Professional Documents
Culture Documents
MANUAL
TRANSMISSION
F5M41, F5M42, W5M42
CONTENTS
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 PLATE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-9
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-2-1
3. TRANSMISSION <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-3-1
4. TRANSMISSION <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-4-1
5. INPUT SHAFT <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-5-1
6. INPUT SHAFT <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-6-1
7. OUTPUT SHAFT <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-7-1
8. OUTPUT SHAFT <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-8-1
9. REVERSE IDLER GEAR <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . 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 <F5M41, F5M42>,
FRONT DIFFERENTIAL <W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-15-1
16. CENTER DIFFERENTIAL <W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-16-1
17. TRANSFER <W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-17-1
Mar. 2002
PWEE9508-I
Revised
22B-0-2
NOTES
22B-0-3
GENERAL INFORMATION
F5M41 <Types with single synchronizer ring for 2nd gear>
6
10
15
14 13
12
11
TFM0809
July 1999
PWEE9508-F
8.
9.
10.
11.
12.
13.
14.
15.
Clutch housing
Release bearing retainer
Input shaft
Differential
1st speed gear
1st-2nd speed synchronizer hub
2nd speed gear
Output shaft
Revised
22B-0-4
10
15
14
13
12
11
July 1999
PWEE9508-F
8.
9.
10.
11.
12.
13.
14.
15.
Clutch housing
Release bearing retainer
Input shaft
Differential
1st speed gear
1st-2nd speed synchronizer hub
2nd speed gear
Output shaft
Revised
22B-0-4a
F5M41 <Types with single synchronizer ring for 2nd gear and synchronizer lever
for 5th gear>
2 3
14
13
12
11
10
1.
2.
3.
4.
5.
6.
7.
Dec. 2000
PWEE9508-H
8.
9.
10.
11.
12.
13.
14.
Added
22B-0-4b
Intentionally blank
Dec. 2000
PWEE9508-H
Added
22B-0-5
F5M42
<Types with single synchronizer ring for 1st gear and double synchronizer ring
for 2nd gear>
4
2
16
15
14
13
12
11
10
1.
2.
3.
4.
5.
6.
7.
8.
July 1999
9.
10.
11.
12.
13.
14.
15.
16.
PWEE9508-F
Output shaft
Differential
1st speed gear
1st-2nd speed synchronizer hub
2nd speed gear
5th speed gear
5th-reverse speed synchronizer hub
Reverse gear
Revised
22B-0-6
F5M42
<Types with double synchronizer ring for both 1st and 2nd gears, types with
double synchronizer ring for 1st gear and triple synchronizer ring for 2nd gear>
4
1
16
15
14
13
12
11
10
1.
2.
3.
4.
5.
6.
7.
8.
July 1999
9.
10.
11.
12.
13.
14.
15.
16.
PWEE9508-F
Output shaft
Differential
1st speed gear
1st-2nd speed synchronizer hub
2nd speed gear
5th speed gear
5th-reverse speed synchronizer hub
Reverse gear
Revised
22B-0-7
10
19 18 17 16 15 14
13
11
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Jun. 1998
11.
12.
13.
14.
15.
16.
17.
18.
19.
PWEE9508-E
Front differential
Transfer driven gear
Center differential
1st speed gear
1st-2nd speed synchronizer hub
2nd speed gear
5th speed gear
5th-reverse speed synchronizer hub
Reverse gear
Added
22B-1-1
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE MODEL 1996
Transmission model
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M41-1-B8A1
31/36
3.454
CJ4A
4G92-MVV
F5M41-1-F8A1
31/36
3.714
CJ4A, CK4A
4G92-MPI
F5M41-1-R8A
31/36
4.052
CJ1A, CK1A
4G13
F5M41-1-F8A1
31/36
3.714
CJ4A, CK4A
4G92-MPI
F5M41-1-R8A
31/36
4.052
CJ1A, CK1A
4G13
F5M41-1-R8A
31/36
4.052
CJ2A, CK2A
4G15
F5M42-1-Y8A
31/36
4.625
CK4A
4G92-MIVEC
EXP
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M42-1-F7N
30/36
3.722
EA2A, EA2W
4G63
F5M42-2-F6N2
29/36
3.722
EA5A, EA5W
6A13
F5M42-2-F6N5
29/36
3.722
EA6A, EA6W
4D68
F5M42-1-F6N4
29/36
3.722
EA2A
4G63-MPI
F5M42-1-F7N
30/36
3.722
EA2A
4G63-MPI
F5M42-1-R6N2
29/36
4.058
EA1A
4G93
F5M42-1-R6N3
29/36
4.058
EA2A
4G63-CARB
F5M42-2-F6N2
29/36
3.722
EA5A
6A13
F5M42-2-V6N
29/36
4.312
EA4A
6A12
EXP
Dec. 2000
