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GENERAL INFORMATION 22B-0-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. SPECIFICATIONS 22B-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION MODEL TABLE 22B-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR RATIO TABLE 22B-1-2f. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 22B-1-2f. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEALANTS AND ADHESIVES 22B-1-2g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICANTS 22B-1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SNAP RINGS, SPACERS AND THRUST PLATEADJUSTMENT 22B-1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 22B-1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SPECIAL TOOLS 22B-2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TRANSMISSION 22B-3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TRANSMISSION 22B-4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. INPUT SHAFT 22B-5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. INPUT SHAFT 22B-6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. OUTPUT SHAFT 22B-7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. OUTPUT SHAFT 22B-8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. REVERSE IDLER GEAR 22B-9-1. . . . . . . . . . . . . . . . . . . . . .

10. SPEEDOMETER GEAR 22B-10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. SELECT LEVER 22B-11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. CONTROL HOUSING 22B-12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. CLUTCH HOUSING 22B-13-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. TRANSMISSION CASE 22B-14-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. DIFFERENTIAL ,FRONT DIFFERENTIAL 22B-15-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

16. CENTER DIFFERENTIAL 22B-16-1. . . . . . . . . . . . . . . . . . . . . . . . . .

17. TRANSFER 22B-17-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22B-0-1

MANUALTRANSMISSIONF5M41, F5M42, W5M42

CONTENTS

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22B-0-2

NOTES

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MANUAL TRANSMISSION (E- W) - General Information 22B-0-3

GENERAL INFORMATION

F5M41

1 2 3 4 5

6 7

10

9

8

11

1214 1315

TFM0809

1. Reverse gear meshing noise pre-vention device

2. 5th-reverse speed synchronizer hub3. 5th speed gear4. 4th speed gear5. 3rd-4th speed synchronizer hub6. 3rd speed gear7. Transmission case

8. Clutch housing9. Release bearing retainer

10. Input shaft11. Differential12. 1st speed gear13. 1st-2nd speed synchronizer hub14. 2nd speed gear15. Output shaft

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MANUAL TRANSMISSION (E- W) - General Information22B-0-4

F5M41

1 2 3 4 5

6 7

10

9

8

11

1214 1315

1. Reverse gear meshing noise pre-vention device

2. 5th-reverse speed synchronizer hub3. 5th speed gear4. 4th speed gear5. 3rd-4th speed synchronizer hub6. 3rd speed gear7. Transmission case

8. Clutch housing9. Release bearing retainer

10. Input shaft11. Differential12. 1st speed gear13. 1st-2nd speed synchronizer hub14. 2nd speed gear15. Output shaft


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MANUAL TRANSMISSION (E–W) – General Information 22B-0-4a

F5M41

1 2 3 4 5 67

10

9

8

111214 13

1. 5th-reverse speed synchronizer hub2. 5th speed gear3. 4th speed gear4. 3rd-4th speed synchronizer hub5. 3rd speed gear6. Transmission case7. Clutch housing

8. Release bearing retainer9. Input shaft

10. Differential11. 1st speed gear12. 1st-2nd speed synchronizer hub13. 2nd speed gear14. Output shaft

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F5M42

1 2 3

4 5 6

7

10

9

8

111214 131516

1. Reverse idler gear2. 4th speed gear3. 3rd-4th speed synchronizer hub4. 3rd speed gear5. Transmission case6. Clutch housing7. Release bearing retainer8. Input shaft

9. Output shaft10. Differential11. 1st speed gear12. 1st-2nd speed synchronizer hub13. 2nd speed gear14. 5th speed gear15. 5th-reverse speed synchronizer hub16. Reverse gear


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MANUAL TRANSMISSION (E- W) - General Information22B-0-6

F5M42

1 2 3

4 5 6

7

10

9

8

111214 131516

1. Reverse idler gear2. 4th speed gear3. 3rd-4th speed synchronizer hub4. 3rd speed gear5. Transmission case6. Clutch housing7. Release bearing retainer8. Input shaft

9. Output shaft10. Differential11. 1st speed gear12. 1st-2nd speed synchronizer hub13. 2nd speed gear14. 5th speed gear15. 5th-reverse speed synchronizer hub16. Reverse gear


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W5M42

1 2 3 4 5 6

7

109

8

11

12

14

13

1516171819

1. Reverse idler gear2. 4th speed gear3. 3rd-4th speed synchronizer hub4. 3rd speed gear5. Transmission case6. Clutch housing7. Release bearing retainer8. Input shaft9. Output shaft

10. Viscous coupling

11. Front differential12. Transfer driven gear13. Center differential14. 1st speed gear15. 1st-2nd speed synchronizer hub16. 2nd speed gear17. 5th speed gear18. 5th-reverse speed synchronizer hub19. Reverse gear

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MANUAL TRANSMISSION (E–W) – Specifications 22B-1-1

1. SPECIFICATIONS

TRANSMISSION MODEL TABLE – MODEL 1996

Transmission model Gear ratio Speedometergear ratio

Final gear ratio Vehicle model Engine model

EUR F5M41-1-B8A1 B 31/36 3.454 CJ4A 4G92-MVV

F5M41-1-F8A1 A 31/36 3.714 CJ4A, CK4A 4G92-MPI

F5M41-1-R8A A 31/36 4.052 CJ1A, CK1A 4G13

EXP F5M41-1-F8A1 A 31/36 3.714 CJ4A, CK4A 4G92-MPI

F5M41-1-R8A A 31/36 4.052 CJ1A, CK1A 4G13

F5M41-1-R8A A 31/36 4.052 CJ2A, CK2A 4G15

F5M42-1-Y8A C 31/36 4.625 CK4A 4G92-MIVEC




EUR F5M42-1-F7N D 30/36 3.722 EA2A, EA2W 4G63

F5M42-2-F6N2 F 29/36 3.722 EA5A, EA5W 6A13

F5M42-2-F6N5 E 29/36 3.722 EA6A, EA6W 4D68

EXP F5M42-1-F6N4 D 29/36 3.722 EA2A 4G63-MPI

F5M42-1-F7N D 30/36 3.722 EA2A 4G63-MPI

F5M42-1-R6N2 D 29/36 4.058 EA1A 4G93

F5M42-1-R6N3 D 29/36 4.058 EA2A 4G63-CARB

F5M42-2-F6N2 F 29/36 3.722 EA5A 6A13

F5M42-2-V6N D 29/36 4.312 EA4A 6A12

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MANUAL TRANSMISSION (E–W) – Specifications22B-1-2




EUR F5M41-1-B8A2 B 31/36 3.454 CJ4A 4G92

F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M41-1-R8A1 A 31/36 4.052 CK1A, CJ1A 4G13

F5M42-2-F7N2 D 30/36 3.722 EA2A, EA2W 4G63

F5M42-1-F8A4 G 31/36 3.722 DA2A 4G93-GDI

F5M42-2-F6NA E 29/36 3.722 EA6A, EA6W 4D68

F5M42-2-F6N7 F 29/36 3.722 EA5A, EA5W 6A13

EXP F5M41-1-F8A5 A 31/36 3.714 CJ4A, CK4A 4G92

F5M41-1-R8A1 A 31/36 4.052 CJ1A, CK1A 4G13

F5M41-1-R8A1 A 31/36 4.052 CJ2A, CK2A 4G15

F5M42-1-R6N6 D 29/36 4.058 EA1A 4G93

F5M42-1–F6N9 D 29/36 3.722 EA2A 4G63

F5M42-2-R6N8 E 29/36 4.058 EA6A 4D68


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MANUAL TRANSMISSION (E–W) – Specifications 22B-1-2a




