22B-0-1
MANUAL
TRANSMISSION
F5M41, F5M42, W5M42
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-1
TRANSMISSION MODEL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-1
GEAR RATIO TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-2d
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-2d
SEALANTS AND ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-2e
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-3
SNAP RINGS, SPACERS AND THRUST PLATE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-9
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-2-1
3. TRANSMISSION <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-3-1
4. TRANSMISSION <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-4-1
5. INPUT SHAFT <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-5-1
6. INPUT SHAFT <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-6-1
7. OUTPUT SHAFT <F5M41> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-7-1
8. OUTPUT SHAFT <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-8-1
9. REVERSE IDLER GEAR <F5M42, W5M42> . . . . . . . . . . . . . . . . . . . . . . 22B-9-1
10. SPEEDOMETER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-10-1
11. SELECT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-11-1
12. CONTROL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-12-1
13. CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-13-1
14. TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-14-1
15. DIFFERENTIAL <F5M41, F5M42>,
FRONT DIFFERENTIAL <W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-15-1
16. CENTER DIFFERENTIAL <W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-16-1
17. TRANSFER <W5M42> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-17-1
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
MANUAL TRANSMISSION (E-W) - General Information
22B-0-3
GENERAL INFORMATION
F5M41 <Types with single synchronizer ring for 2nd gear>
6
7
8
2
3
1
5
4
9
10
14 13
12
15
11
TFM0809
1. Reverse gear meshing noise pre-
vention device
8. Clutch housing
9. Release bearing retainer
10. Input shaft
<Models with reverse brake>
2. 5th-reverse speed synchronizer hub
3. 5th speed gear
11. Differential
12. 1st speed gear
4. 4th speed gear
13. 1st-2nd speed synchronizer hub
14. 2nd speed gear
5. 3rd-4th speed synchronizer hub
6. 3rd speed gear
15. Output shaft
7. Transmission case
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-0-4
MANUAL TRANSMISSION (E-W) - General Information
F5M41 <Types with double synchronizer ring for 2nd gear>
6
7
8
3
4
1
2
5
9
10
14
13
12
15
11
1. Reverse gear meshing noise pre-
vention device
8. Clutch housing
9. Release bearing retainer
10. Input shaft
2. 5th-reverse speed synchronizer hub
3. 5th speed gear
11. Differential
12. 1st speed gear
13. 1st-2nd speed synchronizer hub
14. 2nd speed gear
15. Output shaft
4. 4th speed gear
5. 3rd-4th speed synchronizer hub
6. 3rd speed gear
7. Transmission case
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - General Information
22B-0-5
F5M42
<Types with single synchronizer ring for 1st gear and double synchronizer ring
for 2nd gear>
5
4
6
2
1
3
7
8
9
16
15 14
13
12
11
10
1. Reverse idler gear
2. 4th speed gear
9. Output shaft
10. Differential
3. 3rd-4th speed synchronizer hub
4. 3rd speed gear
11. 1st speed gear
12. 1st-2nd speed synchronizer hub
13. 2nd speed gear
5. Transmission case
6. Clutch housing
7. Release bearing retainer
8. Input shaft
14. 5th speed gear
15. 5th-reverse speed synchronizer hub
16. Reverse gear
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-0-6
