Mitsubishi L200. Manual — part 252
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-33
<<D>> TRANSMISSION CLUTCH HUB No.2 /
SYNCHRONIZER SHIFTING KEY No.2 /
COMPRESSION SPRING / TRANSMISSION HUB
SLEEVE No.2 / SYNCHRONIZER RING SET No.2 /
3RD GEAR SUB-ASSEMBLY REMOVAL
AK404020
MD998801
AB
Using special tool Bearing remover (MD998801),
support the 3rd gear sub-assembly and remove the
transmission clutch hub No.2, synchronizer shifting
key No.2, compression spring, the transmission hub
sleeve No.2, synchronizer ring set and the 3rd gear
sub-assembly.
REASSEMBLY SERVICE POINTS
>>A<< TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 / COM-
PRESSION SPRING / TRANSMISSION HUB
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY INSTALLATION
AK500607
Installation
direction
AB
1. Check the installation direction of the transmission
clutch hub No. 2, and put it on the output shaft.
AK404029
AC
MD998812
MD998823
MD998813
2. Using special tools to install the transmission
clutch hub No. 2, synchronizer shifting key No. 2,
compression spring, the transmission hub sleeve
No. 2, synchronizer ring set No. 2 and the 3rd
gear sub-assembly.
• Installer cap (MD998812)
• Installer-100 (MD998813)
•
AK500508
Installer adapter (48) (MD998823)
3. Confirm the thrust clearance of the 3rd gear sub-
assembly is within the standard value.
Standard value: 0.10
− 0.25 mm
Limit: 0.25 mm
>>B<< SHAFT SNAP RING INSTALLATION
AK404019
1. Select a shaft snap ring to secure the standard
clearance between the transmission clutch hub
No.2 and the output shaft.
Standard value: 0
− 0.1 mm
2. Install the selected snap ring.
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-34
>>C<< REVERSE GEAR / SYNCHRONIZER
SHIFTING KEY No. 1 / COMPRESSION SPRING /
TRANSMISSION CLUTCH No. 1 HUB /
SYNCHRONIZER RING SET No. 1 / 2ND GEAR
SUB-ASSEMBLY INSTALLATION
AK500608
Installation
direction
AB
1. Check the installation direction of the reverse
gear, and put it on the output shaft.
AK404030
AC
MD998812
MD998823
MD998813
MD998814
2. Using special tools to install the reverse gear,
synchronizer shifting key No. 1, compression
spring, the transmission clutch No. 1 hub,
synchronizer ring set No. 1 and the 2nd gear sub-
assembly.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer-200 (MD998814)
•
AK404032
Installer adapter (48) (MD998823)
3. Confirm the thrust clearance of the 2nd gear sub-
assembly is within the standard value.
Standard value: 0.10
− 0.25 mm
Limit: 0.25 mm
>>D<< SHAFT SNAP RING INSTALLATION
AK404031
1. Select a snap ring to secure the standard
clearance between the transmission clutch No. 1
hub and the output shaft.
Standard value: 0
− 0.1 mm
2. Install the selected snap ring.
>>E<< RADIAL BALL BEARING / 1ST GEAR SUB-
ASSEMBLY INSTALLATION
AK500606AB
Installation
direction
1. Check the installation direction of the radial ball
bearing, and put it on the output shaft.
CAUTION
Never push on the sealing area when installing.
AK404038
AB
MD998812
MD998823
MD998814
2. Using special tools to install the radial ball bearing
and the 1st gear sub-assembly.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
AK500513
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-35
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value.
Standard value: 0.20
− 0.45 mm
Limit: 0.45 mm
>>F<< 5TH GEAR INSTALLATION
AK500609
Installation
direction
AB
1. Check the installation direction of the 5th gear,
and put it on the output shaft.
AK404039
AB
MD998812
MD998823
MD998814
2. Using special tools to install the 5th gear.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
>>G<< SHAFT SNAP RING INSTALLATION
AK404040
1. Select a shaft snap ring to secure the standard
clearance between the 5th gear and the output
shaft
Standard value: 0
− 0.1 mm
2. Install the selected snap ring.
INSPECTION
M1222002300261
SYNCHRONIZER RING
CAUTION
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
AK500672AB
1. Check to ensure that the clutch gear tooth surface
and cone surface are not damaged and broken.
AK500603
2. After applying oil to the taper portion on each
gear, press and fit the synchronizer ring by hand.
Confirm the synchronizer ring cannot be rotated.
AK404022
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-36
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
Gear
Standard value mm
Limit mm
1st
0.65
− 1.75
0.65
2nd
0.65
− 1.75
0.65
3rd
0.65
− 1.75
0.65
HUB SLEEVE AND SHIFT FORK
CAUTION
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
AK404023
Using the thickness gauge, check the clearance
between the sleeve and the shift fork.
sleeve
Standard
value mm
Limit mm
No.1
0.15
− 0.41
0.41
No.2
0.15
− 0.35
0.35
No.3
0.26
− 0.84
0.84
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.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the output
shaft and gear, and check that it rotates smoothly
without noise or play.
2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER KEYS
AK500680AB
Check the synchronizer hub contact surfaces of each
synchronizer key for damage and excessive wear.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404024
AB
A
B
C
1. Using the micrometer, check the outer shape of
the needle roller bearing race.
Measurement
part
Standard value mm Limit mm
A
37.984
− 38.000
37.984
B
46.984
− 47.000
46.984
C
38.979
− 38.995
38.979
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