EUR F5M42-1-V5A4 D 28/36 4.312 N61W 4G93-GDI

F5M42-2-R5A3 G 28/36 4.058 N84W 4G64-GDI

W5M42-1-V5A1 H 28/36 4.352 N94W 4G64-GDI

F5M42-1-F8A4 G 31/36 3.722 DA2A 4G93-GDI

F5M42-2-F7N2 D 30/36 3.722 EA2A, EA2W 4G93

F5M42-2-F6NC G 29/36 3.722 EA3A, EA3W 4G64-GDI

F5M42-2-F6N7 F 29/36 3.722 EA5A, EA5W 6A13

F5M42-2-F6NA E 29/36 3.722 EA6A, EA6W 4D65

EXP F5M42-1-R6N6 D 29/36 4.058 EA1A 4G93

F5M42-1-R6N7 D 29/36 4.058 EA2A 4G63

F5M42-1-F6N9 D 29/36 3.722 EA2A 4G63

F5M42-1-F7N1 D 30/36 3.722 EA2A 4G63

F5M42-2-V6N1 D 29/36 4.312 EA4A 6A12-MIVEC

F5M42-2-F6N7 F 29/36 3.722 EA5A 6A13

F5M42-2-R6N8 E 29/36 4.058 EA6A 4D56

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

MMAL F5M41-1-F8A5 A 31/36 3.714 CJ2A, CK2A 4G15

F5M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64


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EUR F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13

F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M41-1-B8A2 B 31/36 3.454 CJ4A 4G92-MVV

F5M42-1-R7A2 G 30/36 4.058 DA2A 4G93-GDI

F5M42-1-V5A4 D 28/36 4.312 N61W 4G93-GDI

F5M42-2-R5A3 G 28/36 4.058 N64W, N84W 4G64-GDI

W5M42-1-V5A1 H 28/36 4.352 N94W 4G64-GDI

EXP F5M41-1-R8A1 A 31/36 4.052 CJ1A, CK1A 4G13

F5M41-1-F8A5 A 31/36 3.714 CJ4A, CK4A 4G92

F5M42-1-R6N6 D 29/36 4.058 EA1A 4G93

F5M42-1-R6N7 D 29/36 4.058 EA2A 4G63

F5M42-1-F6N9 D 29/36 3.722 EA2A, EA2W 4G63

F5M42-2-F6N7 F 29/36 3.722 EA5A 6A13

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

MMAL F5M42-2-R5A2 D 28/36 4.058 N84W 4G64


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MANUAL TRANSMISSION (E–W) – Specifications 22B-1-2c




EUR F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13

F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M42-1-F8AC I 31/36 3.722 DG5A 4G93

F5M42-1-R7A2 G 30/36 4.058 DA2A 4G93

F5M42-2-F7N2 D 30/36 3.722 EA2A, W 4G63

F5M42-2-F6NC G 29/36 3.722 EA3A, W 4G64

F5M42-2-F6N7 F 29/36 3.722 EA5A, W 6A13

F5M42-2-V5A D 28/36 4.312 N63W 4G63

F5M42-2-R5A3 G 28/36 4.058 N64W 4G64

EXP F5M41-1-R8A1 A 31/36 4.052 CJ1A, CJ2A 4G13, 4G15

F5M41-1-R7B A 30/36 4.052 CS1A, CS3A 4G13, 4G18

F5M41-1-R8B A 31/36 4.052 CS1A, CS3A 4G13, 4G18

F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M42-1-F6N9 D 29/36 3.722 EA2W 4G63

F5M42-1-F7N1 D 30/36 3.722 EA2W 4G63

F5M42-1-R6N6 D 29/36 4.058 EA1A 4G93

F5M42-2-R6N7 D 29/36 4.058 EA2A 4G63

F5M42-1-F6N9 D 29/36 3.722 EA2A 4G63

F5M42-2-F6N7 F 29/36 3.722 EA5A 6A13

F5M42-2-R6N8 E 29/36 4.058 EA6A 4D68

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

MMAL F5M41-1-F8A5 A 31/36 3.714 CJ2A, CK2A 4G15

F5M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64


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MANUAL TRANSMISSION (E–W) – Specifications22B-1-2d




EUR F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13

F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M41-1-R8B A 31/36 4.052 CS3A 4G18

F5M42-1-F8AC I 31/36 3.722 DG5A 4G93

F5M42-1-R7A2 G 30/36 4.058 DA2A 4G93

F5M42-2-V5A D 28/36 4.312 N83W 4G63

F5M42-2-R5A3 G 28/36 4.058 N84W 4G64

W5M42-1-V5A1 H 28/36 4.352 N94W 4G64

EXP F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M41-1-R8A1 A 31/36 4.052 CJ1A, CJ2A 4G13, 4G15

F5M42-2-F6N7 F 29/36 3.722 EA5A 6A13

F5M42-1-R6N6 D 29/36 4.058 EA1A 4G93

F5M42-1-R6N7 D 29/36 4.058 EA2A 4G63

F5M42-1-F6N9 D 29/36 3.722 EA2A, W 4G63

F5M42-2-R6N8 E 29/36 4.058 EA6A 4D68

F5M41-1-R7B A 30/36 4.052 CS1A, CS3A 4G13, 4G18

F5M41-1-R8B A 31/36 4.052 CS1A, CS3A 4G13, 4G18

F5M41-1-V7B A 30/36 4.333 CS1A 4G13

F5M41-1-V8B1 A 31/36 4.333 CS1A 4G13

F5M42-1-R7A2 G 30/36 4.058 DA3A 4G93

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

MMAL F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

F5M41-1-F8A5 A 31/36 3.714 CJ2A 4G15

F4M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93


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MANUAL TRANSMISSION (E–W) – Specifications 22B-1-2e




EUR F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13

F5M42-2-V5A D 28/36 4.312 N83W 4G64

F5M42-2-R5A3 G 28/36 4.058 N84W 4G64

W5M42-1-V5A1 H 28/36 4.325 N94W 4G64

F5M42-1-R7A2 G 30/36 4.058 DA2A 4G93

EXP F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92

F5M41-1-R8A1 A 31/36 4.052 CJ1A, CJ2A 4G13, 4G15

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

F5M41-1-R7B1 A 30/36 4.052 CS1A, CS3A 4G13, 4G18

F5M41-1-R8B1 A 31/36 4.052 CS1A, CS3A 4G13, 4G18

MMAL F5M41-1-F8A5 A 31/36 3.714 CJ2A 4G15

F5M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93

F5M42-2-R5A2 D 28/36 4.058 N84W 4G64

F5M42-1-F8B2 F 31/36 3.722 CS6A 4G93


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MANUAL TRANSMISSION (E–W) – Specifications22B-1-2f

GEAR RATIO TABLE

A B C D E F G

1st 3.583 3.727 3.071 3.583 3.583 3.583 3.583

2nd 1.947 1.947 1.947 1.947 1.947 1.947 1.947

3rd 1.343 1.343 1.379 1.379 1.379 1.379 1.266

4th 0.976 0.976 1.030 1.030 1.030 1.030 0.970

5th 0.804 0.804 0.767 0.820 0.733 0.767 0.767

Reverse 3.416 3.416 3.363 3.363 3.363 3.363 3.363

H I

1st 3.583 3.583

2nd 1.947 1.947

3rd 1.266 1.2664th 0.970 0.970

5th 0.767 0.820

Reverse 3.363 3.363

Transfer 0.3018 –

SERVICE SPECIFICATIONS

Items Allowable range Limit

Input shaft front bearing end play mm –0.01–0.12 –

Input shaft rear bearing end play mm –0.01–0.09 –

Input shaft rear bearing end play mm –0.01–0.12 –

Input shaft 5th speed gear end play mm –0.01–0.09 –

Output shaft front bearing end play mm –0.01–0.12 –

Output shaft rear bearing end play mm –0.01–0.09 –

Output shaft 3rd speed gear end play mm –0.01–0.09 –

Differential case end play mm 0.05–0.17 –

Differential case pinion backlash mm 0–0.150 –

Differential case preload mm 0.05–0.11 –

NOTE: Standard play = 0 mm


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MANUAL TRANSMISSION (E–W) – Specifications 22B-1-2g

Items Allowable range Limit

Center differential case pinion backlash mm 0.025–0.150 –

Center differential case preload mm 0.05–0.11 –

Synchronizer ring back surface to gear clearance mm – 0.5

NOTE: Standard play = 0 mm

SEALANTS AND ADHESIVES

TRANSMISSION

Items Specified sealants and adhesives

Clutch housing–transmission case mating surface MITSUBISHI genuine sealant part No. MD997740

Control housing–transmission case mating surfaceor equ va en

Under cover–transmission case mating surface

Air breather 3M SUPER WEATHERSTRIP No. 8001 orequivalent

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

Center differential drive gear bolt

Front bearing retainer bolt (countersink head bolt)

TRANSFER

Item Specified sealant

Air breather 3M SUPER WEATHERSTRIP No. 8001 orequivalent

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MANUAL TRANSMISSION (E–W) – Specifications22B-1-2h

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MANUAL TRANSMISSION (E- W) - Specifications 22B-1-3

FORM-IN-PLACE GASKET

The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that thegasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Toothick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessaryto apply the gasket evenly without a break, while observing the correct bead size.Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the

metallic flange areas.DISASSEMBLY

The parts assembled with the FIPG can be easily disassembled without use of a special method. In somecases, however, the sealant between the joined surfaces may have to be broken by lightly striking witha mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joinedsurfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.