PWEE9508-H
Revised
22B-1-2
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M41-1-B8A2
31/36
3.454
CJ4A
4G92
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M41-1-R8A1
31/36
4.052
CK1A, CJ1A
4G13
F5M42-2-F7N2
30/36
3.722
EA2A, EA2W
4G63
F5M42-1-F8A4
31/36
3.722
DA2A
4G93-GDI
F5M42-2-F6NA
29/36
3.722
EA6A, EA6W
4D68
F5M42-2-F6N7
29/36
3.722
EA5A, EA5W
6A13
F5M41-1-F8A5
31/36
3.714
CJ4A, CK4A
4G92
F5M41-1-R8A1
31/36
4.052
CJ1A, CK1A
4G13
F5M41-1-R8A1
31/36
4.052
CJ2A, CK2A
4G15
F5M42-1-R6N6
29/36
4.058
EA1A
4G93
F5M42-1F6N9
29/36
3.722
EA2A
4G63
F5M42-2-R6N8
29/36
4.058
EA6A
4D68
EXP
Dec. 2000
PWEE9508-H
Revised
22B-1-2a
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M42-1-V5A4
28/36
4.312
N61W
4G93-GDI
F5M42-2-R5A3
28/36
4.058
N84W
4G64-GDI
W5M42-1-V5A1
28/36
4.352
N94W
4G64-GDI
F5M42-1-F8A4
31/36
3.722
DA2A
4G93-GDI
F5M42-2-F7N2
30/36
3.722
EA2A, EA2W
4G93
F5M42-2-F6NC
29/36
3.722
EA3A, EA3W
4G64-GDI
F5M42-2-F6N7
29/36
3.722
EA5A, EA5W
6A13
F5M42-2-F6NA
29/36
3.722
EA6A, EA6W
4D65
F5M42-1-R6N6
29/36
4.058
EA1A
4G93
F5M42-1-R6N7
29/36
4.058
EA2A
4G63
F5M42-1-F6N9
29/36
3.722
EA2A
4G63
F5M42-1-F7N1
30/36
3.722
EA2A
4G63
F5M42-2-V6N1
29/36
4.312
EA4A
6A12-MIVEC
F5M42-2-F6N7
29/36
3.722
EA5A
6A13
F5M42-2-R6N8
29/36
4.058
EA6A
4D56
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M41-1-F8A5
31/36
3.714
CJ2A, CK2A
4G15
F5M42-1-F8A7
31/36
3.722
CJ5A, CK5A
4G93
F5M42-2-R5A2
28/36
4.058
N84W
4G64
EXP
MMAL
Dec. 2000
PWEE9508-H
Revised
22B-1-2b
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M41-1-R8A1
31/36
4.052
CJ1A
4G13
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M41-1-B8A2
31/36
3.454
CJ4A
4G92-MVV
F5M42-1-R7A2
30/36
4.058
DA2A
4G93-GDI
F5M42-1-V5A4
28/36
4.312
N61W
4G93-GDI
F5M42-2-R5A3
28/36
4.058
N64W, N84W
4G64-GDI
W5M42-1-V5A1
28/36
4.352
N94W
4G64-GDI
F5M41-1-R8A1
31/36
4.052
CJ1A, CK1A
4G13
F5M41-1-F8A5
31/36
3.714
CJ4A, CK4A
4G92
F5M42-1-R6N6
29/36
4.058
EA1A
4G93
F5M42-1-R6N7
29/36
4.058
EA2A
4G63
F5M42-1-F6N9
29/36
3.722
EA2A, EA2W
4G63
F5M42-2-F6N7
29/36
3.722
EA5A
6A13
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M42-2-R5A2
28/36
4.058
N84W
4G64
EXP
MMAL
Dec. 2000
PWEE9508-H
Revised
22B-1-2c
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M41-1-R8A1
31/36
4.052
CJ1A
4G13
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M42-1-F8AC
31/36
3.722
DG5A
4G93
F5M42-1-R7A2
30/36
4.058
DA2A
4G93
F5M42-2-F7N2
30/36
3.722
EA2A, W
4G63
F5M42-2-F6NC
29/36
3.722
EA3A, W
4G64
F5M42-2-F6N7
29/36
3.722
EA5A, W
6A13
F5M42-2-V5A
28/36
4.312
N63W
4G63
F5M42-2-R5A3
28/36
4.058
N64W
4G64
F5M41-1-R8A1
31/36
4.052
CJ1A, CJ2A
4G13, 4G15
F5M41-1-R7B
30/36
4.052
CS1A, CS3A
4G13, 4G18
F5M41-1-R8B
31/36
4.052
CS1A, CS3A
4G13, 4G18
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M42-1-F6N9
29/36
3.722
EA2W
4G63
F5M42-1-F7N1
30/36
3.722
EA2W
4G63
F5M42-1-R6N6
29/36
4.058
EA1A
4G93
F5M42-2-R6N7
29/36
4.058
EA2A
4G63
F5M42-1-F6N9
29/36
3.722
EA2A
4G63
F5M42-2-F6N7
29/36
3.722
EA5A
6A13
F5M42-2-R6N8
29/36
4.058
EA6A
4D68
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M41-1-F8A5
31/36
3.714
CJ2A, CK2A
4G15
F5M42-1-F8A7
31/36
3.722
CJ5A, CK5A
4G93
F5M42-2-R5A2
28/36
4.058
N84W
4G64
EXP
MMAL
Dec. 2000
PWEE9508-H
Revised
22B-1-2d
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M41-1-R8A1
31/36
4.052
CJ1A
4G13
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M41-1-R8B
31/36
4.052
CS3A
4G18
F5M42-1-F8AC
31/36
3.722
DG5A
4G93
F5M42-1-R7A2
30/36
4.058
DA2A
4G93
F5M42-2-V5A
28/36
4.312
N83W
4G63
F5M42-2-R5A3
28/36
4.058
N84W
4G64
W5M42-1-V5A1
28/36
4.352
N94W
4G64
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M41-1-R8A1
31/36
4.052
CJ1A, CJ2A
4G13, 4G15
F5M42-2-F6N7
29/36
3.722
EA5A
6A13
F5M42-1-R6N6
29/36
4.058
EA1A
4G93
F5M42-1-R6N7
29/36
4.058
EA2A
4G63
F5M42-1-F6N9
29/36
3.722
EA2A, W
4G63
F5M42-2-R6N8
29/36
4.058
EA6A
4D68
F5M41-1-R7B
30/36
4.052
CS1A, CS3A
4G13, 4G18
F5M41-1-R8B
31/36
