Mitsubishi L200. Manual — part 260

AK403986

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-25

58.Remove the rear bearing output shaft retainer.

AK403987

59.Remove the snap ring.

AK403989

AK403989

Reverse idler gear
sub-assembly

Reverse idler
gear shaft

AB

60.Remove the reverse idler gear shaft and reverse

idler gear sub-assembly.

AK403990

61.Remove the counter gear sub-assembly and

cylindrical roller bearing.

AK403991

62.Remove the input shaft sub-assembly.

AK403992

63.Remove the output shaft sub-assembly.

AK403993

64.Remove the reverse shift arm bracket.

REASSEMBLY

AK403993

1. Set the reverse shift arm bracket to the

intermediate plate and tighten the bolts to the
specified torque of 18

± 5 N⋅m.

AK403992

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-26

2. Install the output shaft sub-assembly to the

intermediate plate.

AK403991

3. Install the input shaft sub-assembly to the output

shaft sub-assembly.

AK403990

AB

Counter gear
sub-assembly

Cylindrical roller
bearing

4. Insert the counter gear sub-assembly into the

intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.

AK403989

AK403989

Reverse idler gear
sub-assembly

Reverse idler
gear shaft

AB

5. Install the reverse idler gear shaft and reverse

idler gear sub-assembly to the intermediate plate.

AK403987

6. Install the shaft snap ring to the radial ball bearing

of the input shaft sub-assembly.

AK403986

AB

7. Set the rear bearing output shaft retainer and

tighten the bolts to the specified torque of 18

± 5

N

⋅m.

NOTE: Fit the rear bearing output shaft retainer
into the reverse idler gear shaft slot.

AK403785

AB

8. Install the straight pin.

AK501229

5th gear
thrust
washer

Penetration
groove

Straight pin

Installtion
direction

AB

AK403985

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-27

9. Check the installation direction of 5th gear thrust

washer, and install it.

AK500459

10.Install the needle roller bearing.

AK500458

11.Install the synchromesh shifting key No.3 to the

counter shaft gear No.5.

AK500457

12.Install the synchromesh shifting key spring No.3

to the counter shaft gear No.5.

AK500456

13.Install the synchromesh shifting key spring No.3

to the counter shaft gear No.5.

AK500526

14.Install the shaft snap ring to the counter shaft gear

No.5.

AK403984

15.Install the counter shaft gear No.5.

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-28

CAUTION

Fit the protrusions of synchronizer ring between
keys.

AK403983

AB

Protrusion

Key

16.Install the synchronizer outer race No.3.

AK404049

AB

MD998812

MD998813

MD998827

17.Using special tools to install the gear spline piece

No.5.

• Installer cap (MD998812)

• Installer-100 (MD998813)

•

AK500610

Installation
direction

AB

AK500269

AB

Transmission
hub sleeve No.3

Installer adapter (56) (MD998827)

18.Check the installation direction of the

transmission hub sleeve No.3 and install it on the
counter shaft.
NOTE: After installation, check the sleeve operate
smoothly.

AK403807

19.Select a snap ring to secure the thrust clearance.

Install it into the counter gear sub-assembly.

Standard value: 0

− 0.1 mm

AK500454AB

Reverse shift fork

Reverse shift arm

20.Install the reverse shift arm to the reverse shift

fork.

AK500455

21.Install the E ring.