Mitsubishi Outlander (2003+). Manual — part 170
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-33
DISASSEMBLY SERVICE POINTS
<<A>> BALL BEARING REMOVAL
1. Using special tool Bearing remover (MD998917),
support the ball bearing, and then set them on the
press.
2. Push down on the output shaft with the press, and
remove the ball bearing.
<<B>> REVERSE GEAR BEARING SLEEVE
REMOVAL
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
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.
<<D>> 3RD SPEED GEAR REMOVAL
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
1. Using special tool Bearing remover (MD998917),
support the 1st speed gear, and then set them on
the press.
<<G>>
>>A<<
35. Roller bearing inner race
36. Output shaft
Disassembly steps (Continued)
AK204252
Ball bearing
MD998917
AC
AK204253
Reverse gear
bearing sleeve
MD998801
AB
AK204254 AB
Synchronizer hub
MD998801
AK204255
3rd speed gear
MD998917
AB
AK204256
MD998917
2nd speed gear sleeve
AC
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-34
2. Push down on the output shaft with the press and
remove the 2nd speed gear sleeve.
<<F>> 1ST SPEED GEAR SLEEVE REMOVAL
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>> ROLLER BEARING INNER RACE
REMOVAL
1. Using special tool Bearing remover (MD998917),
support the roller bearing inner race, and then set
them on the press.
2. Push down on the output shaft with the press and
remove the roller bearing inner race.
REASSEMBLY SERVICE POINTS
>>A<< ROLLER BEARING INNER RACE
INSTALLATION
1. Using special tool Bearing remover (MD998801),
support the output shaft gear, and then set them
on the press.
2. Using special tools, install the roller bearing inner
race with the press.
•
Installer cap (MD998812)
•
Installer adapter (MD998818)
>>B<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in
the groove of output shaft.
2. Make sure that the front bearing inner race end
play meets the standard value.
Standard value: 0
−
0.12 mm
>>C<<1ST SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.
AK204257
1st speed gear sleeve
MD998801
AC
AK204258
Roller bearing
inner race
MD998917
AB
AK204260
MD998812
MD998801
MD998818
Roller bearing
inner race
AB
AK204261
Snap ring
AB
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-35
2. Using special tools, install the 1st speed gear
sleeve with the press.
•
Installer cap (MD998812)
•
Installer-200 (MD998814)
•
Installer adapter (MD998825)
>>D<< SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring onto the outer
synchronizer ring
as shown.
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
1. Set the output shaft on the press support stand.
2. Check that the 1st-2nd speed synchronizer hub is
in the correct installation direction, and put it on
the output shaft.
3. Using special tools, install the 1st-2nd speed
synchronizer hub with the press.
•
Installer cap (MD998812)
•
Installer-200 (MD998814)
•
Installer adapter (MD998825)
4. Make sure that the outer synchronizer ring on the
1st speed gear side can rotate freely.
>>F<< SYNCHRONIZER SLEEVE INSTALLATION
1. Check that the synchronizer sleeve is in the
correct direction for installation, and install it on
the 1st-2nd speed synchronizer hub.
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).
AK204262
MD998812
MD998814
1st speed
gear sleeve
MD998825
AC
AK204316
Synchronizer spring
AC
AK204305
Installation direction
AC
AK204265
MD998812
MD998814
MD998825
1st-2nd speed
synchronizer
hub
AC
AK204296
Identification
groove
Installation
direction
AC
AK204199AB
Projecting portion
Deep grooves
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-36
>>G<< 2ND SPEED GEAR SLEEVE
INSTALLATION
1. Set the output shaft on the press support stand.
2. Using special tools, install the 2nd speed sleeve
onto the output shaft with the press.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998822)
>>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).
2. Using special tools, install the 3rd speed gear
onto the output shaft with the press.
•
Installer cap (MD998812)
•
Installer-200 (MD998814)
•
Installer adapter (MD998822)
3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
>>I<< SNAP RING INSTALLATION
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.
2. Using special tools, install the 4th speed gear onto
the output shaft with the press.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998819)
>>K<< 5TH SPEED GEAR SLEEVE
INSTALLATION
Using special tools, install the 5th speed gear sleeve
onto the output shaft with the press.
•
Installer cap (MD998812)
AK204266
MD998812
MD998813
MD998822
AC
AK204267
MD998812
MD998814
MD998822
3rd speed gear
AB
AK204268AB
Snap ring
AK204269
MD998812
MD998813
MD998819
4th speed gear
AB
AK204300
MD998812
MD998813
MD998819
5th speed
gear sleeve
AB
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