4.052
CS1A, CS3A
4G13, 4G18
F5M41-1-V7B
30/36
4.333
CS1A
4G13
F5M41-1-V8B1
31/36
4.333
CS1A
4G13
F5M42-1-R7A2
30/36
4.058
DA3A
4G93
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M41-1-F8A5
31/36
3.714
CJ2A
4G15
F4M42-1-F8A7
31/36
3.722
CJ5A, CK5A
4G93
EXP
MMAL
Mar. 2002
PWEE9508-I
Revised
22B-1-2e
Gear ratio
Speedometer
gear ratio
Vehicle model
Engine model
EUR
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M41-1-R8A1
31/36
4.052
CJ1A
4G13
F5M42-2-V5A
28/36
4.312
N83W
4G64
F5M42-2-R5A3
28/36
4.058
N84W
4G64
W5M42-1-V5A1
28/36
4.325
N94W
4G64
F5M42-1-R7A2
30/36
4.058
DA2A
4G93
F5M41-1-F8A5
31/36
3.714
CJ4A
4G92
F5M41-1-R8A1
31/36
4.052
CJ1A, CJ2A
4G13, 4G15
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M41-1-R7B1
30/36
4.052
CS1A, CS3A
4G13, 4G18
F5M41-1-R8B1
31/36
4.052
CS1A, CS3A
4G13, 4G18
F5M41-1-F8A5
31/36
3.714
CJ2A
4G15
F5M42-1-F8A7
31/36
3.722
CJ5A, CK5A
4G93
F5M42-2-R5A2
28/36
4.058
N84W
4G64
F5M42-1-F8B2
31/36
3.722
CS6A
4G93
EXP
MMAL
Mar. 2002
PWEE9508-I
Revised
22B-1-2f
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
1st
3.583
3.583
2nd
1.947
1.947
3rd
1.266
1.266
4th
0.970
0.970
5th
0.767
0.820
Reverse
3.363
3.363
Transfer
0.3018
SERVICE SPECIFICATIONS
Items
Allowable range
Limit
0.010.12
0.010.09
0.010.12
0.010.09
0.010.12
0.010.09
0.010.09
0.050.17
00.150
0.050.11
Mar. 2002
PWEE9508-I
Revised
22B-1-2g
Allowable range
Limit
0.0250.150
0.050.11
0.5
TRANSFER
Item
Specified sealant
Air breather
Mar. 2002
PWEE9508-I
Added
22B-1-2h
Intentionally blank
Mar. 2002
PWEE9508-I
Added
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 the
gasket 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. Too
thick 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 necessary
to 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 some
cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with
a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined
surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget
to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple 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 bolt
hole 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 are
mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any
oil 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 the
text when applying the FIPG.
LUBRICANTS
TRANSMISSION
Items
Specified lubricants
TRANSFER
Items
Specified lubricants
Jun. 1998
PWEE9508-E
Revised
22B-1-4
Thickness mm
Identification
symbol
Part No.
Snap ring
(For adjustment o
of input sha
shaftt front
ront bearing end
play)
2.24
None
MD706537
2.31
Blue
MD706538
2.38
Brown
MD706539
2.31
Black (2)
MD747149
2.35
None
MD746561
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
2.82
MD748015
2.86
MD748016
2.90
MD748017
2.94
MD748018
2.98
MD748019
3.02
MD748020
3.06
MD748021
3.10
MD748022
1.43
Green (2)
MD746708
1.51
White (2)
MD746709
1.59
Yellow (2)
MD746710
Snap ring
(For adjustment o
of input sha
shaftt rear bearing end
play ....F5M41)
(For adjustment of output shaft rear bearing end
play ....F5M42, W5M42)
Snap ring
(For adjustment o
of output sha
shaftt front
ront bearing end
play)
(For adjustment o
of input sha
shaftt rear bearing end
play ....F5M42, W5M42)
Dec. 2000
PWEE9508-H
Revised
22B-1-5
Thickness mm
Identification
symbol
Part No.
2.31
Black (2)
MD748800
2.35
None
MD748801
2.39
Blue
MD748802
2.43
Brown
MD748803
2.47
Green
MD748804
2.51
White
MD748805
2.55
Yellow
MD748806
2.59
Black
MD748807
2.63
Orange
MD748808
2.67
Blue
MD748809
2.71
Brown
MD748810
2.81
Green
MD748782
2.85
White
MD748783
2.89
Yellow
MD748784
2.93
Black
MD748785
2.97
Orange
MD748786
3.01
Red
MD748787
3.05
Pink
MD748788
3.09
Blue
MD748789
2.81
Green
MD745799
2.85
White
MD745800
2.89
Yellow
MD745801
2.93
Black
MD745802
2.97
Orange
MD745803
3.01
Red
MD745804
3.05
Pink
MD745805
3.09
Blue
MD745806
July 1999
PWEE9508-F
Revised
22B-1-6
Part name
Thickness mm
Identification
symbol
Part No.