MANUAL TRANSMISSION (E-W) - General Information
F5M42
<Types with double synchronizer ring for both 1st and 2nd gears, types with
double synchronizer ring for 1st gear and triple synchronizer ring for 2nd gear>
4
6
5
1
3
2
7
8
9
16
13
12
11
15 14
10
1. Reverse idler gear
2. 4th speed gear
9. Output shaft
10. Differential
3. 3rd-4th speed synchronizer hub
4. 3rd speed gear
11. 1st speed gear
12. 1st-2nd speed synchronizer hub
13. 2nd speed gear
5. Transmission case
6. Clutch housing
7. Release bearing retainer
8. Input shaft
14. 5th speed gear
15. 5th-reverse speed synchronizer hub
16. Reverse gear
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - General Information
22B-0-7
W5M42
2
4
1
3
5
6
7
8
10
9
16
19 18 17
15
14
13
11
12
1. Reverse idler gear
2. 4th speed gear
11. Front differential
12. Transfer driven gear
13. Center differential
14. 1st speed gear
3. 3rd-4th speed synchronizer hub
4. 3rd speed gear
5. Transmission case
6. Clutch housing
15. 1st-2nd speed synchronizer hub
16. 2nd speed gear
7. Release bearing retainer
8. Input shaft
17. 5th speed gear
18. 5th-reverse speed synchronizer hub
19. Reverse gear
9. Output shaft
10. Viscous coupling
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
MANUAL TRANSMISSION (E-W) - Specifications
22B-1-1
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE - MODEL 1996
Transmission model
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model
Engine model
EUR
EXP
F5M41-1-B8A1
B
A
A
A
A
A
C
31/36
31/36
31/36
31/36
31/36
31/36
31/36
3.454
3.714
4.052
3.714
4.052
4.052
4.058
CJ4A
4G92-MVV
4G92-MPI
4G13
F5M41-1-F8A1
F5M41-1-R8A
F5M41-1-F8A1
F5M41-1-R8A
F5M41-1-R8A
F5M42-1-Y8A
CJ4A, CK4A
CJ1A, CK1A
CJ4A, CK4A
CJ1A, CK1A
CJ2A, CK2A
CK4A
4G92-MPI
4G13
4G15
4G92-MIVEC
TRANSMISSION MODEL TABLE - MODEL 1997
Transmission model
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model
Engine model
EUR
EXP
F5M42-1-F7N
F5M42-2-F6N2
F5M42-2-F6N5
F5M42-1-F6N4
F5M42-1-F7N
F5M42-1-R6N2
F5M42-1-R6N3
F5M42-2-F6N2
F5M42-2-V6N
D
D
E
D
D
D
D
D
D
30/36
29/36
29/36
29/36
30/36
29/36
29/36
29/36
29/36
3.722
3.722
3.722
3.722
3.722
4.058
4.058
3.722
4.312
EA2A, EA2W
EA5A, EA5W
EA6A, EA6W
EA2A
4G63
6A13
4D68
4G63-MPI
4G63-MPI
4G93
EA2A
EA1A
EA2A
4G63-CARB
6A13
EA5A
EA4A
6A12
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-1-2
MANUAL TRANSMISSION (E-W) - Specifications
TRANSMISSION MODEL TABLE - MODEL 1998
Transmission model
EUR F5M41-1-B8A2
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model
Engine model
B
A
A
D
D
E
F
31/36
31/36
31/36
30/36
31/36
29/36
29/36
31/36
31/36
31/36
29/36
29/36
29/36
3.454
3.714
4.052
3.722
3.722
3.722
3.722
3.714
4.052
4.052
4.052
3.722
3.722
CJ4A
4G92
4G92
4G13
4G63
4G93-GDI
4D68
6A13
F5M41-1-F8A5
F5M41-1-R8A1
F5M42-1-F71
CJ4A
CK1A, CJ1A
EA2A, EA2W
DA2A
F5M42-1-F8A4
F5M42-2-F6NA
F5M42-2-F6N7
F5M41-1-F8A5
F5M41-1-R8A1
F5M41-1-R8A1
F5M42-1-R6N6
F5M42-2-R6N7
F5M42-2-R6N8
EA6A, EA6W
EA5A, EA5W
CJ4A, CK4A
CJ1A, CK1A
CJ2A, CK2A
EA1A
EXP
A
A
A
D
D
D
4G92
4G13
4G15
4G93
4G63
4D68
EA2A
EA6A
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Specifications
TRANSMISSION MODEL TABLE - MODEL 1999
22B-1-2a
Transmission model
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model
Engine model
EUR F5M42-1-V5A4
D
G
H
G
D
G
F
28/36
28/36
28/36
31/36
30/36
29/36
29/36
29/36
29/36
29/36
29/36
30/36
29/36
29/36
29/36
28/36
31/36
31/36
28/36
4.312
4.058
4.352
3.722
3.722
3.722
3.722
3.722
4.058
4.058
3.722
3.722
4.352
3.722
4.058
4.058
3.722
3.722
4.058
N61W
4G93-GDI
4G64-GDI
4G64-GDI
4G93-GDI
4G93
F5M42-2-R5A3
