Mitsubishi F5M42,W5M42, W5M42 F5M42,W5M42 manual transmission Workshop manual

22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
<F5M42,W5M42>
CONTENTS
GENERAL INFORMATION . . . . . . . .
22B-3
GENERAL SPECIFICATIONS . . . . . .
22B-5
SERVICE SPECIFICATIONS. . . . . . .
22B-5
DISASSEMBLY AND REASSEMBLY . . . . .
22B-31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
22B-38
REVERSE IDLER GEAR . . . . . . . . . . 22B-40
DISASSEMBLY AND REASSEMBLY . . . . .
SNAP RING, SPACER AND THRUST
PLATE FOR ADJUSTMENT . . . . . . .
22B-6
TORQUE SPECIFICATIONS . . . . . . .
22B-8
SEALANTS AND ADHESIVES . . . . .
22B-9
LUBRICANTS . . . . . . . . . . . . . . . . . .
22B-9
SPECIAL TOOLS. . . . . . . . . . . . . . . .
22B-10
TRANSMISSION . . . . . . . . . . . . . . . .
22B-14
DISASSEMBLY AND REASSEMBLY. . . . .
22B-14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
22B-24
INPUT SHAFT . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B-31
22B-25
DISASSEMBLY AND REASSEMBLY. . . . .
22B-25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
22B-29
22B-40
VEHICLE SPEED SENSOR . . . . . . . . 22B-41
DISASSEMBLY AND REASSEMBLY . . . . .
22B-41
SELECT LEVER . . . . . . . . . . . . . . . . . 22B-42
DISASSEMBLY AND REASSEMBLY . . . . .
22B-42
CONTROL HOUSING . . . . . . . . . . . . . 22B-43
DISASSEMBLY AND REASSEMBLY . . . . .
22B-43
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-45
DISASSEMBLY AND REASSEMBLY . . . . .
22B-45
TRANSMISSION CASE . . . . . . . . . . . 22B-48
DISASSEMBLY AND REASSEMBLY . . . . .
22B-48
Continued on next page
22B-2
DIFFERENTIAL . . . . . . . . . . . . . . . . .
DISASSEMBLY AND REASSEMBLY. . . . .
CENTRE DIFFERENTIAL . . . . . . . . .
DISASSEMBLY AND REASSEMBLY. . . . .
22B-50
22B-50
22B-53
22B-53
TRANSFER . . . . . . . . . . . . . . . . . . . . . 22B-56
DISASSEMBLY AND REASSEMBLY . . . . .
22B-56
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
GENERAL INFORMATION
22B-3
GENERAL INFORMATION
M1222000100584
MANUAL TRANSMISSION MODELS
Transmission model
Combined engine
Vehicle model
F5M42-2-Y4B3
4G63-D4-MPI
CU2W
W5M42-1-Z4B1
4G63-D4-MPI
CU2W
W5M42-1-V4B1
4G69-S4-MIVEC
CU5W
SECTIONAL VIEW
<F5M42>
AK302709
22B-4
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
GENERAL INFORMATION
<W5M42>
AK302711
22B-5
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
M1222000200699
TRANSMISSION MODEL TABLE
Transmission
Speedomerter
model
gear ratio
Final gear
ratio
Vehicle model
Engine model
Transfer
gear ratio
F5M42-2-Y4B3
27/36
4.625
CU2W
4G63-D4-MPI
−
W5M42-1-Z4B1
27/36
4.687
CU2W
4G63-D4-MPI
0.3018
W5M42-1-V4B1
27/36
4.352
CU5W
4G69-S4-MIVEC
0.3018
GEAR RATIO TABLE
F5M42-2-Y4B3
1st
3.583
2nd
1.947
3rd
1.379
4th
1.030
5th
0.820
Reverse
3.363
W5M42-1-Z4B1
W5M42-1-V4B1
SERVICE SPECIFICATIONS
M1222000300481
Item
Standard value
Minimum limit
Differential case preload mm
0.05 − 0.11
−
Input shaft front bearing end play mm
0 − 0.12
−
Input shaft 5th speed gear end play mm
0 − 0.09
−
Input shaft rear bearing end play mm
0 − 0.12
−
Synchronizer ring back surface to gear clearance mm
−
0.5
Output shaft front bearing end play mm
0 − 0.12
−
Output shaft 3rd speed gear end play mm
0 − 0.09
−
Output shaft rear bearing end play mm
0 − 0.09
−
Backlash between differential gear and pinion mm
<F5M42>
0.025 − 0.150
−
Backlash between center differential gear and pinion mm 0.025 − 0.150
<W5M42>
−
22B-6
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
SNAP RING, SPACER AND THRUST PLATE FOR
ADJUSTMENT
M1222012000584
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>
Thickness mm
Identification symbol
Thickness mm
Identification symbol
0.71
71
1.01
01
0.74
74
1.04
04
0.77
77
1.07
07
0.80
80
1.10
J
0.83
83
1.13
D
0.86
86
1.16
K
0.89
89
1.19
L
0.92
92
1.22
G
0.95
95
1.25
M
0.98
98
SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD) <W5M42>
Thickness mm
Identification symbol
Thickness mm
Identification symbol
0.74
74
1.04
04
0.77
77
1.07
07
0.80
80
1.10
J
0.83
83
1.13
D
0.86
86
1.16
K
0.89
89
1.19
L
0.92
92
1.22
G
0.95
95
1.25
M
0.98
98
1.28
N
1.01
01
1.31
E
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
2.24
None
2.38
Brown
2.31
Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
Thickness mm
Identification symbol
Thickness mm
Identification symbol
2.82
0
2.98
6
2.86
2
3.02
7
2.90
3
3.06
8
2.94
5
3.10
9
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22B-7
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY AND OUTPUT SHAFT
FRONT BEARING END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
1.43
Green (2)
1.59
Yellow (2)
1.51
White (2)
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
2.81
Green
2.97
Orange
2.85
White
3.01
Red
2.89
Yellow
3.05
Pink
2.93
Black
3.09
Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
2.31
Black (2)
2.55
Yellow
2.35
None
2.59
Black
2.39
Blue
2.63
Orange
2.43
Brown
2.67
Blue
2.47
Green
2.71
Brown
2.51
White
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION)
<F5M42>
Thickness mm
Identification symbol
Thickness mm
Identification symbol
0.76 − 0.84
−
1.06 − 1.14
−
0.81 − 0.89
−
1.11 − 1.19
−
0.86− 0.94
−
1.16 − 1.24
−
0.91 − 0.99
−
1.21 − 1.29
−
0.96 − 1.04
−
1.26 − 1.34
−
1.01 − 1.09
−
SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN CENTER DIFFERENTIAL SIDE GEAR AND
PINION) <W5M42>
Thickness mm
Identification symbol
Thickness mm
Identification symbol
0.48 − 0.55
−
0.74 − 0.81
−
0.56 − 0.65
−
0.82 − 0.89
−
0.66 − 0.73
−
22B-8
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
M1222012100484
Item
Specifications
Transfer - clutch housing mounting bolt <W5M42>
69 ± 9 N⋅m
Roll stopper bracket mounting bolt
70 ± 10 N⋅m
Shift cable bracket mounting bolt
18 ± 3 N⋅m
Select lever mounting bolt
18 ± 3 N⋅m
Vehicle speed sensor mounting bolt
3.9 ± 1.0 N⋅m
Back-up lamp switch
32 ± 2 N⋅m
Poppet spring
32 ± 2 N⋅m
Harness bracket bolt
18 ± 3 N⋅m
Harness bracket bolt <Except 2.4L model>
3.9 ± 1.0 N⋅m
Interlock plate bolt
30 ± 3 N⋅m
Control housing mounting bolt
18 ± 3 N⋅m
Under cover mounting bolt
6.9 ± 0.9 N⋅m
Reverse idler gear shaft mounting bolt
48 ± 5 N⋅m
Clutch housing-transmission case mounting bolt
44 ± 5 N⋅m
Front bearing retainer mounting bolt
18 ± 3 N⋅m
Select lever mounting nut
11 ± 1 N⋅m
Stopper bracket mounting bolt
21.7 ± 0.3 N⋅m
Clutch release bearing retainer mounting bolt
9.8 ± 0.2 N⋅m
Differential drive gear mounting bolt
133 ± 4 N⋅m
Center differential drive gear mounting bolt
133 ± 4 N⋅m
Center differential flange to differential case mounting bolt
3.9 ± 1.0 N⋅m
Transfer cover mounting bolt <W5M42>
23 ± 3 N⋅m
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SEALANTS AND ADHESIVES
22B-9
SEALANTS AND ADHESIVES
M1222000500106
Item
Specified sealant
Clutch housing-transmissin case mating surface
MITSUBISHI Genuine sealant part No. MD997740 or
equivalent
Under cover-transmissin case mating surface
Control housing-transmissin case mating surface
Air breather
3M SUPER WEATHERSTRIP No.8001 or equivalent
Differential drive gear bolt
3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)
Surface Preparation
This transmission has several areas where the
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when applying it. 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 fluid passages. To
prevent leaks or blocking of passages, therefore, it is
absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surface is flat
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.
