Mitsubishi Grandis. Manual — part 877
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-18
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
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
AK305121AB
MD998801
AK305175AB
AK305122AB
MD998801
AK305123AB
MD998801
AK305124AB
MD998801
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-19
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.
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.
AK204243
3.5 mm
Oil seal
AC
AK305126AB
MD998801
MD998812
MD998813
MD998816
AK305127 AB
Snap ring
AK305144AB
Synchronizer spring
AK204312
Notch
AB
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-20
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.
>>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)
AK305177
Installation
direction
Identification mark
AB
AK305128AB
MD998801
MD998812
MD998813
MD998825
AK305178AB
Identification groove
Installation
direction
AK204199AB
Projecting portion
Deep grooves
AK305129AB
MD998801
MD998812
MD998813
MD998824
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-21
• Installer adapter (MD998824)
>>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.
AK305130AB
MD998801
MD998812
MD998813
MD998824
AK305131AB
Surface stamped with
identification mark
Thrust plate
AK305176AB
MD998812
MD998813
MD998824
AK305132AB
MD998801
MD998812
MD998818
AK305133AB
Snap ring
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