Mitsubishi Outlander (2003+). Manual — part 166

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-17

<W5M42>

AK204184

32 ± 2 N·m

3.9 ± 1.0 N·m

70 ± 10 N·m

18 ± 3 N·m

4

3

8

6

9

7

10

11

12

13

5

2

1

70 ± 10 N·m

69 ± 10 N·m

18 ± 3 N·m

14

3.9 ± 1.0 N·m

AB

Disassembly steps

1.

Transfer

2.

O-ring

3.

Roll stopper bracket, front

4.

Roll stopper bracket, rear

5.

Roll stopper bracket, adaptor

6.

Shift cable bracket

>>J<<

7.

Select lever

>>I<<

8.

Speedometer gear

9.

Backup light switch

10. Gasket
11. Poppet spring
12. Gasket
13. Harness bracket
14. Harness bracket <Except 2.4L

model>

Disassembly steps (Continued)

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-18

AK204218

Apply gear oil to all
moving parts before
installation.

18 ± 3 N·m

30 ± 3 N·m

44 ± 5 N·m

48 ± 6 N·m

6.9 ± 0.9 N·m

14

15

12

13

20

21

23

22

17

18

19

24

25

16

AC

Disassembly steps

15. Interlock plate bolt
16. Gasket

>>H<<

17. Control housing
18. Neutral return spring

>>G<<

19. Under cover
20. Reverse idler gear shaft bolt
21. Gasket
22. Reverse idler gear assembly

<<A>>

>>F<<

23. Sealing cap

<<B>>

>>E<<

24. Transaxle case

>>D<<

25. Outer race

>>D<<

26. Spacer
27. Magnet holder
28. Magnet

Disassembly steps (Continued)

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-19

AK204189

30

29

31

41

37

36

34

42

39

40

18 ± 3 N·m

38

32

35

33

AB

Apply gear oil to all
moving parts before
installation.

Disassembly steps

>>C<<

29. Spring pin
30. 1st-2nd speed shift rail
31. 1st-2nd speed shift fork

>>C<<

32. Spring pin

>>C<<

33. Spring pin

<<C>>

>>B<<

34. 3rd-4th speed shift rail

<<C>>

>>B<<

35. 3rd-4th speed shift fork

<<C>>

>>B<<

36. 5th speed-reverse shift rail

<<C>>

>>B<<

37. 5th speed-reverse shift fork
38. Front bearing retainer

<<D>>

>>A<<

39. Input shaft

<<D>>

>>A<<

40. Output shaft
41. Differential
42. Clutch housing

Disassembly steps (Continued)

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-20

DISASSEMBLY SERVICE POINTS

<<A>> SEALING CAP REMOVAL

1. Drive a screwdriver into the center of the sealing

cap.

2. Bend the screwdriver back to remove the sealing

cap.

<<B>> TRANSAXLE CASE REMOVAL
1. Remove all sixteen bolts securing the transaxle

case to the clutch housing.

2. Use snap ring pliers to expand the indicated snap

ring. The snap ring will release the grooved ball
bearing, and the output shaft assembly will fall
under its own weight.

CAUTION

Do not use a scraper or chisel to remove the
transaxle case.
3. Remove the transaxle case from the clutch

housing by gently prying on opposite sides at the
same time.

<<C>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH
SPEED SHIFT FORK/5TH SPEED-REVERSE
SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK
REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th

speed-reverse shift fork in the direction shown.

2. Pull up on the 3rd-4th speed shift rail and 5th

speed-reverse shift rail and take them out of the
hole in the clutch housing.

3. Slide the 3rd-4th speed shift rail and 5th

speed-reverse shift rail in the direction shown and
remove them together with the shift forks.

<<D>> INPUT SHAFT AND OUTPUT SHAFT
REMOVAL

Remove the input and output shafts together.

AK204301

Sealing cap

AB

AK204226

Snap ring

AB

AK204222

3rd-4th
speed
shift fork

5th speed
reverse
shift fork

AB

AK204223

5th speed-
reverse
shift rail

3rd-4th speed
shift rail

AB

AK204224

Input shaft

Output shaft

AB