Disassembly
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.
FIPG Application
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 10 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installation. Avoid operating the transmission or letting oils
or water come in contact with the sealed area before
a time sufficient for FIPG to harden (approximately
one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
LUBRICANTS
M1222000400284
TRANSMISSION
Item
Each O-ring
Specified lubricant
Each oil seal
Hypoid gear oil SAE 75W-90 or 75W-85W conforming to
API classification GL-4
Select lever shoe
MITSUBISHI part No.0101011 or equivalent
Input shaft front oil seal
TRANSFER
Item
Specified lubricant
Each O-ring
Hypoid gear oil API classification GL-5 SAE 90
Each oil seal
22B-10
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SPECIAL TOOLS
SPECIAL TOOLS
M1222000600341
Tool
Number
Name
Use
MB990935
Installer adapter
• Installation of differential
case taper roller bearing
outer race <F5M42>
• Installation of center
differential case rear taper
roller bearing outer race
<W5M42>
MB990938
Handle
Use with Installer adapter
MB990927
Installer adapter
Installation of sealing cap
MD998801
Bearing remover
Installation and removal of
gears, bearings and sleeves
MD998812
Installer cap
Use with Installer and Installer
adapter
MD998813
Installer-100
Use with Installer cap and
Installer adapter
MD998816
Installer adapter (30) Installation of input shaft front
bearing
MD998825
Installer adapter (52)
• Installation of 1st-2nd speed
synchronizer hub
• Installation of 3rd-4th speed
synchronizer hub
• Installation of 1st speed gear
sleeve
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SPECIAL TOOLS
Tool
22B-11
Number
Name
Use
MD998824
Installer adapter (50)
• Installation of 4th speed gear
sleeve
• Installation of 5th speed gear
and thrust plate stopper
MD998818
Installer adapter (38)
• Installation of input shaft rear
bearing, roller bearing inner
race
• Installation of reverse gear
sleeve and output shaft rear
ball bearing
• Installation of output shaft
rear ball bearing
MD998917
Bearing remover
Installation and removal of
gears, bearing and sleeves
MD998814
Installer-200
Use with Installer cap and
Installer adapter
MD998822
Installer adapter (46) Installation of 2nd speed gear
sleeve and 3rd speed gear
MD998819
Installer adapter (40)
• Installation of 5th-reverse
speed synchronizer hub
• Installation of 4th speed gear
and 5th speed gear sleeve
MD999566
Claw
Removal of taper roller bearing
outer race
MD998772
Valve spring
compressor
Removal of output shaft front
roller bearing outer race
22B-12
Tool
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SPECIAL TOOLS
Number
Name
Use
MD998346
Bearing outer race
remover
Removal of output shaft front
roller bearing outer race
MB990934
Installer adapter
Installation of output shaft front
roller bearing outer race
MB991550
Bearing outer race
installer
Installation of center differential
case front taper roller bearing
outer race <W5M42>
MD998325
Differential oil seal
installer
Installation of differential oil seal
MB990926
Installer adapter
Installation of clutch housing
input shaft oil seal
MD998823
Installer adapter (48)
• Installation of differential
case taper roller bearing
<F5M42>
• Installation of center
differential case rear taper
roller bearing <W5M42>
MB990930
Installer adapter
Removal of center differential
case front taper roller bearing
bearing <W5M42>
MD998830
Installer adapter (66) Installation of center differential
case front taper roller bearing
<W5M42>
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SPECIAL TOOLS
Tool
22B-13
Number
Name
Use
MB990937
Installer adapter
Installation of transfer oil seal
<W5M42>
MD998800
Oil seal adapter
Installation of transfer oil seal
<W5M42>
MB990887
Ring
Installation of transfer oil seal
<W5M42>
MB990891
Bushing remover
installer base
Using with ring
MB990933
Installer adapter
Installation of transfer oil seal
<W5M42>
22B-14
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001000449
<F5M42>
4
3
32 ± 2 N·m
18 ± 3 N·m
6
3.9 ± 1.0 N·m
8
3.9 ± 1.0 N·m
11
7
18 ± 3 N·m
5
70 ± 10 N·m
9
10
2
1
70 ± 10 N·m
AK500272 AB
>>J<<
>>I<<
1.
2.
3.
4.
5.
6.
7.
Disassembly steps
Roll stopper bracket, front
Roll stopper bracket, rear
Shift cable bracket
Select lever
Vehicle speed sensor
Backup lamp switch
Gasket
8.
9.
10.
11.
Disassembly steps (Continued)
Poppet spring
Gasket
Corrugate clamp bracket
Corrugate clamp bracket
22B-15
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
14
Apply gear oil to all
moving parts before
installation.
30 ± 3 N·m
18 ± 3 N·m
12
15
13
20
44 ± 5 N·m
22
21
23
18
17
19
24
48 ± 5 N·m
25
16
6.9 ± 0.9 N·m
AK500273 AC
>>H<<
>>G<<
12.
13.
14.
15.
16.
17.
18.
19.
Disassembly steps
Interlock plate bolt
Gasket
Control housing
Neutral return spring
Under cover
Reverse idler gear shaft bolt
Gasket
Reverse idler gear assembly
<<A>>
<<B>>
>>F<<
>>E<<
>>D<<
>>D<<
20.
21.
22.
23.
24.
25.
Disassembly steps (Continued)
Sealing cap
Transmission case
Outer race
Spacer
Magnet holder
Magnet
22B-16
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
Apply gear oil to all
moving parts before
installation.
30
29
27
28
26
32
38
31
34
33
39
36
37
18 ± 3 N·m
35
AK204219AB
>>C<<
<<C>>
<<C>>
<<C>>
>>C<<
>>C<<
>>B<<
>>B<<
>>B<<
26.
27.
28.
29.
30.
31.
32.
33.
Disassembly steps
Spring pin
1st-2nd speed shift rail
1st-2nd speed shift fork
Spring pin
Spring pin
3rd-4th speed shift rail
3rd-4th speed shift fork
5th speed-reverse shift rail
<<C>>
>>B<<
<<D>>
<<D>>
>>A<<
>>A<<
34.
35.
36.
37.
38.
39.