Surface PreparationThoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraperor wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make surethat there are no oils, greases and foreign substances deposited on the application surfaces. Do not forgetto remove the old sealant remaining in the bolt holes.

FORM-IN-PLACE GASKET APPLICATIONWhen assembling parts with the FIPG, you must observe some precautions, but the procedures is verysimple as in the case of a conventional precut gasket.

Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolthole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened.While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts aremounted, make sure that the gasket is applied to the required area only. In addition, do not apply anyoil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour)has passed after installation is completed.The FIPG application procedure may vary on different areas. Observe the procedure described in thetext when applying the FIPG.

LUBRICANTS

TRANSMISSION

Items Specified lubricants

Drive shaft oil seal lip area Hypoid gear oil SAE 75W-85W conforming to API

Control shaft oil seal lip areaclassification GL-4 or higher

Input shaft oil seal lip area MITSUBISHI genuine grease part No. 0101011 or

Select lever shoe

equivalent

TRANSFER

Items Specified lubricants

Drive shaft oil seal lip area Hypoid gear oil SAE 75W-85W conforming to API

Front differential oil seal lip areaclassification GL-4 or higher

Each O-ring

PWEE9508-EE Jun. 1998Mitsubishi Motors Corporation Revised

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SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT

Part name Thickness mm Identificationsymbol

Part No.

Snap ringf f f

2.24 None MD706537

play) 2.31 Blue MD706538

2.38 Brown MD706539

Snap ringf f

2.31 Black (2) MD747149

play ....F5M41)f f

2.35 None MD746561or a us men o ou pu s a rear ear ng en

play ....F5M42, W5M42) 2.39 Blue MD746562

2.43 Brown MD746563

2.47 Green MD746564

2.51 White MD746565

2.55 Yellow MD746566

2.59 Black MD746567

2.63 Orange MD746568

2.67 Blue MD746569

2.71 Brown MD746570

Thrust plate: F5M42, W5M42f f

2.82 0 MD748015

end play) 2.86 2 MD748016

2.90 3 MD748017

2.94 5 MD748018

2.98 6 MD748019

3.02 7 MD748020

3.06 8 MD748021

3.10 9 MD748022

Snap ringf f f

1.43 Green (2) MD746708

play)f f

1.51 White (2) MD746709

play ....F5M42, W5M42) 1.59 Yellow (2) MD746710


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MANUAL TRANSMISSION (E- W) - Specifications 22B-1-5

Part name Part No.Identificationsymbol

Thickness mm

Snap ring: F5M41 2.31 Black (2) MD748800(For adjustment of output shaft rear bearing endplay) 2.35 None MD748801

2.39 Blue MD748802

2.43 Brown MD748803

2.47 Green MD748804

2.51 White MD748805


2.59 Black MD748807


2.67 Blue MD748809

2.71 Brown MD748810

Snap ring: F5M41 2.81 Green MD748782(For adjustment of output shaft 3rd speed gearend play) 2.85 White MD748783


2.93 Black MD748785


3.01 Red MD748787

3.05 Pink MD748788

3.09 Blue MD748789

Snap ring: F5M42, W5M42 2.81 Green MD745799(For adjustment of output shaft 3rd speed gearend play) 2.85 White MD745800


2.93 Black MD745802


3.01 Red MD745804

3.05 Pink MD745805

3.09 Blue MD745806


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MANUAL TRANSMISSION (E- W) - Specifications22B-1-6


Thickness mm

Spacer: F5M41 0.77 77 MD754476(For adjustment of differential case end play)

0.86 86 MD720938

0.95 95 MD720941

1.04 04 MD720944

1.13 D MD700270

1.22 G MD700271

1.31 E MD706574

1.40 None MD706573

1.49 C MD706572

1.58 B MD706571

1.67 A MD706570

1.76 F MD706575


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Part name Thickness mm Identificationsymbol

Part No.

Spacer: F5M42f ff

0.71 71 MD754475

0.74 74 MD727660

0.77 77 MD754476

0.80 80 MD727661

0.83 83 MD720937

0.86 86 MD720938

0.89 89 MD720939

0.92 92 MD720940

0.95 95 MD720941

0.98 98 MD720942

1.01 01 MD720943

1.04 04 MD720944

1.07 07 MD720945

1.10 J MD710454

1.13 D MD700270

1.16 K MD710455

1.19 L MD710456

1.22 G MD700271

1.25 M MD710457


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Thickness mm

Spacer: W5M42f ff

0.74 74 MD727660

preload) 0.77 77 MD745476

0.80 80 MD727661

0.83 83 MD720937

0.86 86 MD720938

0.89 89 MD720939

0.92 92 MD720940

0.95 95 MD720941

0.98 98 MD720942

1.01 01 MD720943

1.04 04 MD720944

1.07 07 MD720945

1.10 J MD710454

1.13 D MD700270

1.16 K MD710455

1.19 L MD710456

1.22 G MD700271

1.25 M MD710457

1.28 N MD710458

1.31 E MD706574

Spacer: F5M41, F5M42f ff

0.72 – 0.79 – MA180862

0.85 – 0.90 – MA180861

0.94 – 0.98 – MA180860

1.02 – 1.06 – MA180875

1.06 – 1.10 – MR581570

1.12 – 1.16 – MA180876

1.16 – 1.20 – MR581571

Spacer: W5M42f ff

0.48 – 0.55 – MD744236

backlash) 0.56 – 0.65 – MD744235

0.66 – 0.73 – MD744234

0.74 – 0.81 – MD744233

0.82 – 0.89 – MD744232


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TORQUE SPECIFICATIONS

TRANSMISSION

Items Nm

Under cover mounting bolt 6.9

Interlock plate bolt 30

Clutch housing–transmission case mounting bolt 44

Clutch release bearing retainer mounting bolt 9.8

Control housing mounting bolt 18

Shift cable bracket mounting bolt 18

Speedometer gear mounting bolt 3.9

Stopper bracket mounting bolt 19

Select lever mounting bolt 18

Select lever mounting nut 11

Center differential flange mounting screw 3.9

Center differential drive gear mounting bolt 132

Differential drive gear mounting bolt 132

Back-up lamp switch 32

Front bearing retainer mounting bolt 18

Poppet spring 32

Restrict ball 32

Reverse idler gear shaft mounting bolt 48

Reverse shift lever mounting bolt 18

Roll stopper bracket mounting bolt 70

Oil temperature sensor 22

Connector bracket mounting bolt 18

Clutch fluid line bracket mounting bolt 18

TRANSFER

Items Nm

Transfer cover mounting bolt 23

Transmission – transfer mounting bolt 69


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MANUAL TRANSMISSION (E- W) - Special Tools 22B-2-1

2. SPECIAL TOOLS

TRANSMISSION

Tool Number Name Use

MB990926 Installer adapter Installationof clutchhousing input shaft oil seal

MB990927 Installer adapter Installation of sealing cap

MB990930 Installer adapter Removal of center differential taper rollerbearing

MB990934 Installer adapter Installation of roller bearing outer race

MB990935 Installer adapter Installation of differential case taper rollerbearing outer race

MB990937 Installer adapter Installation of center differential taper rollerbearing