Spacer: F5M41
(For adjustment of differential case end play)
0.77
77
MD754476
0.86
86
MD720938
0.95
95
MD720941
1.04
04
MD720944
1.13
MD700270
1.22
MD700271
1.31
MD706574
1.40
None
MD706573
1.49
MD706572
1.58
MD706571
1.67
MD706570
1.76
MD706575
July 1999
PWEE9508-F
Revised
22B-1-7
Thickness mm
Identification
symbol
Part No.
Spacer: F5M42
(For adjustment o
of di
differential
erential case preload)
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
MD710454
1.13
MD700270
1.16
MD710455
1.19
MD710456
1.22
MD700271
1.25
MD710457
Dec. 2000
PWEE9508-H
Revised
22B-1-8
Part name
Thickness mm
Identification
symbol
Part No.
Spacer: W5M42
(For adjustment o
of center di
differential
erential case
preload)
0.74
74
MD727660
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
MD710454
1.13
MD700270
1.16
MD710455
1.19
MD710456
1.22
MD700271
1.25
MD710457
1.28
MD710458
1.31
MD706574
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
0.48 0.55
MD744236
0.56 0.65
MD744235
0.66 0.73
MD744234
0.74 0.81
MD744233
0.82 0.89
MD744232
Spacer: W5M42
(For adjustment o
erential case pinion
of center di
differential
backlash)
Dec. 2000
PWEE9508-H
Revised
22B-1-9
TORQUE SPECIFICATIONS
TRANSMISSION
Items
Nm
6.9
30
44
9.8
18
18
3.9
19
18
11
3.9
132
132
32
18
Poppet spring
32
32
48
18
70
22
18
18
TRANSFER
Items
Nm
23
69
Dec. 2000
PWEE9508-H
Revised
22B-2-1
2. SPECIAL TOOLS
TRANSMISSION
Tool
Number
Name
Use
MB990926
Installer adapter
MB990927
Installer adapter
MB990930
Installer adapter
MB990934
Installer adapter
MB990935
Installer adapter
MB990937
Installer adapter
MB990938
Handle
MD998325
Jun. 1998
PWEE9508-E
Revised
22B-2-2
Tool
Number
Name
Use
MD998346
MD998772
MD998801
Bearing remover
MD998812
Installer cap
MD998813
Installer-100
MD998814
Installer-200
MD998816
Installer
(30)
adapter
MD998817
Installer
(34)
adapter
MD998818
Installer
(38)
adapter
Jun. 1998
PWEE9508-E
Revised
22B-2-3
Number
Name
MD998819
Installer
(40)
adapter
MD998820
Installer
(42)
adapter
MD998822
Installer
(46)
adapter
MD998823
Installer
(48)
adapter
MD998824
Installer
(50)
adapter
MD998825
Installer
(52)
adapter
MD998826
Installer
(54)
adapter
MD998917
Bearing remover
MD999566
Claw
Jun. 1998
Use
PWEE9508-E
Revised
22B-2-4
TRANSFER
Tool
Number
Name
Use
MB990887
MB990891
MB990933
Installer adapter
MD998304
MD998800
Jun. 1998
PWEE9508-E
Added
22B-3-1
3. TRANSMISSION <F5M41>
DISASSEMBLY AND REASSEMBLY
18 Nm
32 Nm
10
6
11
3.9 Nm
70 Nm
70 Nm
Disassembly steps
1. Roll stopper bracket
2. Insulator washer <some model>
3. Shift cable bracket
"MA 4. Select lever
"LA 5. Speedometer gear
6. Back-up lamp switch
7. Gasket
8. Restrict ball
9. Gasket
10. Poppet spring
11. Gasket
E Mitsubishi Motors Corporation
Nov. 2000
1995
Dec.
PWEE9508-A
PWEE9508-H
Added
Revised
22B-3-2
14
30 Nm
18 Nm
15
12
13
18
44 Nm
24
19
27
17
16
25
48 Nm
26
18 Nm
23
20
22
21
TFM0719
"KA
"JA
AA" "IA
AB" "HA
Disassembly steps
12. Interlock plate bolt
13. Gasket
14. Control housing
15. Neutral return spring
16. Reverse idler gear shaft bolt
17. Gasket
18. Sealing cap
19. Transmission case
Nov.
Dec. 1995
2000
PWEE9508-A
PWEE9508-H
Added
Revised
22B-3-3
30
32
29
41
31
45
33
35
40
36
34
39
46
38
37
42
18 Nm
44
43
TFM0720
AD"
AD"
AD"
AD"
Disassembly steps
"DA 29. Spring pin
30. 1st-2nd speed shift rail
31. 1st-2nd speed shift fork
"DA 32. Spring pin
"DA 33. Spring pin
"CA 34. 5th speed shift rail
"CA 35. 5th speed shift fork
"CA 36. Reverse shift lug
"CA 37. Snap ring
Nov. 1995
AD"
AD"
AD"
AD"
"CA
"CA
"CA
"CA
"BA
AE" "AA
AE" "AA
PWEE9508-A
38.
39.
40.
41.
42.
43.
44.
45.
46.
Added
22B-3-4
(2) While sliding the 3rd-4th speed shift rail in the direction
shown, remove it together with the shift fork.
3rd-4th
speed
shift rail
Nov. 1995
PWEE9508-A
Added
22B-3-5
Output shaft
Input shaft
Solders
Detent
5 7 mm
2 3 mm
E Mitsubishi Motors Corporation
Nov.
