Mitsubishi L200. Manual — part 250

AK500527

AB

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-25

48.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.

49.Apply a 1.2 mm diameter bead of liquid gasket to

the intermediate plate mounting surface of the
transmission case sub-assembly.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

AK701366

50.Install the transmission case sub-assembly to the

intermediate plate.

AK403783

51.Install the snap ring to the cylindrical roller

bearing.

AK403782

52.Install the snap ring to the radial ball bearing.

AK600320

MB990938

MB990929

AB

53.Using special tool, install the oil seal to the front

bearing retainer.

• Installer adapter (MB990929)

•

AK403775

AB

Installer bar (MB990938)

54.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.

55.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

AK403774

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-26

CAUTION

Do not damage to the oil seal lip during the
installation.
56.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.

AK403781

57.Install the reverse restrict pin assembly to the

extension housing sub-assembly.

AK604897AB

58.Install the slotted spring pin to the reverse restrict

pin assembly.

AK604896

AB

59.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

60.Install the oil receiver pipe into the extension

housing sub-assembly.

AK500527

AB

61.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.

62.Apply a 1.2 mm diameter bead of liquid gasket to

the intermediate plate mounting surface of the
extension housing sub-assembly.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

AK604895

Wiring harness
clamp bracket

Wiring
harness
clamp
bracket

AB

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-27

63.Install the extension housing sub-assembly.

Install the wiring harness clamp bracket (3 places)
and tighten the bolts to the specified torque of 37
± 11 N⋅m.

AK500816

64.Install the vehicle speed sensor and tighten the

bolts to the specified torque of 11

± 1 N⋅m.

AK500460AB

CAUTION

Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.
65.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

AK704967

AC

Back-up lamp switch
assembly

Shift position switch
assembly

<R5MB1-J-NC>

AK704968

AD

Back-up lamp switch
assembly

<R5MB1-J-ND1>

66.Tighten the shift position switch assembly of 34

±

5 N

⋅m. <R5MB1-J-NC>

67.Tighten the back-up lamp switch assembly and of

44

± 9 N⋅m.

INSPECTION

M1222001100491

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

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-28

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