Mitsubishi L200. Manual — part 244
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
<R5MB1>
CONTENTS
GENERAL INFORMATION . . . . . . . .
GENERAL SPECIFICATIONS . . . . . .
SERVICE SPECIFICATIONS. . . . . . .
SNAP RING, SPACER AND THRUST PLATE
FOR ADJUSTMENT. . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . .
SEALANT(S) AND ADHESIVE(S) . . .
LUBRICANTS . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . .
TRANSMISSION DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION INSPECTION . . . . . . . . .
INPUT SHAFT. . . . . . . . . . . . . . . . . . .
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INPUT SHAFT INSPECTION . . . . . . . . . . .
OUTPUT SHAFT. . . . . . . . . . . . . . . . .
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT INSPECTION . . . . . . . . .
COUNTERSHAFT. . . . . . . . . . . . . . . .
COUNTERSHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
COUNTERSHAFT INSPECTION . . . . . . . .
REVERSE IDLER GEAR . . . . . . . . . .
REVERSE IDLER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
REVERSE IDLER GEAR INSPECTION . . .
EXTENSION HOUSING . . . . . . . . . . .
EXTENSION HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-2
GENERAL INFORMATION
M1222000101275
MANUAL TRANSMISSION MODELS
Transmission model
Engine model
Vehicle model
R5MB1-J-NC
4D56 DI-D DOHC
KA4T
R5MB1-J-ND1
GENERAL SPECIFICATIONS
M1222000200785
Item
Specifications
Transmission model
R5MB1
Transmission type
5-speed transmission, floor shift
Transmission gear ratio
1st
4.313
2nd
2.330
3rd
1.436
4th
1.000
5th
0.789
Reverse
4.220
SERVICE SPECIFICATIONS
M1222000300492
Item
Standard value
Limit
Transmission
Gear spline piece No.5 end play mm
0
− 0.1
−
Clearance between the synchronizer ring and the gear mm
0.52 - 1.88
0.52
Counter shaft gear No.5
thrust
clearance mm
0.10 - 0.35
0.35
radial
clearance mm
0.015
− 0.068
0.068
inside diameter
mm
38.015
− 38.040
38.040
Input shaft
Input shaft radial ball bearing end play mm
0
− 0.1
−
clearance between the synchronizer ring and the 4th gear mm
0.70
− 1.70
0.70
Output shaft
Thrust clearance mm
1st gear
0.20
− 0.45
0.45
2nd gear
0.10
− 0.25
0.25
3rd gear
0.10
− 0.25
0.25
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-3
SNAP RING, SPACER AND THRUST PLATE FOR
ADJUSTMENT
M1222012000595
Shaft snap ring (For adjustment of gear spline piece No.5 end play)
Thickness mm
Identification symbol Thickness mm
Identification symbol
2.80
− 2.85
A
3.00
− 3.05
E
2.85
− 2.90
B
3.05
− 3.10
F
2.90
− 2.95
C
3.10
− 3.15
G
2.95
− 3.00
D
Radial clearance mm
1st gear
0.020
− 0.073
0.073
2nd gear
0.015
− 0.068
0.068
3rd gear
0.015
− 0.068
0.068
Transmission clutch hub No.1 end play mm
0
− 0.1
−
Transmission clutch hub No.2 end play mm
0
− 0.1
−
5th gear end play mm
0
− 0.1
−
Clearance between the synchronizer ring and the
each gear mm
1st gear
0.65
− 1.75
0.65
2nd gear
0.65
− 1.75
0.65
3rd gear
0.65
− 1.75
0.65
Clearance between the each sleeve and the shift
fork mm
sleeve No.1
0.15
− 0.41
0.41
sleeve No.2
0.15
− 0.35
0.35
sleeve No.3
0.26
− 0.84
0.84
Output shaft outer shape of the needle roller
bearing race mm
A
37.984
− 38.000
37.984
B
46.984
− 47.000
46.984
C
38.979
− 38.995
38.979
Output shaft flange thickness mm
−
4.800
Output shaft runout mm
−
0.015
Each gear inside diameter mm
1st gear
46.015
− 46.040
46.040
2nd gear
53.015
− 53.040
53.040
3rd gear
44.015
− 44.040
44.040
Counter shaft
Counter gear shaft cylindrical roller bearing end play mm
0
− 0.1
−
Counter shaft outer shape of the needle roller
bearing race mm
D
34.000
− 34.105
34.000
E
29.984
− 30.000
29.984
Reverse idler gear
Reverse idler gear radial clearance mm
0.040
− 0.082
0.082
Item
Standard value
Limit
TORQUE SPECIFICATIONS
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-4
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
Thickness mm
Identification symbol Thickness mm
Identification symbol
2.10
− 2.15
A
2.30
− 2.35
E
2.15
− 2.20
B
2.35
− 2.40
F
2.20
− 2.25
C
2.40
− 2.45
G
2.25
− 2.30
D
Shaft snap ring (For adjustment of transmission clutch hub No.2 end play)
Thickness mm
Identification symbol Thickness mm
Identification symbol
1.80
− 1.85
A
2.00
− 2.05
E
1.85
− 1.90
B
2.05
− 2.10
F
1.90
− 1.95
C
2.10
− 2.15
G
1.95
− 2.00
D
Shaft snap ring (For adjustment of transmission clutch hub No.1 end play)
Thickness mm
Identification symbol Thickness mm
Identification symbol
2.30
− 2.35
A
2.50
− 2.55
E
2.35
− 2.40
B
2.55
− 2.60
F
2.40
− 2.45
C
2.60
− 2.65
G
2.45
− 2.50
D
Shaft snap ring (For adjustment of 5th gear end play)
Thickness mm
Identification symbol Thickness mm
Identification symbol
2.75
− 2.80
C
3.05
− 3.10
J
2.80
− 2.85
D
3.10
− 3.15
K
2.85
− 2.90
E
3.15
− 3.20
L
2.90
− 2.95
F
3.20
− 3.25
M
2.95
− 3.00
G
3.25
− 3.30
N
3.00
− 3.05
H
3.30
− 3.35
P
Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
Thickness mm
Identification symbol Thickness mm
Identification symbol
2.05
− 2.10
A
2.20
− 2.25
D
2.10
− 2.15
B
2.25
− 2.30
E
2.15
− 2.20
C
2.30
− 2.35
F
TORQUE SPECIFICATIONS
M1222013900494
Item
N
⋅m
Intermediate plate
− reverse shift arm bracket mounting bolt
18
± 5
Transmission case
− clutch housing mounting bolt
36
± 7
Transmission case
− clutch housing mounting bolt (with seal)
34
± 6
Transmission case
− front bearing retainer sub-assembly mounting bolt
16.5
± 5.0
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