Mitsubishi Grandis. Manual — part 876
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-14
3. Install the clutch housing and tighten the bolts to
the specified torque of 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.
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.
AK305233
AK305106AB
Input shaft
Output shaft
AK305111AB
3rd-4th speed
synchronizer
sleeve
5th speed-reverse
synchronizer
sleeve
AK305112AB
3rd-4th speed
shift rail
3rd-4th speed
shift fork
5th speed-reverse
shift fork
5th speed-reverse
shift rail
AK305104AC
3rd-4th speed
shift rail
5th speed-reverse
shift rail
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-15
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 as
illustrated onto the transaxle case.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740
or equivalent
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 of 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.
>>F<< SEALING CAP INSTALLATION
1. Using special tools, press install the sealing cap
onto the case.
• Installer adapter (MB990927)
• Handle (MB990938)
AK204302
Shift fork
2.5 mm
Shift rail
Spring pin
AC
AK305113AB
MB990938
MB990935
AK204232AB
AK305108AB
Snap ring
AK305116AB
MB990938
MB990927
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
22B-16
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 as
illustrated onto the under cover.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740
or equivalent
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 of 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 as
illustrated onto the control housing.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740
or equivalent
NOTE: Be sure to install the housing 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 of 18
± 3
N
⋅m.
NOTE: After installation, keep the sealed area
away from the oil for approximately one hour.
>>I<< 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 of 18
± 3 N⋅m.
AK204233
Sealing cap
AB
AK204235AC
AK204236AB
AK204238
Control shaft
Select lever
shoe
AB
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-17
INSPECTION
M1222001100189
BACKUP LIGHT SWITCH
Check for continuity between terminals.
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222001600203
AK201630
SWITCH CONDITION
CONTINUITY
Pressed
Open
Released
Conductive
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.
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