Dec. 1995
2000
PWEE9508-A
PWEE9508-H
Added
Revised
22B-3-6
3rd-4th
speed
shift rail
5th
speed
shift rail
Reverse interlock
rail
(2) Install the reverse interlock rail, steel ball, 5th speed shift
rail, 5th speed shift fork, reverse shift lug and snap ring
in the illustrated positions.
Steel ball
(inside)
Snap ring
Reverse
shift lug
Reverse
interlock rail
Snap ring
Steel ball
(3) While sliding the reverse shift lug in the direction shown,
install the 5th speed shift fork, 5th speed shift rail, reverse
shift lug, snap ring, steel ball and reverse interlock rail.
Reverse
shift lug
Nov. 1995
PWEE9508-A
Added
22B-3-7
Oil guide
(2) Face the threaded hole of the reverse idler gear shaft
toward the direction shown.
Reverse
idler gear
shaft
Nov. 1995
PWEE9508-A
Added
22B-3-8
Snap ring
Sealing cap
MB990938
MB990927
Nov. 1995
PWEE9508-A
Added
22B-3-9
O-ring
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
Control shaft
Select
lever
shoe
INSPECTION
BACK-UP LAMP SWITCH
Check for continuity between terminals.
Nov. 1995
Switch condition
Continuity
Pressed
Not exist
Released
Exists
PWEE9508-A
Added
18 Nm
32 Nm
5
4
8
9
3.9 Nm
10
11
70 Nm
22 Nm
16
15
14
12
18 Nm
13
1
70 Nm
69 Nm
TFM1069
Disassembly steps
1. Transfer <W5M42>
2. O-ring <W5M42>
3. Roll stopper bracket
4. Insulator washer <some model>
5. Shift cable bracket
"KA 6. Select lever
"JA 7. Speedometer gear
8. Back-up lamp switch
9. Gasket
10. Poppet spring
11. Gasket
12. Connector bracket <For GDI engine except DA2A>
13. Clutch fluid line blacket <DA2A only>
14. Oil temperature sensor harness <For GDI engine only>
15. Oil temperature sensor <For GDI engine only>
16. Gasket <For GDI engine only>
Dec. 2000
PWEE9508-H
Revised
19
18 Nm
30 Nm
20
17
18
44 Nm
25
26
28
27
22
23
24
29
48 Nm
30
21
6.9 Nm
TFM0597
"IA
"HA
AA" "GA
AB" "FA
"EA
"DA
Disassembly steps
17. Interlock plate bolt
18. Gasket
19. Control housing
20. Neutral return spring
21. Under cover
22. Reverse idler gear shaft bolt
23. Gasket
24. Reverse idler gear
25. Sealing cap
26. Transmission case
27. Outer race
28. Spacer
29. Magnet holder
30. Magnet
Dec. 2000
PWEE9508-H
Revised
31
33
34
32
30
42
36
38
37
35
43
39 18 Nm
41
40
TFM0598
AC"
AC"
AC"
AC"
AD"
AD"
Disassembly steps
"CA 30. Spring pin
31. 1st-2nd speed shift rail
32. 1st-2nd speed shift fork
"CA 33. Spring pin
"CA 34. Spring pin
"BA 35. 3rd-4th speed shift rail
"BA 36. 3rd-4th speed shift fork
"BA 37. 5th-reverse speed shift rail
"BA 38. 5th-reverse speed shift fork
39. Front bearing retainer
"AA 40. Input shaft
"AA 41. Output shaft
42. Differential
43. Clutch housing
Jun. 1998
PWEE9508-E
Revised
3rd-4th speed
shift fork
5th-reverse
speed shift
fork
3rd-4th speed
shift rail
Output shaft
5th-reverse
speed shift rail
Input shaft
Jun. 1998
(2) Slide the 3rd-4th speed shift rail and 5th-reverse speed
shift rail in the direction shown and remove them together
with the shift fork.
PWEE9508-E
Revised
Solders
Input shaft
Output shaft
3rd-4th
speed
synchronizer
sleeve
5th-reverse
speed synchronizer sleeve
(2) Install the 3rd-4th speed shift rail and fork and the
5th-reverse speed shift rail and fork.
5th-reverse
speed shift rail
Jun. 1998
PWEE9508-E
Revised
(3) While fitting each shift fork in the sleeve, slide the shift
rails in the direction shown and install.
3rd-4th speed
shift rail
Shift rail
Shift fork
2.5 mm
Spring pin
Slit
MB990938
MB990935
Jun. 1998
PWEE9508-E
Revised
Sealing cap
MB990938
MB990927
Jun. 1998
PWEE9508-E
Revised
O-ring
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
Control shaft
Select
lever shoe
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 <For GDI engine only>
(1) Check for continuity between terminals.
Temperature (C)
20
2.31 - 2.59
110
0.1451 - 0.1491
(2) If the standard value is not met, replace the oil temperature
sensor with a new one.