Disassembly steps (Continued)
5th speed-reverse shift fork
Front bearing retainer
Input shaft
Output shaft
Differential
Clutch housing
22B-17
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
<W5M42>
18 ± 3 N·m
7
6
32 ± 2 N·m
3.9 ± 1.0 N·m
4
9
11
14
3.9 ± 1.0 N·m
10
18 ± 3 N·m
5
13
8
70 ± 10 N·m
12
2
70 ± 10 N·m
1
3
69 ± 9 N·m
AK500545 AB
>>J<<
>>I<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disassembly steps
Transfer
O-ring
Roll stopper bracket, front
Roll stopper bracket, rear
Roll stopper bracket, adaptor
Shift cable bracket
Select lever
Vehicle speed sensor
Back-up lamp switch
10.
11.
12.
13.
14.
Disassembly steps (Continued)
Gasket
Poppet spring
Gasket
Corrugate clamp bracket
Corrugate clamp bracket <2.0 L
models>
22B-18
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
17
Apply gear oil to all
moving parts before
installation.
18 ± 3 N·m
30 ± 3 N·m
18
15
25
23
16
44 ± 5 N·m
24
26
21
20
19
27
48 ± 6 N·m
28
19
6.9 ± 0.9 N·m
AK500522 AC
>>H<<
>>G<<
15.
16.
17.
18.
19.
20.
21.
22.
Disassembly steps
Interlock plate bolt
Gasket
Control housing
Neutral return spring
Under cover
Reverse idler gear shaft bolt
Gasket
Reverse idler gear assembly
<<A>>
<<B>>
>>F<<
>>E<<
>>D<<
>>D<<
23.
24.
25.
26.
27.
28.
Disassembly steps (Continued)
Sealing cap
Transmission case
Outer race
Spacer
Magnet holder
Magnet
22B-19
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
33
Apply gear oil to all
moving parts before
installation.
32
30
31
29
35
41
34
37
36
42
39
40
18 ± 3 N·m
38
AK204189AB
>>C<<
<<C>>
<<C>>
>>C<<
>>C<<
>>B<<
>>B<<
29.
30.
31.
32.
33.
34.
35.
Disassembly steps
Spring pin
1st-2nd speed shift rail
1st-2nd speed shift fork
Spring pin
Spring pin
3rd-4th speed shift rail
3rd-4th speed shift fork
<<C>>
<<C>>
>>B<<
>>B<<
<<D>>
<<D>>
>>A<<
>>A<<
36.
37.
38.
39.
40.
41.
42.
Disassembly steps (Continued)
5th speed-reverse shift rail
5th speed-reverse shift fork
Front bearing retainer
Input shaft
Output shaft
Differential
Clutch housing
22B-20
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
DISASSEMBLY SERVICE POINTS
<<A>> SEALING CAP REMOVAL
Sealing cap
<<C>> 3RD-4TH SPEED SHIFT
RAIL/3RD-4TH SPEED SHIFT FORK/5TH
SPEED-REVERSE SHIFT RAIL/5TH
SPEED-REVERSE SHIFT FORK
REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th
speed-reverse shift fork in the direction shown.
3rd-4th
speed
shift fork
AK204301 AB
1. Drive a screwdriver into the center of the sealing
cap.
2. Bend the screwdriver back to remove the sealing
cap.
5th speed
reverse
shift fork
AK204222 AB
<<B>> TRANSMISSION CASE REMOVAL
1. Remove all sixteen bolts securing the
transmission case to the clutch housing.
2. Pull up on the 3rd-4th speed shift rail and 5th
speed-reverse shift rail and take them out of the
hole in the clutch housing.
3rd-4th speed
shift rail
5th speedreverse
shift rail
Snap ring
AK204226 AB
AK204223 AB
2. Use snap ring pliers to expand the indicated snap
ring. The snap ring will release the grooved ball
bearing, and the output shaft assembly will fall
under its own weight.
3. Slide the 3rd-4th speed shift rail and 5th
speed-reverse shift rail in the direction shown and
remove them together with the shift forks.
CAUTION
Do not use a scraper or chisel to remove the
transmission case.
3. Remove the transmission case from the clutch
housing by gently prying on opposite sides at the
same time.
<<D>> INPUT SHAFT AND OUTPUT
SHAFT REMOVAL
Input shaft
Output shaft
AK204224 AB
Remove the input and output shafts together.
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR DIFFERENTIAL CASE
PREROAD ADJUSTMENT
<Measurement using a solder>
CAUTION
• If soft solder is not available, select the
spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard
value cannot be selected using soft solder,
select the spacer in accordance with Plastigage method.
22B-21
7. Measure the thickness of the crushed solder with
a micrometer and select a spacer that will provide
the standard preload value.
Spacer thickness: (T − 0.05) to (T − 0.11)
T: The crushed solder thickness
Standard value: 0.05 − 0.11 mm preload
<Measurement using Plastigage>
Plastigage
Solders
AK204227AC
AK204227 AB
1. Put solders (1.0 mm diameter, about 10 mm long)
in the illustrated positions of the transmission
case.
2. Install the taper bearing outer race and differential
assembly into the transmission case.
NOTE: If necessary, replace the differential case
and taper bearing before carrying out these
adjustments.
3. Install the clutch housing and tighten the bolts to
the specified torque of 44 ± 5 N⋅m.
4. Remove the clutch housing, and then remove the
differential assembly.
5. Remove the outer race and take out crushed
solders.
6. If the solders have not crushed, use thicker
solders (1.6 mm diameter, about 10 mm long) and
repeat steps 2 to 5.
1. Put plastigage (about 10 mm long) in the
illustrated positions of the transmission case.
2. Install the adjusting spacer having the minimum
thickness.
3. Install the taper bearing outer race and differential
assembly into the transmission case.
NOTE: If necessary, replace the differential case
and taper bearing before carrying out these
adjustments.
4. Install the clutch housing and tighten the bolts to
the specified torque of 44 ± 5 N⋅m.
5. Remove the clutch housing, and then remove the
differential assembly.
6. Remove the outer race and take out crushed
plastigage.
7. If the plastigages have not crushed, replace the
spacer with a thicker one and repeat steps 3 to 6.
Plastigage
Spacer
AKX00953
AK402081 AB
8. Measure the width of the crushed plastigage at its
widest part using a scale printed on the plastigage
package.
Standard value: 0.05 − 0.11 mm preload
22B-22
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
REASSEMBLY SERVICE POINTS
>>A<< OUTPUT SHAFT/INPUT SHAFT
INSTALLATION
Input shaft
5th speedreverse
shift rail
3rd-4th speed
shift rail
Output shaft
AK204223 AC
AK204224 AB
Install the input and output shafts together.
>>B<< 5TH SPEED-REVERSE SHIFT
FORK/5TH SPEED-REVERSE SHIFT
RAIL/3RD-4TH SPEED SHIFT
FORK/3RD-4TH SPEED SHIFT RAIL
INSTALLATION
3. While fitting each shift fork in the groove of
synchronizer sleeve, slide the shift rails in the
direction shown and install.
4. Insert the 3rd-4th speed shift rail and 5th
speed-reverse shift rail into the rail hole in the
clutch housing.
>>C<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork.
Shift fork
Shift rail
2.5 mm
3rd-4th speed
synchronizer
sleeve
Spring pin
5th speedreverse
synchronizer
sleeve
AK204302 AC
AK204229AB
1. Shift the 3rd-4th speed synchronizer sleeve and
5th speed-reverse synchronizer sleeve in the
direction shown.
3rd-4th speed shift rail
5th speedreverse
shift fork
2. Insert the new spring pin. Push it in as shown so
that the slit and center axis of the rail are aligned.
>>D<< SPACER AND OUTER RACE
INSTALLATION
1. Install the spacer selected in the section
"ADJUSTMENT BEFORE REASSEMBLY."
