Mitsubishi 380. Manual — part 978
AK201661
MD998812
MD998813
MD998821
MD998364
AD
Synchronizer
hub
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-25
4. Using special tools, press install the 5th speed-reverse
synchronizer hub with the press.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998821)
• Camshaft oil seal installer (MD998364)
5. Make sure that the synchronizer ring on the 5th speed gear
side can rotate freely.
.
>>N<< SYNCHRONIZER SLEEVE INSTALLATION
AK400081
Installation
direction
(5th speed side)
Identification
groove
AB
1. Check that the synchronizer sleeve is in the correct direction
for installation, and install it on the 5th speed-reverse
synchronizer hub.
AKX00928AD
Teeth with
raised tips
Deep grooves
between the teeth
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).
.
>>O<< REVERSE GEAR BEARING SLEEVE INSTALLATION
AK201662AD
MD998364
MD998812
MD998820
Reverse
gear sleeve
Reverse
gear
1. Make sure the synchronizer ring, reverse gear and needle
roller bearing have been correctly installed.
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 (MD998820)
• Camshaft oil seal installer (MD998364)
.
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-26
>>P<< TAPER ROLLER BEARING INSTALLATION
AK201663
MD998812
MD998819
MD998364
AD
Taper roller
bearing
Using special tools, press install the taper roller bearing.
• Installer cap (MD998812)
• Installer adapter (MD998819)
• Camshaft oil seal installer (MD998364)
.
>>Q<< SNAP RING INSTALLATION
AKX00934
Standard value
Snap ring
Taper roller
bearing
AD
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
INSPECTION
M1222002300227
.
OUTPUT SHAFT
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.
.
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-27
SYNCHRONIZER RING <FOR 5TH SPEED>
AK204298AB
1. Check if the clutch gear teeth are damaged.
2. Check internal surface for damage, wear and broken
threads.
AK204307
A
Gear
Synchronize
ring
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
.
OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER
RING/SYNCHRONIZER CONE <FOR REVERSE>
AK204309AB
CAUTION
When replacing, replace the outer ring, inner ring and cone
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces
are not damaged or broken.
AK204259
Gear
A
Outer ring
Cone
Inner ring
AB
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
.
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-28
OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER
RING/SYNCHRONIZER CONE <FOR 1ST SPEED AND 2ND
SPEED>
AK502785AB
CAUTION
When replacing, replace the outer ring, inner ring and cone
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces
are not damaged or broken.
AK203130AD
A
Outer ring
Inner ring
Cone
Gear
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
.
SYNCHRONIZER SLEEVE AND HUB
AK201697AD
Sleeve
Hub
1. Combine the synchronizer sleeve and hub, and check that
they slide smoothly.
2. Check that the sleeve is free from damage at its inside
splines ends.
.
SYNCHRONIZER SPRING
AKX00943
Check that the spring is not sagging, deformed or broken.
.
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