MB990938 Handle Use with Installer adapter

MD998325 Differential oil sealinstaller

Installation of differential oil seal


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MANUAL TRANSMISSION (E- W) - Special Tools22B-2-2

Tool UseNameNumber

MD998346 Bearing outer raceremover

Removal of roller bearing outer race

MD998772 Valve spring com-pressor Removal of roller bearing outer race

MD998801 Bearing remover Installationand removalof gears, bearingsandsleeves

MD998812 Installer cap Use with Installer and Installer adapter

MD998813 Installer-100 Use with Installer cap and Installer adapter

MD998814 Installer-200 Use with Installer cap and Installer adapter

MD998816 Installer adapter(30)

Installation of input shaft front bearing


Installation of input shaft front bearing, output shaft rear bearing


Installation of input shaft rear bearing, rollerbearing inner race, reverse gear, needle rollerbearing, reverse gear bearing sleeve and reverse bearing sleeve


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MANUAL TRANSMISSION (E- W) - Special Tools 22B-2-3

Tool UseNameNumber


Installation of 5th-reverse speed synchronizerhub, differential case bearing, 4th speed gearand 5th speed gear sleeve

MD998820 Installer adapter(42) Installation of 5th speed gear sleeve, 2ndspeed gear sleeve


Installation of 1st speed gear sleeve,1st-2ndspeed synchronizer hub , 2nd speedgear sleeve and 3rd speed gear

MD998823 Installer adapter

(48)

Installation of differential case taper roller

bearing inner race


Installation of 4th speed gear sleeve and 5thspeed gear


Installation of 1st-2nd speed synchronizer hub,3rd-4th speed synchronizer hub and 1st speedgear sleeve


Installation of 3rd-4th speed synchronizer hub

MD998917 Bearing remover Installationand removalof gears, bearingsandsleeves

MD999566 Claw Removal o f differential c ase taper r oller bearingouter race


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MANUAL TRANSMISSION (E- W) - Special Tools22B-2-4

TRANSFER

Tool Number Name Use

MB990887 Arm bush removerand installer ring

Installation of transfer oil seal

MB990891 Arm bush removerand installer base

Installation of transfer oil seal

MB990933 Installer adapter Installation of transfer cover oil seal

MD998304 Oil seal installer Installation of transfer extension housing oilseal

MD998800 Oil seal installer Installation of transfer cover oil seal


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MANUAL TRANSMISSION (E–W) – Transmission 22B-3-1

PWEE9508-A Nov. 1995Mitsubishi Motors Corporation Added

3. TRANSMISSION

DISASSEMBLY AND REASSEMBLY

1

2 4

5

69

8

7

10

11

32 Nm

18 Nm

70 Nm

70 Nm

1

3

3.9 Nm

Disassembly steps

1. Roll stopper bracket2. Insulator washer 3. Shift cable bracket

M 4. Select leverL 5. Speedometer gear

6. Back-up lamp switch7. Gasket8. Restrict ball9. Gasket

10. Poppet spring11. Gasket


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13

12

14

15

16

17

18

19

21

22

23

24

25

26

27

18 Nm

44 Nm

30 Nm

18 Nm

48 Nm

TFM0719

20

Apply gear oil to allmoving parts beforeinstallation.

Disassembly steps

12. Interlock plate bolt13. GasketK 14. Control housing

15. Neutral return springJ 16. Reverse idler gear shaft bolt

17. GasketA I 18. Sealing capB H 19. Transmission case

C G 20. Reverse idler gear shaft21. Reverse idler gear22. Reverse shift lever shoe23. Reverse shift lever

F 24. Oil guide25. Magnet holder26. Magnet

E 27. Spacer


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MANUAL TRANSMISSION (E- W) - Transmission 22B-3-3

PWEE9508-AE Nov. 1995Mitsubishi Motors Corporation Added

Lubricate all internalparts with gear oil dur-ing reassembly.

18 Nm

29

30

31

32

33

34

35

36

37 38

39

40

41

42

43

44

45

46

TFM0720

Disassembly steps

"DA 29. Spring pin30. 1st-2nd speed shift rail31. 1st-2nd speed shift fork

"DA 32. Spring pin"DA 33. Spring pin

AD" "CA 34. 5th speed shift railAD" "CA 35. 5th speed shift forkAD" "CA 36. Reverse shift lugAD" "CA 37. Snap ring

AD" "CA 38. Reverse interlock railAD" "CA 39. Steel ballAD" "CA 40. 3rd-4th speed shift railAD" "CA 41. 3rd-4th speed shift fork

"BA 42. Front bearing retainerAE" "AA 43. Input shaftAE" "AA 44. Output shaft

45. Differential46. Clutch housing

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DISASSEMBLY SERVICE POINTS

AA" SEALING CAP REMOVAL

AB" TRANSMISSION CASE REMOVAL

Expand the snap ring to remove it from the snap ring grooveof the ball bearing.

NOTEExpansion of the snap ring causes the snap ring groove toget out of position because of the output shaft’s own weight.

AC" REVERSE IDLER GEAR SHAFT REMOVAL

Shift the 3rd-4th speed synchronizer sleeve toward the 4thspeed side.

AD" 3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEEDSHIFT FORK / 5TH SPEED SHIFT FORK / SNAPRING / REVERSE SHIFT LUG / 5TH SPEEDSHIFT RAIL / STEEL BALL / REVERSEINTERLOCK RAIL REMOVAL

(1) While sliding the reverse shift lug in the direction shown,remove the 5th speed shift fork, 5th speedshift rail, reverseshift lug, snap ring, steel ball and reverse interlock rail.

(2) While sliding the 3rd-4th speed shift rail in the directionshown, remove it together with the shift fork.

Sealing cap

Snap ring

3rd-4th speed syn-chronizer sleeve

Reverse shift lug

3rd-4thspeedshift rail

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E INPUT SHAFT / OUTPUT SHAFT REMOVAL

Remove the input and output shafts together.

ADJUSTMENT BEFORE REASSEMBLY

SPACER SELECTION FOR DIFFERENTIAL CASE ENDPLAY ADJUSTMENT

(1) Put solders (about 10 mm long, 1.6 mm in diameter) inthe illustrated positions of the transmission case and installthe differential.

(2) Install the clutch housing and tighten the bolts to thespecified torque.

(3) If the solders are not crushed, put larger diameter soldersand repeat Steps (1) and (2).

(4) Measure the thickness (T) of the crushed solder with amicrometer and select a spacer according to the followingequation.

Spacer thickness: (T – 0.05 mm) to (T – 0.17 mm)

REASSEMBLY SERVICE POINTS

A OUTPUT SHAFT / INPUT SHAFT INSTALLATION

While placing the reverse brake cone detent in the illustratedposition, install the input and output shafts together.

B FRONT BEARING RETAINER INSTALLATION

Apply a sealant to the front bearing retainer mounting bolts(countersunk bolts only).

Specified sealant:3M STUD Locking No. 4170 or equivalent


Output shaft

Input shaft

Solders

Detent

2 – 3 mm

5 – 7 mm

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"CA REVERSE INTERLOCK RAIL / STEEL BALL /5TH SPEED SHIFT RAIL / REVERSE SHIFT LUG/ SNAP RING / 5TH SPEED SHIFT FORK /3RD-4TH SPEED SHIFT FORK / 3RD-4TH SPEEDSHIFT RAIL INSTALLATION

(1) Install the 3rd-4th shift rail and fork.

(2) Install the reverse interlock rail, steel ball, 5th speed shiftrail, 5th speed shift fork, reverse shift lug and snap ringin the illustrated positions.

(3) While sliding the reverse shift lug in the direction shown,install the 5th speed shift fork, 5th speed shift rail, reverseshift lug, snap ring, steel ball and reverse interlock rail.

"DA SPRING PIN INSTALLATION

3rd-4thspeedshift rail

3rd-4thspeedshiftfork

5thspeedshift rail

5th speed shift fork

Reverse interlockrail

Steel ball(inside)

Reverse shift lug

Snap ring

5th speed shift rail

Reverseinterlock rail

Steel ball

Reverseshift lug

Snap ring

Reverseshift lug

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"EA SPACER INSTALLATION

Install the spacer selected in the section “ADJUSTMENTBEFORE REASSEMBLY”.

