Mitsubishi Outlander (2003+). Manual — part 168
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-25
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222001600173
AK204391
9
10
11
12
14
13
15
16
18
2
19
4
20
6
7
1
8
3
17
16
5
AB
AB
Apply gear oil to all
moving parts before
installation.
Disassembly steps
>>M<<
1.
Snap ring
<<A>>
>>L<<
2.
Ball bearing
<<B>>
>>K<<
3.
Thrust plate stopper
>>J<<
4.
Thrust plate
<<C>>
>>I<<
5.
5th speed gear
6.
4th speed gear
7.
Needle roller bearing
<<D>>
>>H<<
8.
4th speed gear sleeve
>>E<<
9.
Synchronizer ring
>>D<<
10. Synchronizer spring
>>G<<
11. Synchronizer sleeve
>>F<<
12. 3rd-4th speed synchronizer hub
>>E<<
13. Synchronizer ring
>>D<<
14. Synchronizer spring
15. 3rd speed gear
16. Needle roller bearing
>>C<<
17. Snap ring
<<E>>
>>B<<
18. Ball bearing
>>A<<
19. Oil seal
20. Input shaft
Disassembly steps (Continued)
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-26
DISASSEMBLY SERVICE POINTS
<<A>> BALL BEARING REMOVAL
1. Using special tool Bearing remover (MD998801),
support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.
<<B>> THRUST PLATE STOPPER REMOVAL
Using a screwdriver, pry up at the position shown in
the illustration and remove the thrust plate stopper.
<<C>> 5TH SPEED GEAR REMOVAL
1. Using special tool Bearing remover (MD998801),
support the 5th speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 5th speed gear.
<<D>> 4TH SPEED GEAR SLEEVE REMOVAL
1. Using special tool Bearing remover (MD998801),
support the 3rd speed gear, and then set them on
the press.
2. Push down on the input shaft with the press and
remove the 4th speed gear sleeve.
<<E>> BALL BEARING REMOVAL
1. Using special tool Bearing remover (MD998801),
support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.
AK204239
MD998801
AB
AK204293AB
AK204240
MD998801
AB
AK204241
MD998801
AB
AK204242
MD998801
AB
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-27
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
Install the oil seal into the end of the input shaft as
shown.
>>B<< BALL BEARING INSTALLATION
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, press install the ball bearing
with the press.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998816)
>>C<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in
the snap ring groove of input shaft.
2. Make sure that the front bearing end play meets
the standard value.
Standard value: 0
−
0.12 mm
>>D<< SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring onto the synchronizer
ring as shown.
>>E<< SYNCHRONIZER RING INSTALLATION
CAUTION
There are 3rd speed and 4th speed synchronizer
rings, if the wrong one is installed it will effect
the shift feeling.
1. Ascertain whether or not there are identification
notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it completely
fits over the machined cone of the gear.
AK204243
3.5 mm
Oil seal
AC
AK204244
MD998812
MD998813
MD998801
MD998816
AC
AK204245
Snap ring
AB
AK204263
SYNCHRONIZER
SPRING
AB
Synchrnizer
spring
AK204312
Notch
AB
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-28
>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Make sure that the synchronizer ring has been
perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th
speed synchronizer hub, and put it on the input
shaft.
4. Using special tools, press install the 3rd-4th
speed synchronizer hub with the press.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998825)
5. Make sure that the synchronizer ring can rotate
freely.
>>G<< SYNCHRONIZER SLEEVE INSTALLATION
1. Check the installation direction of the
synchronizer sleeve, and install it onto the 3rd-4th
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).
>>H<< 4TH SPEED GEAR SLEEVE
INSTALLATION
1. Using special tool Bearing remover (MD998801),
support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, install the 4th speed gear
sleeve with the press.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998824)
AK204295
Installation
direction
Groove
AB
AK204246
MD998812
MD998813
MD998825
MD998801
AC
AK204296
Identification
groove
Installation
direction
AC
AK204199AB
Projecting portion
Deep grooves
AK204247
MD998812
MD998813
MD998824
MD998801
AC
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