3rd-4th speed
shift fork
5th speedreverse
shift rail
AK204230 AB
2. Assemble the 3rd-4th speed shift rail and fork,
and the 5th speed-reverse shift rail and fork.
MB990938
MB990935
AK204231 AB
2. Using special tools, press the outer race into the
transmission case.
• Installer adapter (MB990935)
• Handle (MB990938)
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
>>E<< TRANSMISSION CASE
INSTALLATION
CAUTION
Squeeze sealant evenly onto the transmission
housing. Do not leave gaps or excess amounts,
otherwise oil leaks are likely.
22B-23
>>F<< SEALING CAP INSTALLATION
MB990938
MB990927
AK204234 AB
1. Using special tools, press install the sealing cap
onto the case.
• Installer adapter (MB990927)
• Handle (MB990938)
AK204232AB
1. Apply a 2 mm diameter bead of sealant as
illustrated onto the transmission case.
Specified sealant:
Mitsubishi genuine sealant Part No.
MD997740 or equivalent
NOTE: Be sure to install the transmission case
onto the transmission housing while the sealant is
still wet (within 15 minutes).
Sealing cap
AK204233 AB
2. Evenly press the sealing cap so it is fully seated
and not at an angle.
>>G<< UNDER COVER INSTALLATION
CAUTION
Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
likely.
Snap ring
AK204226 AB
2. Align the transmission case and expand the snap
ring. After the case is on far enough for the snap
ring to ride on the bearing, release the snap ring.
Push down on the transmission case, twisting it
from side to side until the case contacts the
housing.
3. Tighten the transmission case mounting bolts to
the specified torque of 44 ± 5 N⋅m.
4. Place the transmission upside down and let the
snap ring fit in the groove by the output shaft's
own weight.
NOTE: After installation, keep the sealed area
away from oil for approximately one hour.
AK204235AB
1. Apply a 2 mm diameter bead of sealant as
illustrated onto the under cover.
Specified sealant:
Mitsubishi genuine sealant Part No.
MD997740 or equivalent
NOTE: Be sure to install the under cover to the
case quickly while the sealant is still wet (within 15
minutes).
22B-24
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION
2. Install the under cover to the transmission case
and tighten the bolts to specified torque of 6.9 ±
0.9 N⋅m.
NOTE: After installation, keep the sealed area
away from oil for approximately one hour.
>>H<< CONTROL HOUSING
INSTALLATION
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4)
to the O-ring of the vehicle speed sensor. Install
into the transmission housing.
2. Tighten the bolt to specified torque of 3.9 ± 1.0
N⋅m.
>>J<< SELECT LEVER INSTALLATION
CAUTION
Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
likely.
Control shaft
Select lever
shoe
AK204238 AB
AK204236AB
1. Apply a 0.2 mm diameter bead of sealant as
illustrated onto the control housing.
Specified sealant:
Mitsubishi genuine sealant Part No.
MD997740 or equivalent
NOTE: Be sure to install the housing to the case
quickly while the sealant is still wet (within 15 minutes).
2. Install the control housing to the transmission
case and tighten the bolts to specified torque of
18 ± 3 N⋅m.
NOTE: After installation, keep the sealed area
away from the oil for approximately one hour.
1. Apply grease (Mitsubishi Genuine Part number
0101011 or equivalent) to the control shaft sliding
portion of the select lever shoe.
2. Install the select lever and tighten the bolts to
specified torque of 18 ± 3 N⋅m.
INSPECTION
M1222001100297
BACK-UP LMAP SWITCH
AKX00952
>>I<< VEHICLE SPEED SENSOR
INSTALLATION
O-ring
AK204237 AB
Check for continuity between terminals.
Switch condition
Continuity
Pressed
Open
Released
Conductive
22B-25
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
INPUT SHAFT
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222001600333
9
Apply gear oil to all
moving parts before
installation.
11
10
12
14
13
15
16
19
18
2
20
4
6
7
1
8
17
3
16
5
AK204391AB
<<A>>
<<B>>
<<C>>
<<D>>
>>M<<
>>L<<
>>K<<
>>J<<
>>I<<
>>H<<
>>E<<
>>D<<
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
8. 4th speed gear sleeve
9. Synchronizer ring
10. Synchronizer spring
>>G<<
>>F<<
>>E<<
>>D<<
<<E>>
>>C<<
>>B<<
>>A<<
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Disassembly steps (Continued)
Synchronizer sleeve
3rd-4th speed synchronizer hub
Synchronizer ring
Synchronizer spring
3rd speed gear
Needle roller bearing
Snap ring
Ball bearing
Oil seal
Input shaft
22B-26
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
INPUT SHAFT
DISASSEMBLY SERVICE POINTS
<<A>> BALL BEARING REMOVAL
<<D>> 4TH SPEED GEAR SLEEVE
REMOVAL
MD998801
MD998801
AK204241 AB
AK204239 AB
1. Using special tool Bearing remover (MD998801),
support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.
1. Using special tool Bearing remover (MD998801),
support the 3rd speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 4th speed gear sleeve.
<<B>> THRUST PLATE STOPPER
REMOVAL
<<E>> BALL BEARING REMOVAL
MD998801
AK204242 AB
AK204293AB
Using a screwdriver, pry up at the position shown in
the illustration and remove the thrust plate stopper.
<<C>> 5TH SPEED GEAR REMOVAL
1. Using special tool Bearing remover (MD998801),
support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
MD998801
Oil seal
3.5 mm
AK204240 AB
1. Using special tool Bearing remover (MD998801),
support the 5th speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 5th speed gear.
AK204243 AC
Install the oil seal into the end of the input shaft as
shown.
22B-27
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
INPUT SHAFT
>>B<< BALL BEARING INSTALLATION
MD998812
MD998813
MD998801
MD998816
AK204244AC
Install the synchronizer spring onto the synchronizer
ring as shown.
>>E<< SYNCHRONIZER RING
INSTALLATION
CAUTION
There are 3rd speed and 4th speed synchronizer
rings, if the wrong one is installed it will effect
the shift feeling.
Notch
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, press install the ball bearing
with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998816)
>>C<< SNAP RING INSTALLATION
AK204312 AB
1. Ascertain whether or not there are identification
notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it completely
fits over the machined cone of the gear.
>>F<< 3RD-4TH SPEED SYNCHRONIZER
HUB INSTALLATION
Snap ring
Installation
direction
AK204245 AB
1. Install the thickest snap ring that can be fitted in
the snap ring groove of input shaft.
2. Make sure that the front bearing end play meets
the standard value.
Standard value: 0 − 0.12 mm
>>D<< SYNCHRONIZER SPRING
INSTALLATION
SYNCHRONIZER
Synchrnizer
SPRING
spring
AK204263AB
Groove
AK204295 AB
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Make sure that the synchronizer ring has been
perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th
speed synchronizer hub, and put it on the input
shaft.
22B-28
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
INPUT SHAFT
MD998812
>>H<< 4TH SPEED GEAR SLEEVE
INSTALLATION
MD998813
MD998801
MD998812
MD998825
MD998813
MD998801
MD998824
AK204246 AC
4. Using special tools, press install the 3rd-4th
speed synchronizer hub with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998825)
5. Make sure that the synchronizer ring can rotate
freely.
>>G<< SYNCHRONIZER SLEEVE
INSTALLATION
Identification
groove
AK204247 AC
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, install the 4th speed gear
sleeve with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998824)
>>I<< 5TH SPEED GEAR INSTALLATION
MD998812
MD998813
Installation
direction
(3rd speed side)
MD998801
MD998824
AK400082AB
1. Check the installation direction of the
synchronizer sleeve, and install it onto the 3rd-4th
speed synchronizer hub.