"FA OIL GUIDE INSTALLATION

"GA REVERSE IDLER GEAR SHAFT INSTALLATION

(1) Shift the 3rd-4th speed synchronizer sleeve toward the4th speed side.

(2) Face the threaded hole of the reverse idler gear shafttoward the direction shown.

"HA TRANSMISSION CASE INSTALLATION

(1) Apply a 1.5 mm bead of sealant to the illustrated positionsof the transmission case.

Specified sealant:MITSUBISHI genuine sealant part No. MD997740or equivalent

CautionSqueeze out the sealant uniformly, while making surethat it is not broken or excessively applied.

Oilguide

3rd-4th speed synchronizer sleeve

Reverseidler gearshaft

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(2) Install the transmission case and expand the snap ring.(3) Tighten the transmission case mounting bolts to the

specified torque.

NOTEPlace the transmission upside down and let the snap ringfit in the groove by taking advantage of the output shaft’sown weight.

"IA SEALING CAP INSTALLATION

Press-fit the sealing cap allthe way up to theillustrated position.

"JA REVERSE IDLER GEAR SHAFT BOLTINSTALLATION

Using a screwdriver (8 mm in shaft diameter), center the bolthole.

"KA CONTROL HOUSING INSTALLATION

Apply a 1.5 mm bead of sealant to the illustrated positionof the transmission case.

Specified sealant:MITSUBISHI genuine sealant part No. MD997740 orequivalent

CautionSqueeze out the sealant uniformly, while making sure thatit is not broken or excessively applied.

Snap ring

Sealing cap

MB990938

MB990927

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4. TRANSMISSION


12

2

3

5 6

810

911

32 Nm

18 Nm

70 Nm

3.9 Nm

70 Nm

1

3

13

1415

16

22 Nm

18 Nm

69 Nm

7


4

TFM1069

Disassembly steps

1. Transfer 2. O-ring 3. Roll stopper bracket

4. Insulator washer 5. Shift cable bracketK 6. Select leverJ 7. Speedometer gear

8. Back-up lamp switch9. Gasket

10. Poppet spring11. Gasket12. Connector bracket 13. Clutch fluid line blacket 14. Oil temperature sensor harness 15. Oil temperature sensor 16. Gasket


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20

19

21

2223

24

25

26

27

28

29

30

17

18

18 Nm

44 Nm

30 Nm

6.9 Nm

48 Nm

TFM0597


Disassembly steps

17. Interlock plate bolt18. GasketI 19. Control housing

20. Neutral return springH 21. Under cover

22. Reverse idler gear shaft bolt23. Gasket24. Reverse idler gear

A G 25. Sealing capB F 26. Transmission case

E 27. Outer raceD 28. Spacer

29. Magnet holder30. Magnet


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18 Nm

34

35

36

37

38

39

40

41

42

43

30

31

32

33

TFM0598


Disassembly steps

"CA 30. Spring pin31. 1st-2nd speed shift rail32. 1st-2nd speed shift fork

"CA 33. Spring pin"CA 34. Spring pin

AC" "BA 35. 3rd-4th speed shift railAC" "BA 36. 3rd-4th speed shift forkAC" "BA 37. 5th-reverse speed shift railAC" "BA 38. 5th-reverse speed shift fork

39. Front bearing retainerAD" "AA 40. Input shaftAD" "AA 41. Output shaft

42. Differential43. Clutch housing


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AA" SEALING CAP REMOVAL

Drive a screwdriver into the sealing cap at the center, thenpry off the sealing cap with the screwdriver.

AB" TRANSMISSION CASE REMOVAL

Expand the snap ring to remove it from the snap ring grooveof the ball bearing.

NOTEExpansion of the snap ring causes the snap ring groove toget out of position because of the output shaft’s own weight.

AC" 3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEEDSHIFT FORK / 5TH-REVERSE SPEED SHIFT RAIL/ 5TH-REVERSE SPEED SHIFT FORK REMOVAL

(1) Shift the 3rd-4th speed shift fork and 5th-reverse speedshift fork in the direction shown.

(2) Slide the 3rd-4th speed shift rail and 5th-reverse speedshift rail in the direction shown and remove them togetherwith the shift fork.

AD" INPUT SHAFT / OUTPUT SHAFT REMOVAL

Remove the input and output shafts together.


Sealing cap

Snap ring

3rd-4th speedshift fork

5th-reversespeed shiftfork

5th-reversespeed shift rail

3rd-4th speedshift rail

Input shaft

Output shaft

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ADJUSTMENT BEFORE REASSEMBLY

SPACER SELECTION FOR DIFFERENTIAL CASEPRELOAD ADJUSTMENT

(1) Put solders (about 10 mm long, 1.6 mm in diameter) inthe illustrated positions of the transmission case and installthe bearing outer race and differential.

(2) Install the clutch housing and tighten the bolts to thespecified torque.

(3) If the solders are not crushed, put larger diameter soldersand repeat Steps (1) and (2).

(4) Measure the thickness (T) of the crushed solder with amicrometer and select a spacer according to the followingequation.

Spacer thickness:(T + 0.05 mm) to (T + 0.11 mm)


"AA OUTPUT SHAFT / INPUT SHAFT INSTALLATION

Install the input and output shafts together.

"BA 5TH-REVERSE SPEED SHIFT FORK /5TH-REVERSE SPEED SHIFT RAIL / 3RD-4THSPEED SHIFT FORK / 3RD-4TH SPEED SHIFTRAIL INSTALLATION

(1) Shift the 3rd-4th speed synchronizer sleeve and5th-reverse speed synchronizer sleeve in the directionshown.

(2) Install the 3rd-4th speed shift rail and fork and the5th-reverse speed shift rail and fork.


Solders

Input shaftOutput shaft

3rd-4thspeedsynchro-nizersleeve

5th-reversespeedsynchro-nizer sleeve

3rd-4th speed shift rail

3rd-4th speed shift fork

5th-reversespeed shiftfork


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(3) While fitting each shift fork in the sleeve, slide the shiftrails in the direction shown and install.

"CA SPRING PIN INSTALLATION

Install the spring pin such that its slit may face in the axialdirection of the shift rail.

"DA SPACER INSTALLATION

Install the spacer selected in the section “ADJUSTMENTBEFORE REASSEMBLY”.

"EA OUTER RACE INSTALLATION

Use the special tools to install the outer race.

"FA TRANSMISSION CASE INSTALLATION

(1) Apply a 1.5 mm bead of sealant to the illustrated positionof the transmission case.

Specified sealant:MITSUBISHI genuine sealant part No. MD997740or equivalent

CautionSqueeze out the sealant uniformly, while making surethat it is not broken or excessively applied.



3rd-4th speedshift rail

Shift rail

Spring pin

Slit

Shift fork 2.5 mm

MB990938

MB990935

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(2) Install the transmission case and expand the snap ring.(3) Tighten the transmission case to the specified torque.

NOTEPlace the transmission upside down and let the snap ringfit in the groove by taking advantage of the output shaft’sown weight.

"GA SEALING CAP INSTALLATION

Press-fit the sealing cap allthe way up to theillustrated position.

"HA UNDER COVER INSTALLATION




"IA CONTROL HOUSING INSTALLATION





Snap ring

Sealing cap

MB990938

MB990927

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"JA SPEEDOMETER GEAR INSTALLATION

Apply transmission oil to the O-ring of the speedometer gear.

Transmission oil:Hypoid gear oil SAE 75W-85W conforming to APIclassification GL-4 or higher

"KA SELECT LEVER INSTALLATION

Apply grease to the control shaft sliding portion of the selectlever shoe.

Specified grease:MITSUBISHI genuine grease part No. 0101011 orequivalent

INSPECTION

BACK-UP LAMP SWITCH

(1) Check for continuity between terminals.

Switch condition Continuity

Pressed Not exist

Released Exists

(2) If the above requirements are not met, replace the back-up

lamp switch with a new one.

OIL TEMPERATURE SENSOR

(1) Check for continuity between terminals.

Temperature (°C) Standard value (kW)

20 2.31 - 2.59

110 0.1451 - 0.1491

(2) If the standard value is not met, replace the oil temperaturesensor with a new one.


