaft with the press and remove the 3rd speed gear lt lt E gt gt 2ND SPEED GEAR SLEEVE REMOVAL 1 Using special tool MD998917 support the 1st speed gear
57. rvice personnel from inadvertent firing of the air bag or to the driver and passenger from rendering the SRS inoperative e Service or maintenance of any SRS component or SRS related component must be performed only at an e MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 528 Supplemental Restraint System SRS before beginning any service or maintenance of any component of the SRS or any SRS The SRS includes the following components SRS air bag control unit SRS warning light front impact sensors air bag module clock spring and interconnecting wiring Other SRS related components that may have to be removed installed in connection with SRS service or maintenance are indicated in the table of contents by an asterisk d MANUAL TRANSAXLE 22A 2 GENERAL DESCRIPTION GENERAL DESCRIPTION M1221000100611 ITEMS SPECIFICATIONS Transaxle model W5M51 Engine model 4G63 DOHC Charge Air Cooler Turbo Transaxle type 5 speed forward 1 speed reverse constant mesh Transaxle gear ratio 2 928 7950 1407 4th 1 031 0720 3416 Final reduction ratio Differential gear ratio 4 529 Speedometer gear ratio 31 36 TSB Revision MANUAL TRANSAXLE GENERAL DESCRIPTION SECTIONAL VIEW m ij 1 LI f lo 5 tm o5 REPE __ E SOGN 22A 3 AC207467AB 4TH SPEED GEAR 1
58. se with the press to remove the bearing AK103658AB lt lt B gt gt TAPER ROLLER BEARING REMOVAL 1 Support the taper roller bearing with special tools MD998917 and MB990930 and then set them on the press 2 Push down on the differential case with the press to remove the bearing MD998917 EE MB990930 AK103659AC TSB Revision MANUAL TRANSAXLE OVERHAUL CENTER DIFFERENTIAL ASSEMBLY SERVICE POINTS 22B 47 gt gt A lt lt TAPER ROLLER BEARING INSTALLATION Us MB990937 AK103663AC ing special tool MB990937 press install the taper roller bear ing gt gt B lt lt TAPER ROLLER BEARING INSTALLATION MD998824 Us MD998812 y FG lt 103661 ing special tools MD998812 and MD998824 press install the taper roller bearing gt gt C lt lt SPACER SIDE GEAR WASHER PINION AND PINION SHAFT PINION SHAFT HOLDER LOCK PIN FRONT OUTPUT SHAFT SNAP RING CENTER DIFFERENTIAL FLANGE INSTALLATION 1 AK103656 DIFFERENTIAL CASE LOCK PIN PINION SHAFT AK103660AB Mount spacer on the back surface of the side gear and then install the side gear in the differential case NOTE When new side gear is to be installed use medium thickness spacer 0 93 to 1 00 mm 0 0366 to 0 0395 inch
59. t lt 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 Tightening torque 18 3 N m 13 2 ft Ib NOTE After installation keep the sealed area away from the oil for approximately one hour gt gt H lt lt SPEEDOMETER GEAR INSTALLATION 1 Apply gear oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 to the O ring of the speedometer gear 2 Tighten the bolt to specified torque Tightening torque 3 9 1 0 N m 34 8 in Ib gt gt I lt lt SELECT LEVER INSTALLATION 1 Apply grease Mitsubishi Genuine Part number 0101011 or equivalent to the control shaft sliding portion of the select lever shoe 2 Install the select lever and tighten the bolts to specified torque Tightening torque 18 3 N m 13 2 ft Ib gt gt J lt lt O RING INSTALLATION Apply gear oil Hypoid gear oil SAE 75W 90 or 75W 85W con forming to API classification GL 4 to the O ring INSPECTION M122200110007 1 TSB Revision E MANUAL TRANSAXLE OVERHAUL
