Mitsubishi L200. Manual — part 249

AK500610

Installation
direction

AB

AK500269

AB

Transmission
hub sleeve No.3

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-21

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 which will make the gear spline

pice No.5 end play equal the standard value.

Standard value: 0

− 0.1 mm

AK500818AB

Rotor

Ball

Shaft snap ring

20.Install the ball to the rotor.
21.Install the rotor to the output shaft.
22.Remove the shaft snap ring to the output shaft (2

places).

AK500454AB

Reverse shift fork

Reverse shift arm

23.Install the reverse shift arm to the reverse shift

fork.

AK500455

24.Install the E-ring.

AK403806

25.Install the reverse shift fork and the reverse shift

arm to the intermediate plate.

AK403805

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-22

26.Install the compression spring into the reverse

shift fork.

AK403804

27.Install the ball into the reverse shift fork.

AK403803

AK403802

CAUTION

Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc-
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
28.Install the gear shift fork shaft No.4 into the

intermediate plate and the reverse shift fork.

AK500453AB

29.Install the shaft snap ring into the gear shift fork

shaft No.4.

AK403801

30.Install the ball into the reverse shift fork.

AK403800

31.Install the roller A to the intermediate plate.

AK500461AB

Gear shift fork shaft No.3

Gear shift fork No.3

32.Install the gear shift fork No.3 assembly on the

transmission hub sleeve No.3 and hold it. Insert
the gear shift fork shaft No.3 into the gear shift
fork No.3 assembly, the intermediate plate and
the reverse shift fork.

AK500267

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-23

33.Install the slotted spring pin to the gear shift fork

No.3 assembly.

AK500266

AB

34.Install the snap ring to the gear shift fork shaft

No.3.

AK500265

35.Install the gear shift fork No.1 on the reverse gear.

AK500264

36.Install the roller A to the intermediate plate.

AK500270

37.Install the straight pin to the gear shift fork shaft

No.1.

AK500263

38.Install the gear shift fork shaft No.1 to the

intermediate plate and the gear shift fork No.1.

AK500262

AB

39.Install the shaft snap ring to the gear shift fork

shaft No.1. Tighten the washer based hexagon
bolt to the specified torque of 19.5

± 3.9 N⋅m.

AK500261

40.Install the roller A to the intermediate plate.

AK500260

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-24

41.Install the gear shift fork No.2 on the transmission

hub sleeve No.2.

AK500259

42.Install the gear shift fork shaft No.2 to the

intermediate plate, the gear shift fork No.1 and the
gear shift fork No.2.

AK403792

AB

43.Install the shaft snap ring to the gear shift fork

shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5

± 3.9 N⋅m.

AK403789

AB

44.Install the ball to the intermediate plate (3 places).

AK403788

AB

45.Install the compression spring to the intermediate

plate (3 places).

AK403786

AB

46.Apply sealant to the threads. Tighten the straight

screw plug with head to the specified torque of
18.5

± 5.5 N⋅m (3 places).

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.

AK500257

47.Install the transmission magnet to the

intermediate plate.