O-ring

Control shaft

Selectlever shoe

Transmission oil

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MANUAL TRANSMISSION (E- W) - Input Shaft 22B-5-1

5. INPUT SHAFT



TFM0834

18

1920

21

22

23

25

11

24

10

12

13

98

76

5 4

3

2 1

26

27

25

13

14

15

16

17

29

28

Disassembly steps

"MA 1. Snap ring

AA" "LA 2. Ball bearingAB" "KA 3. Reverse brake sleeve

4. Needle roller bearing5. Reverse brake cone6. Reverse brake ring

"DA 7. Synchronizer spring"JA 8. Synchronizer sleeve

AC" "IA 9. 5th-reverse speed synchronizer hub10. Synchronizer ring

"DA 11. Synchronizer spring12. 5th speed gear13. Needle roller bearing

AD" "HA 14. 5th speed gear sleeve

15. 4th speed gear

16. Needle roller bearingAE" "GA 17. 4th speed gear sleeve

18. Synchronizer ring"DA 19. Synchronizer spring"FA 20. Synchronizer sleeve"EA 21. 3rd-4th speed synchronizer hub

22. Synchronizer ring"DA 23. Synchronizer spring

24. 3rd speed gear25. Needle roller bearing

"CA 26. Snap ringAF" "BA 27. Ball bearing

"AA 28. Oil seal29. Input shaft


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18

19

20

21

23

25

11 10

1213

9

8

7

6

5

4

3

2

1

22

14

1516

17

24

21

9


Disassembly steps

"MA 1. Snap ringAA" "LA 2. Ball bearing

3. Collar

"JA 4. Synchronizer sleeveAC" "IA 5. 5th-reverse speed synchronizer hub6. Synchronizer ring


AD" "HA 10. 5th speed gear sleeve11. 4th speed gear12. Needle roller bearing

AE" "GA 13. 4th speed gear sleeve

14. Synchronizer ring"DA 15. Synchronizer spring"FA 16. Synchronizer sleeve

"EA 17. 3rd-4th speed synchronizer hub18. Synchronizer ring"DA 19. Synchronizer spring


"CA 22. Snap ringAF" "BA 23. Ball bearing



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MANUAL TRANSMISSION (E–W) – Input Shaft 22B-5-2a


18

19

20

21

23

25

11 10

1213

9

8

7

6

5

4

3

2

1

22

14

1516

17

24


21

9

Disassembly steps

M 1. Snap ringA L 2. Ball bearing3. Collar

J 4. Synchronizer sleeveC I 5. 5th-reverse speed synchronizer hub

6. Synchronizer ring7. Synchronizer lever8. 5th speed gear9. Needle roller bearing

D H 10. 5th speed gear sleeve11. 4th speed gear12. Needle roller bearing

E G 13. 4th speed gear sleeve

14. Synchronizer ringD 15. Synchronizer springF 16. Synchronizer sleeveE 17. 3rd-4th speed synchronizer hub

18. Synchronizer ringD 19. Synchronizer spring


C 22. Snap ringF B 23. Ball bearing

A 24. Oil seal25. Input shaft


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MANUAL TRANSMISSION (E–W) – Input Shaft 22B-5-2b


A BALL BEARING REMOVAL

B REVERSE BRAKE SLEEVE REMOVAL

Mount a special tool on the 5th speed gear and remove thereverse brake sleeve.

C 5TH-REVERSE SPEED SYNCHRONIZER HUBREMOVAL

Mount a special tool on the 5th speed gear and remove the5th-reverse synchronizer hub.

D 5TH SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the 4th speed gear and remove the5th speed gear sleeve.

E 4TH SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the 3rd speed gear and remove the4th speed gear sleeve.


MD998801

MD998801

MD998917

MD998917

MD998801

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AF" BALL BEARING REMOVAL


"AAOIL SEAL INSTALLATION

Drive in the oil seal all the way up to the illustrated dimension.

"BABALL BEARING INSTALLATION

"CASNAP RING INSTALLATION

Select and install a snap ring so that the input shaft frontbearing end play will have the standard value.

Standard value:-0.01-0.12 mm

"DASYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring securely up to the illustratedposition of the synchronizer ring.

MD998801

3.5 mmOil seal

MD998812

MD998813

MD998817MD998801

Snap ring

Synchronizer spring

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"EA 3RD-4TH SPEED SYNCHRONIZER HUBINSTALLATION

Install the 3rd-4th speed synchronizer hub in such a way thatit will be oriented in the direction shown.

CautionWhen the hub is installed, make sure that the synchronizerring is not caught.

"FA SYNCHRONIZER SLEEVE INSTALLATION

(1) Install the synchronizer sleeve in such a way that it willbe oriented in the direction shown.

(2) When the synchronizer sleeve is installed, make sure thatthe deep groove portion of the synchronizer hub is alignedwith the projecting portion of the sleeve.

"GA4TH SPEED GEAR SLEEVE INSTALLATION

Identification mark

Rear of trans-mission

MD998812

MD998813

MD998826

MD998801

Identificationgroove

Rear of transmission

Synchronizer hub

Synchronizersleeve

MD998812

MD998813

MD998824MD998801

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"HA 5TH SPEED GEAR SLEEVE INSTALLATION

"IA 5TH-REVERSE SPEED SYNCHRONIZER HUBINSTALLATION

Install the 5th-reverse speed synchronizer hub in such a waythat it will be oriented in the direction shown.

CautionWhen the 5th-reverse speed synchronizer hub is installed,make sure that the synchronizer ring is not caught.

"JA SYNCHRONIZER SLEEVE INSTALLATION



MD998801

MD998812

MD998813MD998820

Identification mark


MD998812

MD998819

MD998801



Synchronizer hub

Synchronizersleeve

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"KAREVERSE BRAKE SLEEVE INSTALLATION

"LA BALL BEARING INSTALLATION

"MASNAP RING INSTALLATION

Select and install a snap ring so that the input shaft rearbearing end play will have the standard value.


INSPECTION

INPUT SHAFT

(1) Check the outside diameterof the needle bearing mountingportion for damage, abnormal wear and seizure.

(2) Check the splines for damage and wear.

NEEDLE ROLLER BEARING

(1) Check to ensure that when the input shaft, sleeve andgear are combined and made to rotate, they rotatesmoothly without noise.

(2) Check to ensure that the cage is not deformed.

MD998812

MD998818

MD998801

MD998812

MD998818

MD998801

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SYNCHRONIZER RING

(1) Check to ensure that the clutch gear tooth surfaces arenot damaged and broken.

(2) Check to ensure that the cone inside diameter is notdamaged or worn and that the threads are not crushed.

(3) Press the synchronizer ring against the gear and checkclearance “A”. If “A” is less than the limit, replace.

Limit: 0.5 mm

SYNCHRONIZER SLEEVE AND HUB

(1) Check to ensure that when the synchronizer sleeve andhub are combined and made to slide, they slide smoothlywithout binding.

(2) Check to ensure that the front and rear ends of the sleeveinside surface are not damaged.

SYNCHRONIZER SPRING

Check to ensure that the spring is not sagging, deformedor broken.

SPEED GEARS

(1) Check to ensure that the helical and clutch gear toothsurfaces are not damaged or worn.

(2) Check to ensure that the synchronizer cone surfaces arenot roughened, damaged or worn.

(3) Check to ensure that the gear inside diameter and frontand rear surfaces are not damaged and worn.

PWEE9508-GE Jun. 2000Mitsubishi Motors Corporation Revised

A

Synchronizer r ing Gear

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6. INPUT SHAFT


14

15

16

17

18 19

20

11 10

12

13

9

8

7

6

5

4

3

2

1

16

TFM0591


Disassembly steps

"LA 1. Snap ringAA" "KA 2. Ball bearing

"JA 3. Thrust plate stopper"IA 4. Thrust plate

AB" "HA 5. 5th speed gear6. 4th speed gear7. Needle roller bearing

AC" "GA 8. 4th speed gear sleeve9. Synchronizer ring

"DA 10. Synchronizer spring

"FA 11. Synchronizer sleeve"EA 12. 3rd-4th speed synchronizer hub



"CA 17. Snap ringAD" "BA 18. Ball bearing



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AA" BALL BEARING REMOVAL

Use the special tool to remove the ball bearing.

