Mitsubishi Outlander (2003+). Manual — part 169
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-29
>>I<< 5TH SPEED GEAR 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 5th speed gear onto
the input shaft with the press.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998824)
>>J<< THRUST PLATE INSTALLATION
1. Install the thickest thrust plates that can be fitted
in the groove of the input shaft. Install the thrust
plate so the surface stamped with the
identification mark is facing up.
2. Make sure that the 5th speed gear end play meets
the standard value.
Standard value: 0
−
0.09 mm
>>K<< THRUST PLATE STOPPER INSTALLATION
Install the thrust plate stopper by pressing special
tools, by hand. Make sure that it is not tilted.
•
Installer cap (MD998812)
•
Installer-100 (MD998813)
•
Installer adapter (MD998824)
>>L<< 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, install the ball bearing onto
the input shaft with the press.
•
Installer cap (MD998812)
•
Installer adapter (MD998818)
>>M<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in
the groove of the input shaft.
2. Make sure that the rear bearing end play meets
the standard value.
Standard value: 0
−
0.12 mm
AK204248
MD998812
MD998813
MD998824
MD998801
AB
AK204249AB
Surface stamped
with identification
mark
Thrust plate
AK204294
MD998812
MD998813
MD998824
AB
AK204250
MD998812
MD998818
MD998801
AC
AK204251
Snap ring
AB
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-30
INSPECTION
M1222001700095
INPUT SHAFT
1. Check the outside diameter of the needle bearing
mounting portion for damage, abnormal wear and
seizure.
2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not
damaged or worn.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input
shaft or bearing sleeve and gear, and check that it
rotates smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage and
broken.
2. Check internal surface for damage, wear and
broken threads.
3. Force the synchronizer ring toward the clutch gear
and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
Minimum limit: 0.5 mm
SYNCHRONIZER SLEEVE AND HUB
1. Combine the synchronizer sleeve and hub, and
check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or
broken.
AK204201AB
AK204298AB
AK204307
A
Gear
Synchronizer
ring
AB
AK204217
Sleeve
Hub
AB
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-31
SPEED GEARS
1. Check that the helical and clutch gear tooth
surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
AK204299AB
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-32
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002200156
AK204392
20
22
24
4
26
1
19
18
21
23
13
27
29
25
28
30
31
32
33
36
35
34
5
2
3
4
6
7
8
9
11
14 10
12
17
15
16
13
AB
Apply gear oil to all
moving parts before
installation.
Disassembly steps
>>Q<<
1.
Snap ring
<<A>>
>>P<<
2.
Ball bearing
<<B>>
>>O<<
3.
Reverse gear sleeve
4.
Needle roller bearing
5.
Reverse gear
>>M<<
6.
Synchronizer ring
>>L<<
7.
Synchronizer spring
>>F<<
8.
Synchronizer sleeve
<<C>>
>>N<<
9.
5th speed-reverse synchronizer
hub
>>M<<
10. Synchronizer ring
>>L<<
11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
>>K<<
14. 5th speed gear sleeve
>>J<<
15. 4th speed gear
>>I<<
16. Snap ring
<<D>>
>>H<<
17. 3rd speed gear
18. 2nd speed gear
19. Needle roller bearing
<<E>>
>>G<<
20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring
>>D<<
24. Synchronizer spring
>>F<<
25. Synchronizer sleeve
>>E<<
26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring
>>D<<
28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing
<<F>>
>>C<<
33. 1st speed gear sleeve
>>B<<
34. Snap ring
Disassembly steps (Continued)
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