User manual MITSUBISHI W5M42 MANUAL TRANSMISSION

[. . . ] 22B-0-1 MANUAL TRANSMISSION F5M41, F5M42, W5M42 CONTENTS GENERAL INFORMATION . 2002 PWEE9508-I Revised 22B-0-2 NOTES MANUAL TRANSMISSION (E - W) - General Information 22B-0-3 GENERAL INFORMATION F5M41 <Types with single synchronizer ring for 2nd gear> 6 2 3 7 8 1 4 5 9 10 15 14 13 12 11 TFM0809 1. Reverse gear meshing noise prevention device <Models with reverse brake> 2. 15. Clutch housing Release bearing retainer Input shaft Differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear Output shaft E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised 22B-0-4 MANUAL TRANSMISSION (E - W) - General Information F5M41 <Types with double synchronizer ring for 2nd gear> 6 7 8 1 2 3 4 5 9 10 15 14 13 12 11 1. [. . . ] 2000 PWEE9508-H Revised MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> AF" BALL BEARING REMOVAL MD998801 22B-5-3 REASSEMBLY SERVICE POINTS Oil seal 3. 5 mm "AA OIL SEAL INSTALLATION Drive in the oil seal all the way up to the illustrated dimension. MD998812 MD998813 MD998817 "BA BALL BEARING INSTALLATION MD998801 "CA SNAP RING INSTALLATION Select and install a snap ring so that the input shaft front bearing end play will have the standard value. Standard value: - 0. 01 - 0. 12 mm Snap ring "DA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring securely up to the illustrated position of the synchronizer ring. Synchronizer spring E Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added 22B-5-4 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> "EA 3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION Install the 3rd-4th speed synchronizer hub in such a way that it will be oriented in the direction shown. Rear of transmission Identification mark MD998812 MD998813 MD998801 MD998826 Caution When the hub is installed, make sure that the synchronizer ring is not caught. Identification groove "FA SYNCHRONIZER SLEEVE INSTALLATION (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown. Rear of transmission Synchronizer sleeve (2) When the synchronizer sleeve is installed, make sure that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve. Synchronizer hub MD998812 MD998813 MD998801 MD998824 "GA 4TH SPEED GEAR SLEEVE INSTALLATION E Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> MD998812 MD998813 MD998820 22B-5-5 "HA 5TH SPEED GEAR SLEEVE INSTALLATION MD998801 "IA 5TH-REVERSE SPEED SYNCHRONIZER HUB INSTALLATION Install the 5th-reverse speed synchronizer hub in such a way that it will be oriented in the direction shown. Rear of transmission Identification mark MD998812 MD998819 MD998801 Caution When the 5th-reverse speed synchronizer hub is installed, make sure that the synchronizer ring is not caught. Identification groove "JA SYNCHRONIZER SLEEVE INSTALLATION (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown. Rear of transmission Synchronizer sleeve (2) When the synchronizer sleeve is installed, make sure that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve. Synchronizer hub E Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added 22B-5-6 MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> "KA REVERSE BRAKE SLEEVE INSTALLATION MD998812 MD998818 MD998801 MD998812 MD998818 MD998801 "LA BALL BEARING INSTALLATION "MASNAP RING INSTALLATION Select and install a snap ring so that the input shaft rear bearing end play will have the standard value. Standard value: - 0. 01 - 0. 09 mm 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. NEEDLE ROLLER BEARING (1) Check to ensure that when the input shaft, sleeve and gear are combined and made to rotate, they rotate smoothly without noise. (2) Check to ensure that the cage is not deformed. E Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 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. A (3) Press the synchronizer ring against the gear and check clearance "A". Limit: 0. 5 mm Synchronizer ring Gear SYNCHRONIZER SLEEVE AND HUB (1) Check to ensure that when the synchronizer sleeve and hub are combined and made to slide, they slide smoothly without binding. (2) Check to ensure that the front and rear ends of the sleeve inside surface are not damaged. 