Mitsubishi Grandis. Manual — part 878
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-22
2. Make sure that the rear bearing end play meets
the standard value.
Standard value: 0
− 0.12 mm
INSPECTION
M1222001700169
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.
SPEED GEARS
1. Check that the helical and clutch gear tooth
surfaces are not damaged or worn.
AK204201AC
AK204298AB
AK204307
A
Gear
Synchronizer
ring
AB
AK201697AD
Sleeve
Hub
AK204299AB
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-23
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.
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002200190
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
>>R<<
1.
Snap ring
<<A>>
>>Q<<
2.
Ball bearing
<<B>>
>>P<<
3.
Reverse gear sleeve
4.
Needle roller bearing
5.
Reverse gear
>>M<<
6.
Synchronizer ring
>>L<<
7.
Synchronizer spring
>>O<<
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
25. Synchronizer sleeve
Disassembly steps (Continued)
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-24
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
>>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
>>C<<
33. 1st speed gear sleeve
>>B<<
34. Snap ring
<<G>>
>>A<<
35. Roller bearing inner race
36. Output shaft
Disassembly steps (Continued)
AK305134AB
MD998917
AK305135AB
MD998801
AK305136AB
MD998801
AK305137AB
MD998917
AK305138AB
MD998917
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-25
1. Using special tool Bearing remover (MD998917),
support the 1st speed gear, and then set them on
the press.
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.
AK305139AB
MD998801
AK305140AB
MD998917
AK305141AB
MD998801
MD998812
MD998818
AK305142AB
Snap ring
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