Mitsubishi 380. Manual — part 972
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . .
GENERAL SPECIFICATIONS . . . . . .
SERVICE SPECIFICATIONS. . . . . . .
SNAP RING, SPACER AND THRUST
PLATE FOR ADJUSTMENT . . . . . . .
TORQUE SPECIFICATION . . . . . . . .
SEALANTS . . . . . . . . . . . . . . . . . . . .
LUBRICANTS . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
INPUT SHAFT . . . . . . . . . . . . . . . . . .
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . .
INPUT SHAFT INSPECTION . . . . . . . . . . .
OUTPUT SHAFT . . . . . . . . . . . . . . . .
OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT INSPECTION . . . . . . . . .
REVERSE IDLER GEAR . . . . . . . . . .
REVERSE IDLER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
VEHICLE SPEED SENSOR . . . . . . . .
VEHICLE SPEED SENSOR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
SELECT LEVER . . . . . . . . . . . . . . . . .
SELECT LEVER DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . .
CONTROL HOUSING . . . . . . . . . . . . .
CONTROL HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
CLUTCH HOUSING . . . . . . . . . . . . . .
CLUTCH HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION CASE . . . . . . . . . . .
TRANSMISSION CASE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL. . . . . . . . . . . . . . . . . .
DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
GENERAL INFORMATION
MANUAL TRANSMISSION OVERHAUL
22B-2
GENERAL INFORMATION
M1222000100379
MANUAL TRANSMISSION MODELS
Transmission model
Combined engine
Vehicle model
F5M51-1-S5P
6G75-S4-MPI
DL1ASN
SECTIONAL VIEW
AK502566
GENERAL SPECIFICATIONS
MANUAL TRANSMISSION OVERHAUL
22B-3
GENERAL SPECIFICATIONS
M1222000200495
TRANSMISSION MODEL TABLE
Transmission
model
Speedometer
gear ratio
Final gear
ratio
Vehicle model
Engine model
F5M51-1-S5P
28/36
4.111
DL1ASN
6G75-S4-MPI
GEAR RATIO TABLE
Item
F5M51
1st
3.333
2nd
2.105
3rd
1.407
4th
1.031
5th
0.804
Reverse
3.416
SERVICE SPECIFICATIONS
M1222000300362
Item
Standard value
Minimum limit
Input shaft end play mm
0.05
− 0.17
−
Input shaft front bearing end play mm
0
− 0.12
−
Input shaft rear bearing end play mm
0
− 0.12
−
Input shaft 5th speed gear end play mm
0
− 0.09
−
Output shaft preload mm
0.13
− 0.18
−
Output shaft rear bearing end play mm
0
− 0.09
−
Output shaft 3rd speed gear end play mm
0
− 0.09
−
Backlash between differential gear and pinion mm
0.025
− 0.150
−
Differential case preload mm
0.05
− 0.11
−
Synchronizer ring back surface to gear clearance mm
−
0.5
SNAP RING, SPACER AND THRUST PLATE FOR
ADJUSTMENT
M1222012000409
SPACER (FOR ADJUSTMENT OF INPUT SHAFT END PLAY)
Thickness mm
Identification symbol
Thickness mm
Identification symbol
0.98
98
1.43
43
1.07
07
1.52
52
1.16
16
1.61
61
1.25
25
1.70
70
1.34
34
1.79
79
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
MANUAL TRANSMISSION OVERHAUL
22B-4
SNAP RING (FOR ADJUSTMENT OF INPUT 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 INPUT SHAFT REAR BEARING END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
1.44
None
1.58
Brown
1.51
Blue
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
Thickness mm
Identification symbol
Thickness mm
Identification symbol
3.82
0
3.98
6
3.86
2
4.02
7
3.90
3
4.06
8
3.94
5
4.10
9
SPACER (FOR ADJUSTMENT OF OUTPUT SHAFT PRELOAD)
Thickness mm
Identification symbol
Thickness mm
Identification symbol
0.86
86
1.19
L
0.89
89
1.22
G
0.92
92
1.25
M
0.95
95
1.28
N
0.98
98
1.31
E
1.01
01
1.34
O
1.04
04
1.37
P
1.07
07
1.40
None
1.10
J
1.43
Q
1.13
D
1.46
R
1.16
K
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
1.36
Yellow
1.55
White
1.40
Green
1.58
Brown
1.44
None
1.63
Orange
1.48
Black
1.68
Blue
1.51
Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
Thickness mm
Identification colour
Thickness mm
Identification colour
2.81
None
2.97
Green
2.85
Blue
3.01
Black
2.89
Brown
3.05
White
2.93
Yellow
3.09
Orange
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