Mitsubishi L200. Manual — part 262
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-33
51.Completely degrease the FIPG-applied surface
so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand.
52.Apply a 1.2 mm diameter bead of liquid gasket to
the transmission case sub-assembly mounting
surface of the front bearing retainer sub-assembly
with seal.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
CAUTION
Do not damage to the oil seal lip during the
installation.
AK403774
53.Apply sealant to the threads. Install the front
bearing retainer to the transmission case sub-
assembly and tighten the bolts to the specified
torque of 16.5
± 5.0 N⋅m.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403773
54.Install the wiring harness clamp bracket to the
transmission case sub-assembly and tighten the
bolt to the specified torque of 18
± 3 N⋅m.
AK403781
55.Install the reverse restrict pin assembly to the
transfer adaptor sub-assembly.
AK403780
AB
56.Install the slotted spring pin to the reverse restrict
pin assembly.
AK403779
57.Apply sealant to the threads. Tighten the straight
screw plug with head to the specified torque of
18.5
± 5.5 N⋅m.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403777
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-34
58.Install the oil receiver pipe into the transfer
adaptor sub-assembly.
AK500527
AB
59.Completely degrease the FIPG-applied surface
so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand.
60.Apply a 1.2 mm diameter bead of liquid gasket to
the intermediate plate mounting surface of the
transfer adaptor sub-assembly.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
AK403776
61.Install the transfer adaptor sub-assembly. Install
the wiring harness clamp bracket (3 places) and
tighten the bolts to the specified torque of 37
± 11
N
⋅m.
CAUTION
When installing the shift lever housing, securely
fit the shift lever housing into the head of the fork
shaft.
AK500256AB
Transfer
adaptor
AK501350
AB
62. Install the shift lever housing to the transfer
adaptor sub-assembly.
AK403772
63.Install the control shaft assembly to the transfer
adaptor sub-assembly and the shift lever housing.
AK403771
AB
64.Tighten the flange bolt to the specified torque of
33
± 3 N⋅m.
AK500528
AB
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-35
65.Completely degrease the FIPG-applied surface
so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand.
66.Apply a 1.2 mm diameter bead of liquid gasket to
the case mounting surface of the transfer adaptor
sub-assembly.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
AK403770
67.Install the cover to the transfer adaptor sub-
assembly and tighten the bolt with washer to the
specified torque of 18
± 5 N⋅m.
CAUTION
Install the reverse restrict pin assembly carefully
in the accordance with the identification color as
shown in the illustration.
AK403769
AB
Identification
color: black
Identification
color: white
68.Tighten the reverse restrict pin assembly to the
specified torque of 37
± 11 N⋅m (2 places).
CAUTION
Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.
AK500460AB
69.Install the clutch housing into the transmission
case sub-assembly. Tighten the bolt with washer
to the specified torque of 36
± 7 N⋅m (7 places).
Tighten the bolt with washer (with sealant) to the
specified torque of 34
± 6 N⋅m (2 places).
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
AK403767
AC
Shift position switch
assembly
Back-up lamp switch
assembly
70.Tighten the shift position switch assembly to the
specified torque of 34
± 5 N⋅m.
71.Tighten the back-up lamp switch assembly to the
specified torque of 44
± 9 N⋅m.
72.Install the transfer and the gear change shifter.
Tighten the bolts to the specified torque of 35
± 6
N
⋅m.
73.Install the spring pin.
TRANSMISSION
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-36
INSPECTION
M1222001100899
BACK-UP LAMP SWITCH
AK500505
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− 2
Conductive
Switch end
released
1
− 2
Open
SHIFT POSITION SWITCH
AK501632
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− 2
Open
Switch end
released
1
− 2
Conductive
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.
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
Standard value: 0.52
− 1.88 mm
Limit: 0.52 mm
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the shaft
and gear, and check that it rotates smoothly
without noise or play.
2. Check the needle roller bearing cage for
deformation.
COUNTER SHAFT GEAR No.5
THRUST CLEARANCE
Inspect the thrust clearance of counter shaft gear
No.5.
Standard value: 0.10
− 0.35 mm
Limit: 0.35 mm
RADIAL CLEARANCE
1. Fix the output shaft in a vice.
2. Inspect the radial clearance of counter shaft gear
No.5.
Standard value: 0.015
− 0.068 mm
Limit: 0.068 mm
INSIDE DIAMETER
AK404027
Using the cylinder gauge, check the inside diameter
of the counter shaft gear No.5.
Standard value: 38.015
− 38.040 mm
Limit: 38.040 mm
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