Projecting portion
Deep grooves
AK204199AB
2. Install the synchronizer sleeve so that the areas
with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
AK204248 AB
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, install the 5th speed gear onto
the input shaft with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998824)
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
INPUT SHAFT
>>J<< THRUST PLATE INSTALLATION
Surface stamped
with identification
mark
22B-29
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, install the ball bearing onto
the input shaft with the press.
• Installer cap (MD998812)
• Installer adapter (MD998818)
>>M<< SNAP RING INSTALLATION
Thrust plate
AK204249AB
1. Install the thickest thrust plates that can be fitted
in the groove of the input shaft. Install the thrust
plate so the surface stamped with the
identification mark is facing up.
2. Make sure that the 5th speed gear end play meets
the standard value.
Standard value: 0 − 0.09 mm
Snap ring
AK204251 AB
MD998812
1. Install the thickest snap ring that can be fitted in
the groove of the input shaft.
2. Make sure that the rear bearing end play meets
the standard value.
Standard value: 0 − 0.12 mm
MD998813
INSPECTION
MD998824
INPUT SHAFT
>>K<< THRUST PLATE STOPPER
INSTALLATION
M1222001700095
AK204294 AB
Install the thrust plate stopper by pressing special
tools, by hand. Make sure that it is not tilted.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998824)
AK204201AB
>>L<< BALL BEARING INSTALLATION
MD998812
MD998818
MD998801
AK204250 AC
1. Check the outside diameter of the needle bearing
mounting portion for damage, abnormal wear and
seizure.
2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not
damaged or worn.
22B-30
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
INPUT SHAFT
NEEDLE ROLLER BEARING
SYNCHRONIZER SLEEVE AND HUB
1. Combine the needle roller bearing with the input
shaft or bearing sleeve and gear, and check that it
rotates smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
Sleeve
SYNCHRONIZER RING
Hub
AK204217 AB
1. Combine the synchronizer sleeve and hub, and
check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
AK204298AB
1. Check the clutch gear teeth for damage and
broken.
2. Check internal surface for damage, wear and
broken threads.
Gear
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or
broken.
SPEED GEARS
A
Synchronizer
ring
AK204299AB
AK204307 AB
3. Force the synchronizer ring toward the clutch gear
and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
Minimum limit: 0.5 mm
1. Check that the helical and clutch gear tooth
surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
22B-31
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002200350
20
22
24
Apply gear oil to all
moving parts before
installation.
26
19
27
29
18
21
23
4
25
1
28
5
30
32
33
31
13
3 2
36
12
34
15
35
7
17
14 10
16
11
9
8
6
4
13
AK204392AB
<<A>>
<<B>>
>>R<<
>>Q<<
>>P<<
<<C>>
>>M<<
>>L<<
>>O<<
>>N<<
>>M<<
>>L<<
<<D>>
>>K<<
>>J<<
>>I<<
>>H<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Disassembly steps
Snap ring
Ball bearing
Reverse gear sleeve
Needle roller bearing
Reverse gear
Synchronizer ring
Synchronizer spring
Synchronizer sleeve
5th speed-reverse synchronizer
hub
Synchronizer ring
Synchronizer spring
5th speed gear
Needle roller bearing
5th speed gear sleeve
4th speed gear
Snap ring
3rd speed gear
2nd speed gear
<<E>>
>>G<<
>>D<<
>>F<<
>>E<<
>>D<<
<<F>>
<<G>>
>>C<<
>>B<<
>>A<<
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Disassembly steps (Continued)
Needle roller bearing
2nd speed gear sleeve
Inner synchronizer ring
Synchronizer cone
Outer synchronizer ring
Synchronizer spring
Synchronizer sleeve
1st-2nd speed synchronizer hub
Outer synchronizer ring
Synchronizer spring
Inner synchronizer ring
Synchronizer cone
1st speed gear
Needle roller bearing
1st speed gear sleeve
Snap ring
Roller bearing inner race
Output shaft
22B-32
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
DISASSEMBLY SERVICE POINTS
<<A>> BALL BEARING REMOVAL
MD998917
Ball bearing
1. Using special tool Bearing remover (MD998801),
support the 4th speed gear, and then set them on
the press.
2. Push down on the output shaft with the press and
remove the 5th speed-reverse synchronizer hub.
<<D>> 3RD SPEED GEAR REMOVAL
MD998917
3rd speed gear
AK204252 AC
1. Using special tool Bearing remover (MD998917),
support the ball bearing, and then set them on the
press.
2. Push down on the output shaft with the press, and
remove the ball bearing.
<<B>> REVERSE GEAR SLEEVE
REMOVAL
MD998801
Reverse gear
sleeve
AK204255 AB
1. Using special tool Bearing remover (MD998917),
support the 2nd speed gear, and then set them on
the press.
2. Push down on the output shaft with the press and
remove the 3rd speed gear.
<<E>> 2ND SPEED GEAR SLEEVE
REMOVAL
2nd speed gear sleeve
AK204253 AC
1. Using special tool Bearing remover (MD998801),
support the reverse gear, and then set them on
the press.
2. Push down on the output shaft with the press and
remove the reverse gear sleeve.
<<C>> 5TH SPEED-REVERSE
SYNCHRONIZER HUB REMOVAL
Synchronizer hub
MD998801
AK204254 AB
MD998917
AK204256 AC
1. Using special tool Bearing remover (MD998917),
support the 1st speed gear, and then set them on
the press.
2. Push down on the output shaft with the press and
remove the 2nd speed gear sleeve.
22B-33
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
<<F>> 1ST SPEED GEAR SLEEVE
REMOVAL
1st speed gear sleeve
REASSEMBLY SERVICE POINTS
>>A<< ROLLER BEARING INNER RACE
INSTALLATION
MD998801
MD998812
MD998818
MD998801
Roller bearing
inner race
AK204257 AC
1. Using special tool Bearing remover (MD998801),
support the 1st speed gear sleeve, and then set
them on the press.
2. Push down on the output shaft with the press and
remove the 1st speed gear sleeve.
<<G>> ROLLER BEARING INNER RACE
REMOVAL
MD998917
Roller bearing
inner race
AK204260 AB
1. Using special tool Bearing remover (MD998801),
support the output shaft gear, and then set them
on the press.
2. Using special tools, install the roller bearing inner
race with the press.
• Installer cap (MD998812)
• Installer adapter (MD998818)
>>B<< SNAP RING INSTALLATION
Snap ring
AK204258 AB
1. Using special tool Bearing remover (MD998917),
support the roller bearing inner race, and then set
them on the press.
2. Push down on the output shaft with the press and
remove the roller bearing inner race.
AK204261 AB
1. Install the thickest snap ring that can be fitted in
the groove of output shaft.
2. Make sure that the front bearing inner race end
play meets the standard value.
Standard value: 0 − 0.12 mm
22B-34
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
>>C<< 1ST SPEED GEAR SLEEVE
INSTALLATION
1. Set the output shaft on the press support stand.
2. Check that the 1st-2nd speed synchronizer hub is
in the correct installation direction, and put it on
the output shaft.
MD998812
MD998812
MD998814
MD998814
1st speed
gear sleeve
1st-2nd speed
synchronizer
hub
MD998825
MD998825
AK204265 AC
AK204262 AC
2. Using special tools, install the 1st speed gear
sleeve with the press.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998825)
>>D<< SYNCHRONIZER SPRING
INSTALLATION
3. Using special tools, install the 1st-2nd speed
synchronizer hub with the press.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998825)
4. Make sure that the outer synchronizer ring on the
1st speed gear side can rotate freely.
