Mitsubishi 380. Manual — part 977
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-21
REASSEMBLY SERVICE POINTS
.
>>A<< OIL SEAL INSTALLATION
AK204243
3.5 mm
Oil seal
AC
Make sure that the oil seal is pressed into the position shown in
the illustration.
.
>>B<< TAPER ROLLER BEARING INSTALLATION
AK201653
MD998801
MD998812
MD998819
AD
Taper
roller
bearing
1. Using Bearing remover (MD998801), support the output
shaft gear, and then set them on the press.
2. Using special tools, press install the taper roller bearing with
the press.
• Installer cap (MD998812)
• Installer adapter (MD998819)
.
>>C<<1ST SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.
AK201654
MD998364
MD998812
MD998814
MD998824
1st speed
gear sleeve
AD
2. Using special tools, press install the 1st speed gear sleeve
with the press.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998824)
• Camshaft oil seal installer (MD998364)
.
>>D<< SYNCHRONIZER SPRING INSTALLATION
AK201638AD
Synchronizer spring
Install the synchronizer spring to the illustrated position of the
outer synchronizer ring.
.
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-22
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
1. Set the output shaft on the press support stand.
AK302754
Installation
direction
Groove
AB
2. Check that the 1st-2nd speed synchronizer hub is in the
correct installation direction, and put it on the output shaft.
AK201655
MD998812
MD998814
MD998824
MD998364
AD
1st-2nd speed
synchronizer
hub
3. Using special tools, press install the 1st-2nd speed
synchronizer hub with the press.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998824)
• Camshaft oil seal installer (MD998364)
4. Make sure that the outer synchronizer ring on the 1st speed
gear side can rotate freely.
.
>>F<< SYNCHRONIZER SLEEVE INSTALLATION
AK302755
Installation
direction
Groove
AB
1. Check that the synchronizer sleeve is in the correct direction
for installation, and install it on the 1st-2nd speed
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).
.
>>G<< 2ND SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.
AK201656
MD998812
MD998814
MD998824
MD998364
2nd speed
gear sleeve
AD
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-23
2. Using special tools, press install the 2nd speed sleeve onto
the output shaft.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998824)
• Camshaft oil seal installer (MD998364)
.
>>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).
AK201657
MD998812
MD998814
MD998824
MD998364
AD
3rd speed
gear
2. Using special tools, press install the 3rd speed gear onto the
output shaft.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (MD998824)
• Camshaft oil seal installer (MD998364)
3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
.
>>I<< SNAP RING INSTALLATION
AK201658AD
Snap ring
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.
AK201659
MD998812
MD998813
MD998821
MD998364
AD
4th speed
gear
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-24
2. Using special tools, press install the 4th speed gear onto the
output shaft.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998821)
• Camshaft oil seal installer (MD998364)
.
>>K<< 5TH SPEED GEAR SLEEVE INSTALLATION
AK201660
MD998812
MD998813
MD998821
MD998364
AD
5th speed
gear sleeve
Using special tools, press install the 5th speed gear sleeve
onto the output shaft.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998821)
• Camshaft oil seal installer (MD998364)
.
>>L<< SYNCHRONIZER SPRING INSTALLATION
AK305144AB
Synchronizer spring
Install the synchronizer spring to the illustrated position of the
synchronizer ring.
.
>>M<< 5TH SPEED-REVERSE SYNCHRONIZER HUB
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.
AK302758
Installation
direction
Groove
AB
3. Check that the 5th speed-reverse synchronizer hub is
oriented correctly for installation, and fit it on the output
shaft.
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