Mitsubishi Outlander (2003+). Manual — part 158

SPECIAL TOOLS

MANUAL TRANSMISSION (FF)

22A-3

SPECIAL TOOLS

M1221000600672

Tool

Number

Name

Use

MB991453

Engine hanger
assembly

When the engine hanger is used:
Supporting the engine assembly
during removal and installation of the
transmission assembly
NOTE: Special tool MB991454 is a
part of engine hanger attachment set
MB991453.

MB991454

Engine hanger
balancer

MB991527

Engine hanger

MB991895

Engine hanger

MB991928

A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934

Engine hanger

A: Joint (50)

×

2

B: Joint (90)

×

2

C: Joint (140)

×

2

D: Foot (standard)

×

4

E: Foot (short)

×

2

F: Chain and hook

assembly

B991453

B991454

B991527

MB991895

B991928

A

B

C

D

E

F

Slide bracket (HI)

TROUBLESHOOTING

MANUAL TRANSMISSION (FF)

22A-4

TROUBLESHOOTING

INTRODUCTION

M1221006900660

The manual transmission can exhibit any of the
following symptoms: noise or vibration is generated,
oil leaks, shifting gears is hard or troublesome, or the
transmission jumps out of gear.
The causes of these symptoms could come from:
incorrect mounting, the oil level may be low, or a
component of the transmission may be faulty.

TROUBLESHOOTING STRATEGY

M1221007000585

Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
manual transmission fault.
1. Gather information from the customer.
2. Verify that the condition described by the

customer exists.

3. Find the malfunction by following the Symptom

Chart.

4. Verify malfunction is eliminated.

SYMPTOM CHART

M1221007100571

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise, Vibration

DIAGNOSIS

STEP 1. Check the idle speed.

Q: Does the idle speed meet the standard values?

YES :

Go to Step 2 .

NO :

Refer to GROUP 11A <4G63
Engine>

P.11A-11

, or GROUP 11C <4G69

Engine>

P.11C-14

, On-vehicle Service

−

Kerb Idle Speed Check.

STEP 2. Check whether the transaxle and engine
mount is loose or damaged.

Q: Are the transaxle and engine mount loose or

damaged?

YES :

Tighten or replace the part. Then go to Step

7 .

NO :

Go to Step 3 .

STEP 3. Check that the oil level is up to the lower
edge of the filler plug hole.

Q: Is the oil level up to the lower edge of the filler plug

hole?

YES :

Go to Step 4 .

NO :

Refill gear oil API classification GL-4 SAE
75W

−

85W or 75W

−

90. Then go to Step 7 .

SYMPTOM

INSPECTION
PROCEDURE

REFERENCE
PAGE

Noise, Vibration

1

P.22A-4

Oil Leaks

2

P.22A-5

Hard Shifting

3

P.22A-6

Jumps Out of Gear

4

P.22A-7

AC102278AO

Filler plug

Transmission oil

Filler plug hole

TROUBLESHOOTING

MANUAL TRANSMISSION (FF)

22A-5

STEP 4. Check for the specified oil.

Q: Is the specified oil gear oil API classification GL-4

SAE 75W

−

85W or 75W

−

90?

YES :

Go to Step 5 .

NO :

If in doubt, replace the oil. Refer to

P.22A-8

.

Then go to Step 7 .

STEP 5. Remove the transmission. Check the
end play of the input and output shafts.

Q: Does the end play of the input and output shafts

meet the standard value?

YES :

Go to Step 6 .

NO :

Adjust the end play of the input and output
shafts. Then go to Step 7 .

STEP 6. Disassemble the transmission. Check
the gears for wear and damage.

Q: Are the gears worn or damaged?

YES :

Replace the gears. Go to Step 7 .

NO :

Go to Step 7 .

STEP 7. Retest the systems.

Q: Is the noise or vibration still there?

YES :

Return to Step 1 .

NO :

The procedure is complete.

INSPECTION PROCEDURE 2: Oil Leaks

DIAGNOSIS

STEP 1. Visual check.

Raise the vehicle, and check for oil leaks. If oil leak is
difficult to locate, steam clean the transmission and
drive the vehicle for at 10 minutes. Then check the
leak again.

Q: Is the oil leak(s) found?

YES :

Go to Step 2 .

NO :

Check for the oil leaks around the engine.
Then go to Step 4 .

STEP 2. Visual check at the clutch housing.

Q: Do oil leaks appear around the joint between the

engine and the clutch housing?

YES :

Remove the transmission. Check the input

shaft oil seal, and replace if necessary.
Then go to Step 4 .

NO :

Go to Step 3 .

STEP 3. Check the oil seal or O-ring for damage.

Q: Is the oil seal or O-ring damaged?

YES :

Replace the oil seal or the O-ring. Then go

to Step 4 .

NO :

Go to Step 4 .

STEP 4. Retest the system.

Q: Is the oil still leaking?

YES :

Return to Step 1 .

NO :

The procedure is complete.

TROUBLESHOOTING

MANUAL TRANSMISSION (FF)

22A-6

INSPECTION PROCEDURE 3: Hard Shifting

DIAGNOSIS

STEP 1. Check the transmission control

Q: Are the shift cable and the select cable in good

condition?

YES :

Go to Step 2 .

NO :

Repair or replace the shift cable and the
select cable. Refer to

P.22A-8

. Then go to

Step 7 .

STEP 2. Check the transmission oil.

Q: Is the oil dirty?

YES :

Replace the oil. Refer to

P.22A-8

. Then go

to Step 7

NO :

Go to Step 3 .

STEP 3. Check the clutch system.

Q: Is the clutch system normal?

YES :

Go to Step 4 .

NO :

Repair or replace the clutch system. Refer
to

P.22A-8

. Then go to Step 7 .

STEP 4. Remove and disassemble the
transmission. Check the control housing.

Q: Is the control housing in good condition?

YES :

Go to Step 5 .

NO :

Repair or replace the control housing. Refer
to GROUP 22B, Transmission

P.22B-43

.

Then go to Step 7 .

STEP 5. Check for poor meshing of worn
synchronizer ring and gear cone.

Q: Is poor meshing or worn synchronizer ring and

gear cone found?

YES :

Repair or replace the synchronizer ring and

gear cone. Then go to Step 7 .

NO :

Go to Step 6 .

STEP 6. Check the synchronizer spring for
weakness.

Q: Is the synchronizer spring weak?

YES :

Replace the synchronizer spring. Then go

to Step 7 .

NO :

Go to Step 7 .

STEP 7. Retest the system.

Q: Is the shifting of the gears still hard?

YES :

Return to Step 1 .

NO :

The procedure is complete.