>>F<< SYNCHRONIZER SLEEVE
INSTALLATION
Identification groove
Synchronizer spring
AK204316AC
Install the synchronizer spring onto the outer synchronizer ring
as shown.
>>E<< 1ST-2ND SPEED SYNCHRONIZER
HUB INSTALLATION
Installation
direction
(1st speed side)
AK305817AG
1. Check that the synchronizer sleeve is in the
correct direction for installation, and install it on
the 1st-2nd speed synchronizer hub.
Projecting portion
1. Set the output shaft on the press support stand.
Installation direction
Deep grooves
AK204305 AC
AK204199AB
22B-35
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
2. Install the synchronizer sleeve so that the areas
with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
>>I<< SNAP RING INSTALLATION
>>G<< 2ND SPEED GEAR SLEEVE
INSTALLATION
1. Set the output shaft on the press support stand.
Snap ring
AK204268AB
MD998812
MD998814
MD998822
AK204266 AD
2. Using special tools, install the 2nd speed sleeve
onto the output shaft with the press.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998822)
1. Install the thickest snap ring that can be fitted in
the groove of output shaft.
2. Make sure that the 3rd speed gear end play
meets the standard value.
Standard value: 0 − 0.09 mm
>>J<< 4TH SPEED GEAR INSTALLATION
1. Set the output shaft on the press support stand.
MD998812
MD998813
4th speed gear
MD998819
>>H<< 3RD SPEED GEAR INSTALLATION
1. Check that the 2nd speed gear and the outer
synchronizer ring have been properly installed.
Also, make sure the claws on the synchronizer
cone (four places) are correctly fitted into the
holes in the 2nd speed gear (four places).
MD998812
MD998814
3rd speed gear
MD998822
AK204269 AB
2. Using special tools, install the 4th speed gear onto
the output shaft with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998819)
>>K<< 5TH SPEED GEAR SLEEVE
INSTALLATION
MD998812
AK204267 AB
2. Using special tools, install the 3rd speed gear
onto the output shaft with the press.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998822)
3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
5th speed
gear sleeve
MD998813
MD998819
AK204300 AB
Using special tools, install the 5th speed gear sleeve
onto the output shaft with the press.
22B-36
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998819)
>>N<< 5TH SPEED-REVERSE
SYNCHRONIZER HUB INSTALLATION
>>L<< SYNCHRONIZER SPRING
INSTALLATION
1. Set the output shaft on the press support stand.
2. Make sure that the synchronizer ring is fitted
correctly on the cone of the 5th speed gear.
Installation direction
SYNCHRONIZER
Synchrnizer
SPRING
spring
AK204306 AB
AK204263AB
Install the synchronizer spring onto the synchronizer
ring as shown.
3. Check that the 5th speed-reverse synchronizer
hub is oriented correctly for installation, and fit it
on the output shaft.
>>M<< SYNCHRONIZER RING
INSTALLATION
CAUTION
There is a 5th speed synchronizer ring and a
reverse synchronizer ring. Be careful not to confuse the two when installing, as a mistake can
effect the shift feeling.
MD998812
MD998813
MD998819
Synchronizer hub
AK204228 AB
Notch
AK204393AB
1. Check for the presence of identification notches
on the synchronizer ring.
No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring
2. Install the synchronizer ring so that it fits
completely over the machined cone of the gear.
4. Using special tools, press install the 5th
speed-reverse synchronizer hub with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998819)
5. Make sure that the synchronizer ring on the 5th
speed gear side can rotate freely.
22B-37
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
>>O<< SYNCHRONIZER SLEEVE
INSTALLATION
Identification
groove
2. Using special tools, press fit the reverse gear
sleeve. Make sure that the reverse gear and the
synchronizer ring can rotate freely during the
pressing process.
• Installer cap (MD998812)
• Installer adapter (MD998818)
>>Q<< BALL BEARING INSTALLATION
1. Check the installation direction of the ball bearing.
Installation
direction
(5th speed side)
MD998812
AK400307AC
1. Check that the synchronizer sleeve is in the
correct direction for installation, and install it on
the 5th speed-Reverse synchronizer hub.
MD998818
Ball bearing
Projecting portion
AK204271 AC
2. Using special tools, install the ball bearing with the
press.
• Installer cap (MD998812)
• Installer adapter (MD998818)
Deep grooves
AK204199AB
>>R<< SNAP RING INSTALLATION
2. Install the synchronizer sleeve so that the areas
with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
>>P<< REVERSE GEAR SLEEVE
INSTALLATION
1. Make sure the synchronizer ring, reverse gear
and needle roller bearing have been correctly
installed.
MD998812
MD998818
Reverse
gear
Reverse gear
sleeve
AK204270 AB
Snap ring
AK204272 AC
1. Install the thickest snap ring that can be fitted in
the groove of output shaft.
2. Make sure that the rear bearing end play meets
the standard value.
Standard value: 0 − 0.09 mm
22B-38
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
INSPECTION
SYNCHRONIZER RING
M1222002300131
OUTPUT SHAFT
AK204298AB
AK204310AB
1. Check the splines for damage and wear.
2. Check that the helical gear teeth surfaces are not
damaged or worn.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the
bearing sleeve and gear, and check that it rotates
smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
1. Check if the clutch gear teeth are damaged or
broken.
2. Check internal surface for damage, wear and
broken threads.
Gear
A
Synchronizer
ring
AK204307 AB
3. Force the synchronizer ring toward the clutch gear
and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
Minimum limit: 0.5 mm
22B-39
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
OUTPUT SHAFT
OUTER SYNCHRONIZER RING/INNER
SYNCHRONIZER RING/SYNCHRONIZER
CONE <FOR 1ST, 2ND SPEED>
SYNCHRONIZER SLEEVE AND HUB
Sleeve
CAUTION
When replacing, replace the outer ring, inner ring
and cone as a set.
Hub
AK204217 AB
1. Combine the synchronizer sleeve and hub, and
check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
AK204395AB
1. Check that the clutch gear tooth surfaces and
cone surfaces are not damaged or broken.
SYNCHRONIZER SPRING
A
Gear
Outer ring
Cone
AK204314AB
Inner ring
AK203130AD
2. Install the outer ring, inner ring and cone, force
them toward the gear, and check clearance "A". If
"A" is less than the limit, replace them as a set.
Minimum limit: 0.5 mm
Check that the spring is not sagging, deformed or
broken.
SPEED GEARS
AK204299AB
1. Check that the helical and clutch gear tooth
surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
22B-40
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
REVERSE IDLER GEAR
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
M1222012500136
Apply gear oil to
all moving parts
before installation.
1
2
3
4
5
6
AK302745AC
>>A<<
1.
2.
3.
4.
5.
6.
Disassembly steps
Snap ring
Thrust washer
Reverse idler gear
Needle roller bearing
Friction damper
Reverse idler gear shaft
REASSEMBLY SERVICE POINT
>>A<< FRICTION DAMPER INSTALLATION
21.5 ± 0.2 mm
AK302712AB
After apply gear oil to the outside and inside circumferences of the friction damper, install it using the
special tool in position as shown in Fig.
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
VEHICLE SPEED SENSOR
22B-41
VEHICLE SPEED SENSOR
DISASSEMBLY AND REASSEMBLY
M1222007000038
Apply gear oil to all
moving parts before
installation.
4
2
3
1
AK204397AB
1.
2.
Disassembly steps
E-clip
Speed sensor gear
3.
4.
