Mitsubishi 380. Manual — part 976

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-17

SYNCHRONIZER SLEEVE AND HUB

AK204217

Sleeve

Hub

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.

.

SYNCHRONIZER SPRING
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.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-18

OUTPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1222002200220

AK203133

Apply gear oil

to all moving

parts before

installation.

21

22

23

24

25

26

28

27

30

29

19

18

20

33

4

1

5

3

32

31

35

2

12

36

37

38

4

15

15

14

6

17

7

34

8

9

11 10

13

16

AD

Disassembly steps

>>

Q

<<

1.

Snap ring

<<

A

>>

>>

P

<<

2.

Taper roller bearing

<<

B

>>

>>

O

<<

3.

Reverse gear bearing sleeve

4.

Needle roller bearing

5.

Reverse gear

6.

Inner synchronizer ring

7.

Synchronizer cone

8.

Outer synchronizer ring

>>

L

<<

9.

Synchronizer spring

>>

N

<<

10. Synchronizer sleeve

<<

C

>>

>>

M

<<

11. 5th speed-reverse synchronizer

hub

12. Synchronizer ring

>>

L

<<

13. Synchronizer spring
14. 5th speed gear
15. Needle roller bearing

>>

K

<<

16. 5th speed gear sleeve

>>

J

<<

17. 4th speed gear

>>

I

<<

18. Snap ring

<<

D

>>

>>

H

<<

19. 3rd speed gear
20. 2nd speed gear
21. Needle roller bearing

<<

E

>>

>>

G

<<

22. 2nd speed gear sleeve
23. Inner synchronizer ring
24. Synchronizer cone
25. Outer synchronizer ring

>>

D

<<

26. Synchronizer spring

>>

F

<<

27. Synchronizer sleeve

>>

E

<<

28. 1st-2nd speed synchronizer hub
29. Outer synchronizer ring

>>

D

<<

30. Synchronizer spring
31. Inner synchronizer ring
32. Synchronizer cone
33. 1st speed gear
34. Needle roller bearing

<<

F

>>

>>

C

<<

35. 1st speed gear sleeve

<<

G

>>

>>

B

<<

36. Taper roller bearing

Disassembly steps ( つづき )

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-19

DISASSEMBLY SERVICE POINTS

.

<<A>> TAPER ROLLER BEARING REMOVAL

AK201646

MD998801

AD

Taper roller

bearing

1. Using special tool Bearing remover (MD998801), support

the taper roller bearing, and then set them on the press.

2. Push down on the output shaft with the press, and take out

the taper roller bearing.

.

<<B>> REVERSE GEAR BEARING SLEEVE REMOVAL

AK201647

MD998801

AD

Reverse gear

bearing

sleeve

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 bearing sleeve.

.

<<C>> 5TH SPEED-REVERSE SYNCHRONIZER HUB
REMOVAL

AK201648

MD998801

AD

Synchronizer

hub

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.

.

>>

A

<<

37. Oil seal
38. Output shaft

Disassembly steps ( つづき )

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-20

<<D>> 3RD SPEED GEAR REMOVAL

AK201649

MD998917

AD

3rd

speed gear

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

AK201650

MD998917

2nd speed

gear sleeve

AD

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.

.

<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

AK201651AD

MD998801

1st speed

gear sleeve

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>> TAPER ROLLER BEARING REMOVAL

AK201652

MD998801

AD

Taper roller

bearing

1. Using special tool Bearing remover (MD998801), support

the taper roller bearing, and then set them on the press.

2. Push down on the output shaft with the press and remove

the taper roller bearing.