Mitsubishi Outlander (2003+). Manual — part 167
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-21
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR DIFFERENTIAL CASE
PRELOAD ADJUSTMENT
1. Put solders (1.6 mm diameter, about 10 mm long)
in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential
assembly into the transaxle case.
NOTE: If necessary, replace the differential case
and taper bearing before carrying out these
adjustments.
3. Install the clutch housing and tighten the bolts to
the specified torque.
Tightening torque: 44
±
5 N
⋅
m
4. Remove the clutch housing, and then remove the
differential assembly.
5. Remove the outer race and take out crushed
solders.
6. Measure the thickness of the crushed solder with
a micrometer and select a spacer that will provide
the standard preload value.
Standard value: 0.05
−
0.11 mm preload
REASSEMBLY SERVICE POINTS
>>A<< OUTPUT SHAFT/INPUT SHAFT
INSTALLATION
Install the input and output shafts together.
>>B<< 5TH SPEED-REVERSE SHIFT FORK/5TH
SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/3RD-4TH SPEED SHIFT RAIL
INSTALLATION
1. Shift the 3rd-4th speed synchronizer sleeve and
5th speed-reverse synchronizer sleeve in the
direction shown.
2. Assemble the 3rd-4th speed shift rail and fork,
and the 5th speed-reverse shift rail and fork.
AK204227
Solders
AB
AKX00953
AK204224
Input shaft
Output shaft
AB
AK204229AB
3rd-4th speed
synchronizer
sleeve
5th speed-
reverse
synchronizer
sleeve
AK204230
3rd-4th speed shift rail
3rd-4th speed
shift fork
5th speed-
reverse
shift rail
5th speed-
reverse
shift fork
AB
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-22
3. While fitting each shift fork in the groove of
synchronizer sleeve, slide the shift rails in the
direction shown and install.
4. Insert the 3rd-4th speed shift rail and 5th
speed-reverse shift rail into the rail hole in the
clutch housing.
>>C<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork.
2. Insert the new spring pin. Push it in as shown so
that the slit and center axis of the rail are aligned.
>>D<< SPACER AND OUTER RACE
INSTALLATION
1. Install the spacer selected in the section
"ADJUSTMENT BEFORE REASSEMBLY."
2. Using special tools, press the outer race into the
transaxle case.
•
Installer adapter (MB990935)
•
Handle (MB990938)
>>E<< TRANSAXLE CASE INSTALLATION
CAUTION
Squeeze sealant evenly onto the transaxle
housing. Do not leave gaps or excess amounts,
otherwise oil leaks are likely.
1. Apply a 2 mm diameter bead of sealant
(Mitsubishi Genuine Part number MD997740 or
equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto
the transaxle housing while the sealant is still wet
(within 15 minutes).
2. Align the transaxle case and expand the snap
ring. After the case is on far enough for the snap
ring to ride on the bearing, release the snap ring.
Push down on the transaxle case, twisting it from
side to side until the case contacts the housing.
3. Tighten the transaxle case mounting bolts to the
specified torque.
Tightening torque: 44
±
5 N
⋅
m
4. Place the transaxle upside down and let the snap
ring fit in the groove by the output shaft's own
weight.
NOTE: After installation, keep the sealed area
away from oil for approximately one hour.
AK204223
5th speed-
reverse
shift rail
3rd-4th speed
shift rail
AC
AK204302
Shift fork
2.5 mm
Shift rail
Spring pin
AC
AK204231 AB
MB990938
MB990935
AK204232AB
AK204226
Snap ring
AB
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-23
>>F<< SEALING CAP INSTALLATION
1. Using special tools, press install the sealing cap
onto the case.
•
Installer adapter (MB990927)
•
Handle (MB990938)
2. Evenly press the sealing cap so it is fully seated
and not at an angle.
>>G<< UNDER COVER INSTALLATION
CAUTION
Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
likely.
1. Apply a 2 mm diameter bead of sealant
(Mitsubishi Genuine Part number MD997740 or
equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the
case quickly while the sealant is still wet (within 15
minutes).
2. Install the under cover to the transaxle case and
tighten the bolts to specified torque.
Tightening torque: 6.9
±
0.9 N
⋅
m
NOTE: After installation, keep the sealed area
away from oil for approximately one hour.
>>H<< CONTROL HOUSING INSTALLATION
CAUTION
Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
likely.
1. Apply a 0.2 mm diameter bead of sealant
(Mitsubishi Genuine Part number MD997740 or
equivalent) as llustrated onto the control housing.
NOTE: Be sure to install the housig to the case
quickly while the sealant is still wet (within 15
minutes).
2. Install the control housing to the transaxle case
and tighten the bolts to specified torque.
Tightening torque: 18
±
3 N
⋅
m
NOTE: After installation, keep the sealed area
away from the oil for approximately one hour.
AK204234
MB990938
MB990927
AB
AK204233
Sealing cap
AB
AK204235AB
AK204236AB
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-24
>>I<< SPEEDOMETER GEAR INSTALLATION
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4)
to the O-ring of the speedometer gear. Install into
the transaxle housing.
2. Tighten the bolt to specified torque.
Tightening torque: 3.9
±
1.0 N
⋅
m
>>J<< SELECT LEVER INSTALLATION
1. Apply grease (Mitsubishi Genuine Part number
0101011 or equivalent) to the control shaft sliding
portion of the select lever shoe.
2. Install the select lever and tighten the bolts to
specified torque.
Tightening torque: 18
±
3 N
⋅
m
INSPECTION
M1222001100101
BACKUP LIGHT SWITCH
Check for continuity between terminals.
AK204237
O-ring
AB
AK204238
Control shaft
Select lever
shoe
AB
SWITCH CONDITION
CONTINUITY
Pressed
Open
Released
Conductive
AKX00952
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