Disassembly steps (Continued)
O-ring
Speed sensor
22B-42
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
SELECT LEVER
SELECT LEVER
DISASSEMBLY AND REASSEMBLY
M1222012800074
6
5
7
1
8
2
9
11 ± 1 N·m
3
4
10
AK204398AB
>>A<<
>>A<<
>>A<<
Disassembly steps
1. Dust cover
2. Nut
3. Spring washer
4. Washer
5. Select lever bushing
6. Select lever shoe
7. Select lever
8. Select lever bushing
9. Dust cover
10. Select lever shaft
REASSEMBLY SERVICE POINT
>>A<< DUST COVER AND SELECT
LEVER BUSHING INSTALLATION
Select lever
bushing
Dust cover
AK204311 AB
Make sure the dust cover and select lever bushing
installation direction is correct, and the distinguished
parts are correctly assembled as shown.
22B-43
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CONTROL HOUSING
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
M1222013100335
7
9
3
6
11
5
12
4
13
8
10
14
2
1
21.7 ±0.3 N·m
AK403619AB
<<A>>
>>E<<
>>D<<
>>C<<
>>B<<
>>A<<
1.
2.
3
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Disassembly steps
Spring washer
Stopper bracket
Lock pin
Interlock plate
Control finger
Spring pin
Stopper body
Neutral return spring
Control shaft
Air breather
Control shaft boot
Oil seal
Needle bearing
Control housing
DISASSEMBLY SERVICE POINT
<<A>> LOCK PIN REMOVAL
Lock pin
Control finger
AK204273 AB
Drive out the lock pin from the direction shown.
22B-44
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CONTROL HOUSING
REASSEMBLY SERVICE POINTS
>>A<< NEEDLE BEARING INSTALLATION
Emboss
mark
Control housing
Needle bearing
Model number
stamped side
AK204220 AB
0 – 0.5 mm
AK204176AC
Press fit the needle bearing into the control housing
side as shown.
Make sure that the side with the model number
stamped on it faces the end of the control housing as
shown.
2. Install the air breather so that the emboss mark is
in the direction shown in the figure.
>>D<< SPRING PIN INSTALLATION
Control shaft
Stopper body
Installation direction
>>B<< OIL SEAL INSTALLATION
Slit
Spring pin
AK204177AB
Drive in the spring pin so that the slit is in the direction shown in the figure.
AK204303AB
>>E<< LOCK PIN INSTALLATION
Apply gear oil (DiaQueen NEW MULTI GEAR OIL
API classification GL-3, SAE 75W-80 or Gear oil API
classification GL-4, SAE 75W-85W/75W-90) to the
oil seal lip area.
>>C<< AIR BREATHER INSTALLATION
AK204273 AC
Drive the lock pin in from the direction shown in the
figure.
AK204274AB
1. Apply sealant to the inserting portion of air
breather.
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or equivalent
22B-45
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CLUTCH HOUSING
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
M1222003700422
7
4
6*
3
5
2
1
9.8 ± 2.0 N·m
AK204400AD
<<A>>
<<B>>
>>E<<
>>D<<
>>C<<
>>B<<
1.
2.
3
4.
5.
Disassembly steps
Clutch release bearing retainer
Oil seal
Oil seal <F5M42>
Outer race
Outer race
Disassembly steps (Continued)
6. Bushing
7. Clutch housing
NOTE: * Refer to the bushing installation procedures only
when replacing the clutch housing.
>>A<<
22B-46
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CLUTCH HOUSING
DISASSEMBLY SERVICE POINTS
<<A>> OUTER RACE REMOVAL
1 mm
MD999566
AK204291 AC
AK204276 AB
Using special tool Claw (MD999566), remove the
outer race from the clutch housing.
2. Be sure the bushing is fully seated as shown. It
must be 1 mm below the housing surface.
>>B<< OUTER RACE INSTALLATION
<<B>> OUTER RACE REMOVAL
MD998772
MD998346
Model number
stamped side
AK204279 AB
1. Check the installation direction of the outer race.
AK204277AB
1. Set special tools as indicated in the figure.
• Valve spring compressor (MD998772)
• Bearing outer race remover (MD998346)
2. Turn the nut on special tool Bearing outer race
remover (MD998346) to pull up on the tool and
take out the outer race.
Install the outer race so the side with the model
number stamping can be seen.
MB990938
MB990934
REASSEMBLY SERVICE POINTS
>>A<< BUSHING INSTALLATION
Seam of bushing
AK204280 AB
2. Using special tools, press fit the outer race into
the clutch housing.
• Handle (MB990938)
• Installer adapter (MB990934)
Air vent
AK204278 AB
1. Press fit the bushing so the seam is away from
the air vent.
22B-47
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CLUTCH HOUSING
>>C<< OUTER RACE INSTALLATION
>>E<< OIL SEAL INSTALLATION
1. Check the installation direction of the outer race.
MB990938
MB990935 <F5M42>
MB991550 <W5M42>
AK204281 AC
2. Using special tools, press fit the outer race into
the clutch housing.
• Handle (MB990938)
• Installer adapter (MB990935)
• Bearing outer race installer (MB991550)
AK204284AC
1. Apply specified grease to the oil seal lip.
Specified grease:
Mitsubishi Part number 0101011 or equivalent
MB990938
>>D<<OIL SEAL INSTALLATION
MB990926
AK204285 AB
2.6 mm
AK204282AC
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4)
to the oil seal lip.
MD998325
AK204283 AB
2. Using special tool Differential oil seal installer
(MD998325), press fit the oil seal into the clutch
housing.
2. Using special tools, press fit the oil seal into the
clutch housing.
• Handle (MB990938)
• Installer adapter (MB990926)
22B-48
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION CASE
TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY
M1222013400358
1
2*
5*
4
3
6
AK204407AC
>>D<<
>>C<<
>>B<<
1.
2.
3.
4.
Disassembly steps
Oil seal
Needle bearing
Oil guide
Snap ring
Disassembly steps (Continued)
5. Bushing
6. Transmission case
NOTE: * Refer to the needle bearing and bushing installation procedures only when replacing the transmission
case.
>>A<<
22B-49
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSMISSION CASE
REASSEMBLY SERVICE POINTS
>>A<< BUSHING INSTALLATION
>>C<< NEEDLE BEARING INSTALLATION
1. Check the installation direction of the needle
bearing.
Seam of bushing
Model number
stamped side
Air vent
AK204292 AB
1. Press fit the bushing so the seam is away from
the air vent.
AK204287 AB
2. Press fit the needle bearing until it is flush with the
case.
>>D<<OIL SEAL INSTALLATION
3 mm
AK204304 AC
2. Be sure the bushing is fully seated as shown. It
must be 3 mm below the housing surface.
>>B<< OIL GUIDE INSTALLATION
1.5 mm*1
4.1 mm*2
*1: F5M42
*2: W5M42
AK204286 AE
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4).
Oil guide
MD998325
AK500016 AB
AK204288 AB
1. Evenly press the oil guide so it is fully seated and
at an angle.
2. Using special tool Differential oil seal installer
(MD998325), press fit the oil seal into the
transmission case.
22B-50
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
DIFFERENTIAL
DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
M1222002500339
<F5M42>
2
Apply gear oil to all
moving parts before
installation.
3
8
6
5
4
8
1
7
133 ± 4 N·m
5
2
6
9
AK204408AD
<<A>>
>>D<<
>>C<<
>>B<<
>>A<<
>>A<<
1.
2.
3.
4.
5.
Disassembly steps
Differential drive gear
Taper roller bearing
Lock pin
Pinion shaft
Pinion
>>A<<
>>A<<
>>A<<
6.
7.
8.
9.
Disassembly steps (Continued)
Washer
Side gear
Spacer
Differential case
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
DIFFERENTIAL
22B-51
DISASSEMBLY SERVICE POINT
<<A>> TAPER ROLLER BEARING
REMOVAL
MD998801
AKX00770
3. Insert the pinion shaft.
AK204289 AB
1. Using special tool Bearing remover (MD998801),
support the taper roller bearing, and then set them
on the press.