60. t the output shaft on the press support stand 2 Using special tools MD998812 MD998813 MD998821 and MD998364 press install the 4th speed gear onto the output shaft TSB Revision 5TH SPEED GEAR SLEEVE K gt PASS KIS SA MD998364 MD998812 MD998813 MD998821 MANUAL TRANSAXLE OVERHAUL OUTPUT SHAET 22B 29 gt gt K lt lt 5TH SPEED GEAR SLEEVE INSTALLATION AK201660AC Using special tools MD998812 MD998813 MD998821 and MD998364 press install the 5th speed gear sleeve onto the output shaft gt gt L lt lt SYNCHRONIZER SPRING INSTALLATION Ins AKX00847AB tall the svnchronizer spring to the illustrated position of the svnchronizer ring gt gt M lt lt 5TH SPEED REVERSE SYNCHRONIZER HUB INSTALLATION 1 2 3 E INSTALLATION DIRECTION AKX00926AB 4 MD998812 SYNCHRONIZER MD998813 HUB 5 MD998821 MD998364 AK201661AC Set the output shaft on the press support stand Make sure that the synchronizer ring is fitted correctly on the cone of the 5th speed gear Check that the 5th speed reverse synchronizer hub is oriented correctly for installation and fit it on the output shaft Using special tools MD998812 MD998813 MD998821 and MD998364 press install the 5th speed reverse synchronizer hub with the press Make sure that the synchronizer ring on th
61. that the clutch gear tooth surfaces and cone surfaces are not damaged or broken N Install the outer ring inner ring and cone force them toward the gear and check clearance A If A is less than the limit replace them as a set Minimum limit 0 5 mm 0 020 inch TSB Revision MANUAL TRANSAXLE OVERHAUL OUTPUT SHAET 22B 33 SVNCHRONIZER SLEEVE AND HUB 1 Combine the svnchronizer sleeve and hub and check that thev slide smoothiv 2 Check that the sleeve is free from damage at its inside splines ends AK201697AC SYNCHRONIZER SPRING Check that the spring is not sagging deformed or broken AKX00943 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 and worn AKX00916 TSB Revision MANUAL TRANSAXLE OVERHAUL 22B 34 REVERSE IDLER GEAR REVERSE IDLER GEAR DISASSEMBLY AND ASSEMBLY M1222012500062 APPLY GEAR OIL Sp lo ALL MOVING 1 8 PARTS BEFORE INSTALLATION 2 S AK000202 AB 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 TSB Revision MANUAL TRANSAXLE OVERHAUL SPEEDOME
62. utch gear tooth surface and cone surface are not damaged and broken 2 Install the outer ring inner ring and cone press them against the gear and check clearance A If A is less than the limit replace Minimum limit 0 5 mm 0 020 inch SYNCHRONIZER SLEEVE AND HUB 1 Combine the synchronizer sleeve and hub and check that they slide smoothly 2 Check that the sleeve is free from damage at its inside splines ends SYNCHRONIZER SPRING Check that the spring is not sagging deformed or broken SPEED GEARS 1 Check that the helical and clutch gear tooth surfaces are not damaged or worn 2 Check that the synchronizer cone surfaces are not roughened damaged or worn 3 Check that the gear inside diameter and front and rear surfaces are not damaged and worn TSB Revision MANUAL TRANSAXLE OVERHAUL OUTPUT SHAET 22B 23 OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY M1222002200082 APPLY GEAR OIL Sp TO ALL MOVING PARTS BEFORE INSTALLATION AK203133AC DISASSEMBLY STEPS DISASSEMBLY STEPS gt gt P lt lt 1 SNAP RING gt gt J lt lt 17 4TH SPEED GEAR lt lt A gt gt gt gt 0 lt lt 2 TAPER ROLLER BEARING gt gt 1 lt lt 18 SNAP RING lt lt gt gt gt gt N lt lt 3 REVERSE GEAR BEARING lt D gt gt gt gt H lt lt 19 3RD SPEED GEAR SLEEVE 20 2ND SPEED GEAR 4 NEEDLE ROLLER BEARING 21 NEEDLE ROLLER BEARING 5 REVERSE GEAR lt lt E gt gt gt gt G lt lt 22 2N

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