AB" 5TH SPEED GEAR REMOVAL

Use the special tool to remove the 5th speed gear.

AC" 4TH SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the 3rd gear and remove the 4thspeed gear sleeve.

AD" BALL BEARING REMOVAL



"AA OIL SEAL INSTALLATION

Drive in the oil seal all the way up to the illustrated dimension.


MD998801

MD998801

MD998801

MD998801

Oil seal 3.5 mm

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"BA BALL BEARING INSTALLATION

Use the special tools to install the ball bearing.

"CA SNAP RING INSTALLATION

Select and install a snap ring so that the input shaft frontbearing end play will have the standard value.


"DA SYNCHRONIZER SPRING INSTALLATION


"EA 3RD-4TH SPEED SYNCHRONIZER HUBINSTALLATION

Install the 3rd-4th speed synchronizer hub in such a way thatit will be oriented in the direction shown.



MD998801

MD998812

MD998813

MD998816

Snap ring

Synchronizer spring

Identification mark


MD998801

MD998812

MD998813

MD998825

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"GA 4TH SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 4th speed gear sleeve.

"HA 5TH SPEED GEAR INSTALLATION

Use the special tools to install the 5th speed gear.

"IA THRUST PLATE INSTALLATION

Select and install a thrust plate so that the input shaft 5thspeed gear end play will have the standard value.





Synchronizer sleeve

Synchronizer hub

MD998801

MD998812

MD998813

MD998824

MD998801

MD998812

MD998813

MD998824

Thrust plate

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"JA THRUST PLATE STOPPER INSTALLATION

When the thrust plate is installed, make sure that it is nottilted.

"KA BALL BEARING INSTALLATION


"LA SNAP RING INSTALLATION

Select and install a snap ring so that the input shaft rearbearing end play will have the standard value.


INSPECTION

INPUT SHAFT

(1) Check the outside diameterof the needle bearing mountingportion for damage, abnormal wear and seizure.

(2) Check the splines for damage and wear.


(1) Check to ensure that when the input shaft and gear arecombined and made to rotate, they rotate smoothly withoutlooseness and noise.


Thrust plate stopper

Thrust plate

MD998812

MD998818MD998801

Snap ring

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SYNCHRONIZER RING




Limit: 0.5 mm




SYNCHRONIZER SPRING


SPEED GEARS





GearSynchronizer ring

A

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MANUAL TRANSMISSION (E- W) - Output Shaft 22B-7-1

7. OUTPUT SHAFT


14

15

16

1718

19

20

11

10

12

13

9

8

7

6

5

4

32

1

21

9

22

TFM0715


Disassembly steps

"JA 1. Snap ringAA" "IA 2. Ball bearing

3. Collar4. 5th speed gear5. 4th speed gear

"HA 6. Snap ring7. 3rd speed gear8. 2nd speed gear9. Needle roller bearing

AB" "GA 10. 2nd speed gear sleeve11. Synchronizer ring

"DA 12. Synchronizer spring"FA 13. Synchronizer sleeve"EA 14. 1st-2nd speed synchronizer hub


17. 1st speed gear18. Needle roller bearing

AC" "CA 19. 1st speed gear sleeve"BA 20. Snap ring

AD" "AA 21. Roller bearing inner race22. Output shaft


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23

16

17

18

19

22

11

10

13

15

9

8

7

6

5

4

32

1

21

9

24


12

14

20

Disassembly steps

"JA 1. Snap ringAA" "IA 2. Ball bearing

3. Collar4. 5th speed gear5. 4th speed gear

"HA 6. Snap ring7. 3rd speed gear8. 2nd speed gear9. Needle roller bearing

AB" "GA 10. 2nd speed gear sleeve11. Inner synchronizer ring12. Synchronizer cone

13. Outer synchronizer ring"KA 14. Synchronizer spring"FA 15. Synchronizer sleeve"EA 16. 1st-2nd speed synchronizer hub



AC" "CA 21. 1st speed gear sleeve"BA 22. Snap ring

AD" "AA 23. Roller bearing inner race24. Output shaft


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MANUAL TRANSMISSION (E- W) - Output Shaft 22B-7-2a


AA"BALL BEARING REMOVAL

AB" 2ND SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the synchronizer sleeve and removethe 2nd speed gear sleeve.

AC" 1ST SPEED GEAR SLEEVE REMOVAL

AD"ROLLER BEARING INNER RACE REMOVAL


"AAROLLER BEARING INNER RACE INSTALLATION

PWEE9508-FE July 1999Mitsubishi Motors Corporation Added

MD998801

MD998917

MD998801

MD998917Inner race

MD998801

MD998812

MD998818

Innerrace

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MANUAL TRANSMISSION (E- W) - Output Shaft 22B-7-2b

Intentionally blank


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"BASNAP RING INSTALLATION

Select and install a snap ring so that the output shaft frontbearing end play will have the standard value.


"CA 1ST SPEED GEAR SLEEVE INSTALLATION



"EA 1ST-2ND SPEED SYNCHRONIZER HUBINSTALLATION

Install the 1st-2nd speed synchronizer hub in such a waythat it will be oriented in the direction shown.


Snap ring

MD998812

MD998814

MD998822Sleeve

Synchronizer spring


Identification mark

MD998812

MD998814

MD998822

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"GA2ND SPEED GEAR SLEEVE INSTALLATION

"HASNAP RING INSTALLATION

Select and install a snap ring so that the output shaft 3rdspeed gear end play will have the standard value.


"IA BALL BEARING INSTALLATION


Synchronizer sleeve

Synchronizer hub

MD998812

MD998813

MD998820

Snap ring

MD998812MD998817

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"JA SNAP RING INSTALLATION

Select and install a snap ring so that the output shaft rearbearing end play will have the standard value.


"KASYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring securely inthe illustratedpositionof the outer synchronizer ring.

INSPECTION

OUTPUT SHAFT

Check the splines for damage and wear.


(1) Check to ensure that when the bearing sleeve and gearare combined and made to rotate, they rotate smoothlywithout looseness and noise.


SYNCHRONIZER RING




Synchronizerspring

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Limit: 0.5 mm

OUTER SYNCHRONIZER RING / INNERSYNCHRONIZER RING / SYNCHRONIZER CONE

(1) Check to ensure that the clutch gear tooth surfaces andcone surfaces are not damaged and broken.

(2) Install the outer ring, inner ring and cone, press themagainst the gear, and check clearance “A”. If “A” is lessthan the limit, replace.

Limit: 0.5 mm

CautionWhen the outer ring, inner ring or cone has to bereplaced, make sure that the outer ring, inner ringand cone are replaced as a set.




SYNCHRONIZER SPRING


A

Synchronizer ring Gear

A

Outer ring

Cone

Inner ring

Gear


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SPEED GEARS





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8. OUTPUT SHAFT


14

15

16

17

18

1920

1110

12

13

98

7 6

5

4

3 2

1

21

222324

25

26

2728

29

30

31

32

33

34

13

4


Disassembly steps

"PA 1. Snap ringAA" "OA 2. Ball bearingAB" "NA 3. Reverse gear bearing sleeve

"NA 4. Needle roller bearing"NA 5. Reverse gear


AC" "MA 9. 5th-reverse speed synchronizer hub10. Synchronizer ring


"LA 14. 5th speed gear sleeve"KA 15. 4th speed gear"JA 16. Snap ring

AD" "IA 17. 3rd speed gear

18. 2nd speed gear19. Needle roller bearing

AE" "HA 20. 2nd speed gear sleeve21. Inner synchronizer ring22. Synchronizer cone23. Outer synchronizer ring

"GA 24. Synchronizer spring"FA 25. Synchronizer sleeve"EA 26. 1st-2nd speed synchronizer hub