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. E Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A PWEE9508-G Added Revised MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-1 6. INPUT SHAFT <F5M42, W5M42> DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. 9 11 12 14 13 15 10 16 18 20 19 4 6 7 8 2 1 3 5 17 16 TFM0591 "LA AA" "KA "JA "IA AB" "HA Disassembly steps 1. 1998 PWEE9508-E Revised 22B-6-2 MANUAL TRANSMISSION (E - W) MD998801 Input Shaft <F5M42, W5M42> DISASSEMBLY SERVICE POINTS AA" BALL BEARING REMOVAL Use the special tool to remove the ball bearing. MD998801 AB" 5TH SPEED GEAR REMOVAL Use the special tool to remove the 5th speed gear. MD998801 AC" 4TH SPEED GEAR SLEEVE REMOVAL Mount a special tool on the 3rd gear and remove the 4th speed gear sleeve. MD998801 AD" BALL BEARING REMOVAL Use the special tool to remove the ball bearing. REASSEMBLY SERVICE POINTS Oil seal 3. 5 mm "AA OIL SEAL INSTALLATION Drive in the oil seal all the way up to the illustrated dimension. E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> MD998812 MD998813 MD998801 MD998816 22B-6-3 "BA BALL BEARING INSTALLATION Use the special tools to install the ball bearing. "CA SNAP RING INSTALLATION Select and install a snap ring so that the input shaft front bearing end play will have the standard value. Standard value: - 0. 01 - 0. 12 mm Snap ring "DA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring securely up to the illustrated position of the synchronizer ring. Synchronizer spring "EA 3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION Install the 3rd-4th speed synchronizer hub in such a way that it will be oriented in the direction shown. Rear of transmission Identification mark MD998812 MD998813 MD998801 MD998825 Caution When the hub is installed, make sure that the synchronizer ring is not caught. E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised 22B-6-4 MANUAL TRANSMISSION (E - W) Identification groove Input Shaft <F5M42, W5M42> "FA SYNCHRONIZER SLEEVE INSTALLATION (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown. Rear of transmission Synchronizer sleeve (2) When the synchronizer sleeve is installed, make sure that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve. Synchronizer hub MD998812 MD998813 MD998801 MD998824 "GA 4TH SPEED GEAR SLEEVE INSTALLATION Use the special tools to install the 4th speed gear sleeve. MD998812 MD998813 MD998801 MD998824 "HA 5TH SPEED GEAR INSTALLATION Use the special tools to install the 5th speed gear. "IA THRUST PLATE INSTALLATION Select and install a thrust plate so that the input shaft 5th speed gear end play will have the standard value. Standard value: - 0. 01 - 0. 09 mm Thrust plate E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> Thrust plate stopper 22B-6-5 "JA THRUST PLATE STOPPER INSTALLATION When the thrust plate is installed, make sure that it is not tilted. Thrust plate MD998812 MD998818 "KA BALL BEARING INSTALLATION Use the special tools to install the ball bearing. MD998801 "LA SNAP RING INSTALLATION Select and install a snap ring so that the input shaft rear bearing end play will have the standard value. [. . . ] NOTE Adjust until the backlashes on both sides are equal. "BA LOCK PIN INSTALLATION Install the lock pin in such a way that it will be oriented in the direction shown. MD998812 Taper roller bearing MD998819 "CA TAPER ROLLER BEARING INSTALLATION <F5M42> Use the special tools to install the taper roller bearing. MD998812 MD998819 Ball bearing "DA BALL BEARING INSTALLATION <F5M41> Use the special tools to install the ball bearing. "EA DIFFERENTIAL DRIVE GEAR INSTALLATION (1) Apply a sealant to the entire threaded portion of the bolt. 1998 PWEE9508-E Revised 22B-15-4 3 5 7 MANUAL TRANSMISSION (E - W) 1 8 Differential <F5M41, F5M42>, Front Differential <W5M42> (2) Tighten to the specified torque in the illustrated sequence. 6 2 4 E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised MANUAL TRANSMISSION (E - W) - Center Differential <W5M42> 22B-16-1 16. CENTER DIFFERENTIAL <W5M42> DISASSEMBLY AND REASSEMBLY 1 Apply gear oil to all moving parts before installation. 3 2 5 12 11 12 4 17 9 14 10 12 7 132 Nm 6 13 8 12 11 16 15 9 "DA "CA AA" "BA "CA "CA "CA "CA "CA "CA Disassembly steps 1. [. . . ]