Transmission oil
Jun. 1998
PWEE9508-E
Revised
22B-5-1
15
17
19
20
23
22
24
16
25
18
2
21
27
6
28
29
3
13
25
26
14
8
9
11
10
12
13
TFM0834
Disassembly steps
"MA 1. Snap ring
AA" "LA 2. Ball bearing
AB" "KA 3. Reverse brake sleeve
4. Needle roller bearing
5. Reverse brake cone
6. Reverse brake ring
"DA 7. Synchronizer spring
"JA 8. Synchronizer sleeve
AC" "IA 9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"DA 11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
AD" "HA 14. 5th speed gear sleeve
E Mitsubishi Motors Corporation
July 1999
AE" "GA
"DA
"FA
"EA
"DA
"CA
AF" "BA
"AA
PWEE9508-F
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
22B-5-2
16
17
19
18
20
21
23
24
5
25
21
22
11
10
12
13
6
8
Disassembly steps
"MA 1. Snap ring
AA" "LA 2. Ball bearing
3. Collar
"JA 4. Synchronizer sleeve
AC" "IA 5. 5th-reverse speed synchronizer hub
6. Synchronizer ring
"DA 7. Synchronizer spring
8. 5th speed gear
9. Needle roller bearing
AD" "HA 10. 5th speed gear sleeve
11. 4th speed gear
12. Needle roller bearing
AE" "GA 13. 4th speed gear sleeve
July 1999
PWEE9508-F
Revised
22B-5-2a
16
17
19
18
20
21
23
24
7
25
21
22
11
10
12
13
6
8
Disassembly steps
"MA 1. Snap ring
AA" "LA 2. Ball bearing
3. Collar
"JA 4. Synchronizer sleeve
AC" "IA 5. 5th-reverse speed synchronizer hub
6. Synchronizer ring
7. Synchronizer lever
8. 5th speed gear
9. Needle roller bearing
AD" "HA 10. 5th speed gear sleeve
11. 4th speed gear
12. Needle roller bearing
AE" "GA 13. 4th speed gear sleeve
Dec. 2000
PWEE9508-H
Revised
22B-5-2b
MD998801
MD998801
MD998917
MD998917
MD998801
Dec. 2000
PWEE9508-H
Revised
22B-5-3
3.5 mm
MD998812
MD998801
MD998813
MD998817
Snap ring
Synchronizer spring
E Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
22B-5-4
Identification mark
MD998812
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998813
MD998801
MD998826
Identification
groove
Rear of
transmission
Synchronizer
sleeve
Synchronizer hub
MD998812
MD998813
MD998801
MD998824
Nov. 1995
PWEE9508-A
Added
MD998801
22B-5-5
MD998813
MD998820
Identification mark
MD998812
MD998819
Caution
When the 5th-reverse speed synchronizer hub is installed,
make sure that the synchronizer ring is not caught.
MD998801
Identification
groove
Rear of
transmission
Synchronizer
sleeve
Synchronizer hub
E Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
22B-5-6
MD998801
MD998812
MD998818
MD998801
INSPECTION
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.
Nov. 1995
PWEE9508-A
Added
22B-5-7
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance A. If A is less than the limit, replace.
Limit: 0.5 mm
Synchronizer ring
Gear
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Nov.
1995
Jun. 2000
PWEE9508-A
PWEE9508-G
Added
Revised
22B-6-1
9
11
10
12
14
13
15
16
19
18
4
20
6
7
1
8
3
16
17
TFM0591
Disassembly steps
1. Snap ring
2. Ball bearing
3. Thrust plate stopper
4. Thrust plate
5. 5th speed gear
6. 4th speed gear
7. Needle roller bearing
AC" "GA 8. 4th speed gear sleeve
9. Synchronizer ring
"DA 10. Synchronizer spring
"LA
AA" "KA
"JA
"IA
AB" "HA
Jun. 1998
PWEE9508-E
Revised
MD998801
MD998801
MD998801
MD998801
3.5 mm
Jun. 1998
PWEE9508-E
Revised
22B-6-3
MD998813
MD998801
MD998816
Synchronizer spring
MD998812
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998813
MD998801
MD998825
Jun. 1998
PWEE9508-E
Revised
Identification
groove
Rear of transmission
Synchronizer sleeve
Synchronizer hub
MD998812
MD998813
MD998801
MD998824
MD998812
MD998813
MD998801
MD998824
Thrust plate
E Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
22B-6-5
Thrust plate
MD998812
MD998801
MD998818
INSPECTION
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.
Jun. 1998
PWEE9508-E
Revised
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance A. If A is less than the limit, replace.
Limit: 0.5 mm
Synchronizer ring
Gear
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Jun. 2000
PWEE9508-G
Revised
22B-7-1
19
1
14
22
16
15
17
18
21
6
9
11
12
20
13
7
10
TFM0715
"JA
AA" "IA
"HA
AB" "GA
Disassembly steps
1. Snap ring
2. Ball bearing
3. Collar
4. 5th speed gear
5. 4th speed gear
6. Snap ring
7. 3rd speed gear
8. 2nd speed gear
9. Needle roller bearing
10. 2nd speed gear sleeve
11. Synchronizer ring
July 1999
Revised
22B-7-2
21
24
16
18
17
19
23
20
6
9
3
2
11
22
4
13
15
7
10
12
14
"JA
AA" "IA
"HA
AB" "GA
Disassembly steps
1. Snap ring
2. Ball bearing
3. Collar
4. 5th speed gear
5. 4th speed gear
6. Snap ring
7. 3rd speed gear
8. 2nd speed gear
9. Needle roller bearing
10. 2nd speed gear sleeve
11. Inner synchronizer ring
12. Synchronizer cone
July 1999
PWEE9508-F
Revised
22B-7-2a
MD998801
MD998917
MD998801
MD998917
Inner race
MD998812
MD998801
MD998818
Inner
race
July 1999
PWEE9508-F
Added
Intentionally blank
July 1999
PWEE9508-F
Added
22B-7-3
MD998814
Sleeve
MD998822
Synchronizer spring
Identification mark
MD998812
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998814
MD998822
Nov. 1995
PWEE9508-A
Added
22B-7-4
Rear of
transmission
Synchronizer sleeve
Synchronizer hub
MD998812
MD998813
MD998820
MD998812
MD998817
Nov. 1995
PWEE9508-A
Added
22B-7-5
Synchronizer
spring
INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
Nov.