AF" "CA 31. 1st speed gear sleeve"BA 32. Snap ring

AG" "AA 33. Roller bearing inner race34. Output shaft


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1415

1617

181920

10 11

12

13

98

7

6

5

4

3 2

1

2122

2324

2526

2728 29

30

31

3233

35

13

4

34

36


Disassembly steps

"PA 1. Snap ringAA" "OA 2. Ball bearingAB" "NA 3. Reverse gear bearing sleeve

"NA 4. Needle roller bearing"NA 5. Reverse gear


AC" "MA 9. 5th-reverse speed synchronizer hub10. Synchronizer ring


"LA 14. 5th speed gear sleeve"KA 15. 4th speed gear"JA 16. Snap ring

AD" "IA 17. 3rd speed gear

18. 2nd speed gear19. Needle roller bearing

AE" "HA 20. 2nd speed gear sleeve21. Inner synchronizer ring22. Synchronizer cone

23. Outer synchronizer ring"GA 24. Synchronizer spring"FA 25. Synchronizer sleeve"EA 26. 1st-2nd speed synchronizer hub

27. Inner synchronizer ring28. Synchronizer cone29. Outer synchronizer ring

"GA 30. Synchronizer spring31. 1st speed gear32. Needle roller bearing

AF" "CA 33. 1st speed gear sleeve"BA 34. Snap ring

AG" "AA 35. Roller bearing inner race36. Output shaft


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AA"BALL BEARING REMOVAL


AB"REVERSE GEAR BEARING SLEEVE REMOVAL

Mount a special tool on the reverse gear and remove thereverse gear bearing sleeve.

AC" 5TH-REVERSE SPEED SYNCHRONIZER HUBREMOVAL

Mount a special tool on the 4th speed gear and remove the5th-reverse speed synchronizer hub.

AD" 3RD SPEED GEAR REMOVAL

Mount a special tool on the 2nd speed gear and remove the3rd speed gear.

AE" 2ND SPEED GEAR SLEEVE REMOVAL

Mount a special tool on the 1st speed gear and remove the2nd speed gear sleeve.


MD998917 Ball bearing

MD998801 Sleeve

MD998801

Synchronizer hub

MD998917

3rd speed gear

MD998917Sleeve

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AF" 1ST SPEED GEAR SLEEVE REMOVAL

Use the special tool to remove the 1st speed gear sleeve.

AG"ROLLER BEARING INNER RACE REMOVAL

Use the special tool to remove the roller bearing inner race.


"AAROLLER BEARING INNER RACE INSTALLATION

Use the special tools to install the roller bearing inner race.

"BASNAP RING INSTALLATION

Select and install a snap ring so that the output shaft frontbearing end play will have the standard value.


"CA 1ST SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 1st speed gear sleeve.


MD998801 Sleeve

MD998917 Inner race

MD998801

Inner race

MD998812

MD998818

Snap ring

MD998812

MD998814

MD998825Sleeve

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"EA 1ST-2ND SPEED SYNCHRONIZER HUBINSTALLATION

Install the 1st-2nd speed synchronizer hub in such a waythat it will be oriented in the direction shown.






Synchronizer spring


Identification mark

MD998812

MD998814

MD998825Synchronizer hub



Synchronizer sleeve

Synchronizer hub

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"GASYNCHRONIZER SPRING INSTALLATION


"HA 2ND SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 2nd speed gear sleeve.

"IA 3RD SPEED GEAR INSTALLATION

Use the special tools to install the 3rd speed gear.

"JA SNAP RING INSTALLATION

Select and install a snap ring so that the output shaft 3rdspeed gear end play will have the standard value.


"KA 4TH SPEED GEAR INSTALLATION

Use the special tools to install the 4th speed gear.


Synchronizer spring

Sleeve

MD998812

MD998814

MD998822

3rd speed gear

MD998812

MD998814

MD998822

Snap ring

4th speed gear

MD998812

MD998813

MD998819

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"LA 5TH SPEED GEAR SLEEVE INSTALLATION

Use the special tools to install the 5th speed gear sleeve.

"MA5TH-REVERSE SPEED SYNCHRONIZER HUBINSTALLATION

Install the 5th-reverse speed synchronizer hub in such a waythat it will be oriented in the direction shown.

CautionWhen the 5th-reverse speed synchronizer hub is installed,make sure that the synchronizer ring is not caught.

"NAREVERSE GEAR / NEEDLE ROLLER BEARING /REVERSE GEAR BEARING SLEEVEINSTALLATION

Use the special tools to install the reverse gear, needle rollerbearing and reverse gear bearing sleeve.

"OABALL BEARING INSTALLATION



Sleeve

MD998812

MD998813

MD998819

Identification mark


Synchronizer hub

MD998812

MD998813

MD998819

Reverse gear

MD998812

MD998818

Sleeve

Ball bearing

MD998812

MD998818

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"PA SNAP RING INSTALLATION

Select and install a snap ring so that the output shaft rearbearing end play will have the standard value.


INSPECTION

OUTPUT SHAFT

Check the splines for damage and wear.


(1) Check to ensure that when the bearing sleeve and gearare combined and made to rotate, they rotate smoothlywithout looseness and noise.


SYNCHRONIZER RING




Limit: 0.5 mm


Snap ring

Synchronizer ring Gear

A

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OUTER SYNCHRONIZER RING / INNERSYNCHRONIZER RING / SYNCHRONIZER CONE

(1) Check to ensure that the clutch gear tooth surfaces andcone surfaces are not damaged and broken.

(2) Install the outer ring, inner ring and cone, press themagainst the gear, and check clearance “A”. If “A” is lessthan the limit, replace.

Limit: 0.5 mm

0.3 mm

CautionWhen the outer ring, inner ring or cone has to bereplaced, make sure that the outer ring, inner ring

and cone are replaced as a set.




SYNCHRONIZER SPRING



F5M42-2-R5A3only

AGear

Outer ring

Cone

Inner ring

AGear

Outer ring

Cone

Inner ring

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SPEED GEARS





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MANUAL TRANSMISSION (E- W) - Reverse Idler Gear 22B-9-1

9. REVERSE IDLER GEAR


5

4

3

2

1

TFM0590

Apply gear oil to allmoving parts before

installation.

Disassembly steps

1. Snap ring2. Thrust washer3. Reverse idler gear4. Needle roller bearing5. Reverse idler gear shaft

INSPECTION


(1) Check to ensurethatwhenthe shaft andgear arecombinedand made to rotate, they rotate smoothly withoutloosenessand noise.



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MANUAL TRANSMISSION (E- W) - Speedometer Gear 22B-10-1


10. SPEEDOMETER GEAR


Lubricate all internalparts with gear oil dur-ing reassembly.

4

3

2

1

TFM0593

Disassembly steps

1. e-clip2. Speedometer driven gear3. O-ring4. Sleeve

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MANUAL TRANSMISSION (E- W) - Select Lever 22B-11-1


11. SELECT LEVER


5

4

3

2

1

6

7

8

9

10

11 Nm

TFM0589

Disassembly steps

"AA 1. Dust cover2. Nut3. Spring washer4. Washer5. Select lever bushing

6. Select lever shoe7. Select lever8. Select lever bushing

"AA 9. Dust cover10. Select lever shaft

REASSEMBLY SERVICE POINT

"AADUST COVER INSTALLATIONDust cover

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MANUAL TRANSMISSION (E–W) – Control Housing 22B-12-1


12. CONTROL HOUSING


543

2

1

19 Nm

69

7

8

10

11

12

13

14

1516

17

18

19

20

TFM0916

Disassembly steps

A F 1. Lock pin2. Interlock plate3. Control finger4. Pin5. Return spring6. Stopper plate

E 7. Spring pinD 8. Spring pin

9. Stopper body10. Neutral return spring11. Spacer

12. Control shaft (Except up to MODEL1998 of F5M42-1-F6N4, F7N,R6N3, F5M42-2-F6N2, F6N5 andMODEL 1999)

13. Control shaft (Up to MODEL 1998of F5M42-1-F6N4, F7N, R6N3,F5M42-2-F6N2, F6N5 and MODEL1999)

C 14. Air breather15. Control shaft boot

B 16. Oil sealA 17. Needle bearing

18. Spring washer19. Stopper bracket20. C

f5m42. 41.43 cambio manual

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