2. Push down on the differential case with the press
and remove the bearing.
REASSEMBLY SERVICE POINTS
>>A<< SPACER/SIDE
GEAR/WASHER/PINION/PINION SHAFT
INSTALLATION
AKX00766
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 that should get the back lash with in the
standard value and re-measure the backlash.
NOTE: Repeat until the backlash on both sides
are equal.
>>B<< LOCK PIN INSTALLATION
Differential case
AKX00768
1. After a spacer has been mounted on the back
surface of the side gear, install the side gear in the
differential case.
NOTE: When a new side gear is to be installed,
mount a medium thickness spacer (1.11 − 1.19
mm).
2. Set the washer on the back of each pinion, and
put both pinions simultaneously in mesh with the
side gears. While rotating them, install them in
position.
Lock pin
Pinion shaft
AK204290 AB
Install the lock pin so that it will be oriented in the
direction shown.
22B-52
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
DIFFERENTIAL
>>C<< TAPER ROLLER BEARING
INSTALLATION
MD998812
MD998823
>>D<< DIFFERENTIAL DRIVE GEAR
INSTALLATION
Taper roller
bearing
AK204319 AC
Using special tools, install the taper roller bearing
with the press.
• Installer cap (MD998812)
• Installer adapter (MD998823)
AK204320AB
1. Apply sealant to the entire threaded portion of the
bolt.
Specified sealant:
3M STUD Locking No.4170 or equivalent
3
1
5
8
7
6
2
4
AK204221 AC
2. Tighten to the specified torque of 133 ± 4 N⋅m in
the illustrated sequence.
22B-53
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CENTRE DIFFERENTIAL
CENTRE DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
M1222002800192
<W5M42>
1
Apply gear oil to all
moving parts before
installation.
3
2
11
5
12
6
7
12
133 ± 4 N·m
4
17
3.9 ± 1.0 N·m
9
14
10
12
13
12
11
8
16
9
15
AK602561AC
<<A>>
>>D<<
>>C<<
>>B<<
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disassembly steps
Center differential drive gear
Center differential flange
Taper roller bearing
Snap ring
Front output shaft
Spacer
Side gear
Lock pin
Pinion shaft
<<B>>
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
>>A<<
10.
11.
12.
13.
14.
15.
16.
17.
Disassembly steps (Continued)
Pinion shaft holder
Pinions
Washers
Side gear
Spacer
Taper roller bearing
Speed meter drive gear
Differential case
22B-54
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CENTRE DIFFERENTIAL
DISASSEMBLY SERVICE POINTS
<<A>> TAPER ROLLER BEARING
REMOVAL
REASSEMBLY SERVICE POINTS
>>A<< TAPER ROLLER BEARING
INSTALLATION
MD998830
MD998917
AK204264AB
1. Support the taper roller bearing with special tool
bearing remover (MD998917), and then set them
on the press.
2. Push down on the differential case with the press
to remove the bearing.
<<B>> TAPER ROLLER BEARING
REMOVAL
AK204297AB
Using special tools, install the taper roller bearing
with the press.
• Installer cap (MD998812)
• Installer adapter (MD998830)
>>B<< TAPER ROLLER BEARING
INSTALLATION
MD998823
MD998917
MD998812
MD998812
MB990930
AK204308AB
AK204275AB
1. Support the taper roller bearing with special tools,
and then set them on the press.
• Bearing remover (MD998917)
• Installer adapter (MB990930)
2. Push down on the differential case with the press
to remove the bearing.
Using special tools, install the taper roller bearing
with the press.
• Installer cap (MD998812)
• Installer adapter (MD998823)
22B-55
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
CENTRE DIFFERENTIAL
>>C<< SPACER, SIDE GEAR, WASHER,
PINION AND PINION SHAFT, PINION
SHAFT HOLDER, LOCK PIN, FRONT
OUTPUT SHAFT, SNAP RING, CENTER
DIFFERENTIAL FLANGE, INSTALLATION
AK204389
8. Measure the backlash between the side gear and
pinion.
Standard value: 0.025 − 0.150 mm
AK204315
1. Mount a spacer on the back surface of the side
gear, and then install the side gear in the
differential case.
NOTE: When a new side gear is to be installed,
use a medium thickness spacer (0.66 to 0.73
mm).
2. Place the washers on the back of the pinions, and
simultaneously mesh the four pieces with the side
gears. Place them into position while rotating
them. Then, install the pinion shaft holder.
3. Insert the pinion shaft.
9. If the backlash is out of the standard value, select
a spacer and re-measure the backlash.
NOTE: Adjust until the backlash on both sides are
equal.
>>D<< CENTER DIFFERENTIAL DRIVE
GEAR INSTALLATION
Differential case
Lock pin
Pinion shaft
AK204320AB
1. Apply sealant to the entire threaded portion of the
bolt.
Specified sealant:
3M STUD Locking No.4170 or equivalent
AK204317AC
4. Install the lock pin so that it will be oriented in the
direction shown.
5. Install the front output shaft on the side gear, and
install the snap ring.
6. Mount a spacer on the back surface of the side
gear, and then install the side gear in the
differential case.
NOTE: When a new side gear is to be installed,
use a medium thickness spacer.
7. Install the center differential flange by aligning the
matching marks, and temporarily tighten the four
machine screws.
1
3
10
8
5
6
7
4
9
2
AK204318AB
2. Tighten to the specified torque of 133 ± 4 N⋅m in
the illustrated sequence.
22B-56
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSFER
TRANSFER
DISASSEMBLY AND REASSEMBLY
M1222004000084
4
1
2
5
6
3
7
11
8
9
Apply gear oil to all
moving parts before
installation.
10
23 ± 3 N·m
>>E<<
>>D<<
>>A<<
>>A<<
>>A<<
1.
2.
3.
4.
5.
6.
Disassembly steps
Dust seal guide
Oil seal
Oil seal
O-ring
O-ring
O-ring
AK204413AB
>>C<<
>>B<<
>>A<<
7.
8.
9.
10.
11.
Disassembly steps (Continued)
Oil seal
Oil seal
O-ring
Transfer cover
Transfer
22B-57
MANUAL TRANSMISSION OVERHAUL <F5M42,W5M42>
TRANSFER
REASSEMBLY SERVICE POINTS
>>A<< O-RING INSTALLATION
Install a O-ring to the transfer, and apply gear oil
(Hypoid gear oil API classification GL-5 SAE 90) to
the O-ring.
>>B<< OIL SEAL INSTALLATION
>>D<< OIL SEAL INSTALLATION
1. Apply gear oil (Hypoid gear oil API classification
GL-5 SAE 90).
MB990891
MB990887
1. Apply gear oil (Hypoid gear oil API classification
GL-5 SAE 90).
MB990938
MB990937
AK204416 AB
2. Using special tools, press fit the oil seal into the
transfer.
• Ring (MB990887)
• Bushing remover installer base (MB990891)
AK204414AB
2. Using special tools, press fit the oil seal into the
transfer cover.
• Installer adapter (MB990937)
• Handle (MB990938)
>>E<< OIL SEAL INSTALLATION
1. Apply gear oil (Hypoid gear oil API classification
GL-5 SAE 90).
MB990933
>>C<< OIL SEAL INSTALLATION
1. Apply gear oil (Hypoid gear oil API classification
GL-5 SAE 90).
MD998800
AK204417AB
2. Using special tool installer adapter (MB990933),
press fit the oil seal into the transfer.
AK204415AB
2. Using special tool oil seal installer (MD998800),
press fit the oil seal into the transfer cover.
NOTES