1995
July 1999
PWEE9508-A
PWEE9508-F
Added
Revised
22B-7-6
Limit: 0.5 mm
Synchronizer ring
Gear
(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.
Gear
A
Outer ring
Cone
Limit: 0.5 mm
Caution
When the outer ring, inner ring or cone has to be
replaced, make sure that the outer ring, inner ring
and cone are replaced as a set.
Inner ring
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
Nov.
1995
Jun. 2000
PWEE9508-A
PWEE9508-G
Added
Revised
22B-7-7
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Nov.
1995
July 1999
PWEE9508-A
PWEE9508-F
Added
20 19
22
24
21
23
25
28
26
27
29
30
31
4
1
34
5
33
32
13
3
12
15
7
17
16
AC"
AD"
July 1999
11
10
13
Disassembly steps
"PA 1. Snap ring
"OA 2. Ball bearing
"NA 3. Reverse gear bearing sleeve
"NA 4. Needle roller bearing
"NA 5. Reverse gear
6. Synchronizer ring
"DA 7. Synchronizer spring
"FA 8. Synchronizer sleeve
"MA 9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"DA 11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
"LA 14. 5th speed gear sleeve
"KA 15. 4th speed gear
"JA 16. Snap ring
"IA 17. 3rd speed gear
8
14
AA"
AB"
AE" "HA
"GA
"FA
"EA
"DA
AF" "CA
"BA
AG" "AA
PWEE9508-F
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
22B-8-2
20
31
33
32
24
36
27
28 29
30
19
18
21
22
23 4
25
26
5
6
13
12
15
34
17
35
1
3
14
16
7
8
10
11
13
Disassembly steps
1. Snap ring
2. Ball bearing
3. Reverse gear bearing sleeve
4. Needle roller bearing
5. Reverse gear
6. Synchronizer ring
"DA 7. Synchronizer spring
"FA 8. Synchronizer sleeve
AC" "MA 9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"DA 11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
"LA 14. 5th speed gear sleeve
"KA 15. 4th speed gear
"JA 16. Snap ring
AD" "IA 17. 3rd speed gear
"PA
AA" "OA
AB" "NA
"NA
"NA
July 1999
AE" "HA
"GA
"FA
"EA
"GA
AF" "CA
"BA
AG" "AA
PWEE9508-F
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
MD998801
Ball bearing
Sleeve
Synchronizer hub
MD998801
MD998917
Sleeve
Jun. 1998
PWEE9508-E
Revised
22B-8-4
MD998801
MD998917
Sleeve
Inner race
MD998812
MD998801
MD998818
Inner race
MD998812
MD998814
Sleeve
MD998825
Jun. 1998
PWEE9508-E
Revised
Synchronizer spring
MD998812
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998814
Synchronizer hub
MD998825
Identification
groove
Rear of transmission
Synchronizer sleeve
Synchronizer hub
Jun. 1998
PWEE9508-E
Revised
22B-8-6
Synchronizer spring
MD998812
MD998814
Sleeve
MD998822
MD998812
MD998814
3rd speed gear
MD998822
Snap ring
MD998812
MD998813
MD998819
4th speed gear
Jun. 1998
PWEE9508-E
Revised
MD998813
MD998819
Sleeve
MD998812
MD998813
Synchronizer hub
MD998819
MD998812
MD998818
Reverse gear
Caution
When the 5th-reverse speed synchronizer hub is installed,
make sure that the synchronizer ring is not caught.
Sleeve
MD998812
MD998818
Ball bearing
Jun. 1998
PWEE9508-E
Revised
22B-8-8
Snap ring
INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance A. If A is less than the limit, replace.
Limit: 0.5 mm
Synchronizer ring
E Mitsubishi Motors Corporation
Gear
Jun. 1998
PWEE9508-E
Revised
(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.
A
Outer ring
Cone
Inner ring
<Triple synchronizer ring>
Gear
A
Outer ring
Cone
Inner ring
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
Jun. 2000
PWEE9508-G
Revised
22B-8-10
Jun. 1998
PWEE9508-E
Added
22B-9-1
1
5
2
3
4
TFM0590
Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the shaft and gear are combined
and made to rotate, they rotate smoothly without looseness
and noise.
(2) Check to ensure that the cage is not deformed.
Jun. 1998
PWEE9508-E
Revised
22B-10-1
TFM0593
Disassembly steps
1. e-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve
Nov. 1995
PWEE9508-A
Added
22B-11-1
7
1
11 Nm
2
9
3
4
10
TFM0589
Disassembly steps
"AA 1. Dust cover
2. Nut
3. Spring washer
4. Washer
5. Select lever bushing
Dust cover
6.
7.
8.
"AA 9.
10.
Nov. 1995
PWEE9508-A
Added
22B-12-1
13
7
12
8
1
9
15
16
2
3
17
14
20
11
10
19
18
19 Nm
TFM0916
Disassembly steps
1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate
"EA 7. Spring pin
"DA 8. Spring pin
9. Stopper body
10. Neutral return spring
11. Spacer
AA" "FA
Nov. 2000
1995
Dec.
PWEE9508-A
PWEE9508-H
Added
Revised
22B-12-2
Lock pin
Control finger
Model
number
stamped
side
Needle
bearing
2 mm
TFM0859
Nov.
1995
Jan. 1997
PWEE9508-A
PWEE9508-C
Added
Revised
22B-12-1
22B-12-2a
Stopper body
Installation
direction
Slit
Spring pin
TFM0860
Spring pin
45
TFM0861
Lock pin
Control finger
Nov.
1995
Jan. 1997
PWEE9508-A
PWEE9508-C
Added
22B-13-1
3
6
2
1
9.8 Nm
TFM0759
Disassembly steps
1. Clutch release bearing retainer
"EA 2. Oil seal
"DA 3. Oil seal <F5M41, F5M42>
AA" "CA 4. Outer race <F5M42, W5M42>
AB" "BA 5.
6.
"AA 7.
8.
Outer race
Oil guide <F5M41>
Bushing*
Clutch housing
NOTE:
Referring to INSTALLATION SERVICE POINTS is required only when the clutch housing is replaced.
MD999566
Outer race
E Mitsubishi Motors Corporation
Nov.
1995
Jun. 1998
PWEE9508-A
PWEE9508-E
Added
Revised
22B-13-2
MD998772
MD998346
1 mm
Jun. 1998
PWEE9508-E
Revised
22B-13-3
MB990935
MD998325
MB990938
MB990926
E Mitsubishi Motors Corporation
Nov.
1995
July 1999
PWEE9508-A
PWEE9508-F
Added
Revised
22B-14-1
TFM0600
Disassembly steps
"CA 1. Oil seal
"BA 2. Needle bearing
3. Oil guide
4. Snap ring
"AA 5. Bushing
6. Transmission case
Split ends
Nov. 1995
PWEE9508-A
Added
22B-14-2
1 mm
Model number
stamped side
MD998325
Nov.
1995
July 1999
PWEE9508-A
PWEE9508-F
Added
Revised
MANUAL TRANSMISSION (E - W) -
22B-15-1
7
4
2
6
5
8
132 Nm
9
6
9
7
10
2
TFM0760
"EA
AA" "DA
AB" "CA
"BA
"AA
"AA
"AA
"AA
"AA
Disassembly steps
1. Differential drive gear
2. Ball bearing <F5M41>
3. Taper roller bearing <F5M42, W5M42>
4. Lock pin
5. Pinion shaft
6. Pinion
7. Washer
8. Side gear
9. Spacer
10. Differential case
Jun. 1998
PWEE9508-E
Revised
22B-15-2
MANUAL TRANSMISSION (E - W) -
MD998801
MD998801
Jun. 1998
PWEE9508-E
Revised
MANUAL TRANSMISSION (E - W) -
22B-15-3
(4) Measure the backlash between the side gear and pinion.
Standard value:
0.025 - 0.150 mm
(5) If the backlash is out of specification, select a spacer
and re-measure the backlash.
NOTE
Adjust until the backlashes on both sides are equal.
MD998812
Taper roller
bearing
MD998819
MD998812
MD998819
Ball bearing
Jun. 1998
PWEE9508-E
Revised
22B-15-4
MANUAL TRANSMISSION (E - W) -
7
6
2
4
Jun. 1998
PWEE9508-E
Revised
22B-16-1
5
6
12
7
11
132 Nm
12
4
17
14
10
12
13
8
12 11
16
15
"DA
"CA
AA" "BA
"CA
"CA
"CA
"CA
"CA
"CA
Disassembly steps
1. Center differential drive gear
2. Center differential flange
3. Taper roller bearing
4. Snap ring
5. Front output shaft
6. Spacer
7. Side gear
8. Lock pin
9. Pinion shaft
10.
11.
12.
13.
14.
15.
16.
17.
MD998917
"CA
"CA
"CA
"CA
"CA
AB" "AA
Jun. 1998
PWEE9508-E
Added
22B-16-2
MD998917
MD990930
MB990937
MD998812
MD998823
Differential case
Lock pin
Pinion shaft
Jun. 1998
(2) Fit the washer on the back of each pinion. Engage the
4 pinions simultaneously in the side gear.
Rotate the gears to place them in position, then install
the pinion shaft holder.
(3) Insert the pinion shafts.
(4) Install the lock pins in the illustrated direction.
PWEE9508-E
Added
22B-16-3
(5) Install the front output shaft to the side gear and fit the
snap ring.
(6) Attach the spacer on the other side gear, then install the
side gear in the center differential case.
NOTE:
If a new side gear is to be installed, select a spacer with
medium thickness (0.93 - 1.00 mm).
(8) Measure the backlash between the side gear and the
pinion.
Standard value: 0.025 - 0.150 mm
(9) If the measurement deviates from the standard value,
correct the backlash using a spacer of different thickness
and check it again.
NOTE:
The backlash must be the same on both sides.
10
5
8
7
6
9
2
Jun. 1998
PWEE9508-E
Added
22B-17-1
6
4
8
7
11
10
23 Nm
"FA
"EA
"DA
"AA
"AA
"CA
"BA
"AA
Disassembly steps
1. Air breather
2. Dust seal guard
3. Oil seal
4. Oil seal
5. O-ring
6. O-ring
7. Oil seal
8. Oil seal
9. O-ring
10. Transfer cover
11. Transfer
Jun. 1998
PWEE9508-E
Added
22B-17-2
MD998800
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher.
(2) By using the special tool, install the oil seal.
MB990938
MB990933
MB990891
MB990887
MD998304
Jun. 1998
PWEE9508-E
Added
22B-17-3
Jun. 1998
PWEE9508-E
No.
8001
or
Added
NOTES