W5M42-1-V5A1
F5M42-1-F8A
N84W
N94W
DA2A
F5M42-2-F7N2
F5M42-2-F6NC
F5M42-2-F6N7
F5M42-2-F6NA
F5M42-1-R6N6
F5M42-1-R6N7
F5M42-1-F6N9
F5M42-1-F7N1
F5M42-2-V6N1
F5M42-2-F6N7
F5M42-2-R6N8
F5M42-2-R5A2
EA2A, EA2W
EA3A, EA3W
EA5A, EA5W
EA6A, EA6W
EA1A
4G64-GDI
6A13
E
D
D
D
D
D
F
4D65
EXP
4G93
EA2A
4G63
EA2A
4G63
EA2A
4G63
EA4A
6A12-MIVEC
6A13
EA5A
E
D
D
D
D
EA6A
4D56
N84W
4G64
MMAL F5M41-1-F8A5
F5M42-1-F8A7
CJ2A, CK2A
CJ5A, CK5A
N84W
4G15
4G93
F5M42-2-R5A2
4G64
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-1-2b
MANUAL TRANSMISSION (E-W) - Specifications
TRANSMISSION MODEL TABLE - MODEL 2000
Transmission model
EUR F5M41-1-R8A1
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model
Engine model
A
A
B
D
D
G
H
A
A
D
D
D
F
31/36
31/36
31/36
30/36
28/36
28/36
28/36
31/36
31/36
29/36
29/36
29/36
29/36
28/36
28/36
4.052
3.714
3.454
4.058
4.312
4.058
4.352
4.052
3.714
4.058
4.058
3.722
3.722
4.058
4.058
CJ1A
4G13
F5M41-1-F8A5
F5M41-1-B8A2
F5M42-1-R7A2
F5M42-1-V5A4
F5M42-2-R5A3
W5M42-1-V5A1
F5M41-1-R8A1
F5M41-1-F8A5
F5M42-1-R6N6
F5M42-1-R6N7
F5M42-1-F6N9
F5M42-2-F6N7
F5M42-2-R5A2
CJ4A
4G92
CJ4A
4G92-MVV
4G93-GDI
4G93-GDI
4G64-GDI
4G64-GDI
4G13
DA2A
N61W
N64W, N84W
N94W
EXP
CJ1A, CK1A
CJ4A, CK4A
EA1A
4G92
4G93
EA2A
4G63
EA2A, EA2W
EA5A
4G63
6A13
D
D
N84W
4G64
MMAL F5M42-2-R5A2
N84W
4G64
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-1-2c
MANUAL TRANSMISSION (E-W) - Specifications
TRANSMISSION MODEL TABLE - MODEL 2001
Transmission model
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model
Engine model
EUR F5M41-1-R8A1
A
A
B
D
D
G
F
31/36
31/36
31/36
30/36
30/36
29/36
29/36
28/36
28/36
31/36
31/36
29/36
30/36
29/36
29/36
29/36
29/36
29/36
29/36
28/36
31/36
31/36
31/36
4.052
3.714
3.454
4.058
3.722
3.722
3.722
4.352
4.058
4.052
3.714
3.722
3.722
4.058
3.722
4.058
3.722
3.722
4.058
4.058
3.714
3.722
4.058
CJ1A
4G13
4G92
4G93
4G93
4G63
4G64
6A13
4G63
4G64
4G13
4G92
4G63
4G63
4G93
4G93
4G63
4G63
6A13
4D68
4G64
4G15
4G93
4G64
F5M41-1-F8A5
F5M41-1-F8AC
F5M42-2-R7A2
F5M42-2-F7N2
F5M42-2-F6NC
F5M42-2-F6N7
F5M42-2-V5A
F5M42-2-R5A3
F5M41-1-R8A1
F5M41-1-F8A5
F5M42-1-F6N9
F5M42-1-F7N1
F5M42-1-R6N6
F5M42-1-F6N7
F5M42-1-R6N7
F5M42-1-F6N9
F5M42-1-F6N7
F5M42-2-R6N8
F5M42-2-R5A2
CJ4A
DG5A
DA2A
EA2A, W
EA3A, W
EA5A, W
N63W
N64W
CJ1A
D
G
A
A
D
D
D
F
EXP
CJ4A
EA2W
EA2W
EA1A
EA1A
EA2A
EA2A
EA5A
EA6A
N84W
CJ2A
D
D
F
E
D
A
F
MMAL F5M41-1-F8A5
F5M42-1-F8A7
CJ5A
F5M42-2-R5A2
D
N84W
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
22B-1-2d
MANUAL TRANSMISSION (E-W) - Specifications
GEAR RATIO TABLE
A
B
C
D
E
F
G
1st
3.583
1.947
1.343
0.976
0.804
3.416
3.727
1.947
1.343
0.976
0.804
3.416
3.071
1.947
1.379
1.030
0.820
3.363
3.583
1.947
1.379
1.030
0.820
3.363
3.583
1.947
1.379
1.030
0.733
3.363
3.583
1.947
1.379
1.030
0.767
3.363
3.583
1.947
1.266
0.970
0.767
3.363
2nd
3rd
4th
5th
Reverse
H
1st
3.583
1.947
1.266
0.970
0.767
3.363
0.3018
2nd
3rd
4th
5th
Reverse
Transfer
SERVICE SPECIFICATIONS
Items
Allowable range
Limit
Input shaft front bearing end play mm
-0.01-0.12
-0.01-0.09
-0.01-0.12
-0.01-0.09
-0.01-0.12
-0.01-0.09
-0.01-0.09
0.05-0.17
-
-
-
-
-
-
-
-
-
-
-
Input shaft rear bearing end play <F5M41> mm
Input shaft rear bearing end play <F5M42, W5M42> mm
Input shaft 5th speed gear end play <F5M42, W5M42> mm
Output shaft front bearing end play mm
Output shaft rear bearing end play mm
Output shaft 3rd speed gear end play mm
Differential case end play <F5M41> mm
Differential case pinion backlash <F5M41, F5M42> mm
Front differential case backlash <W5M42> mm
Differential case preload <F5M42> mm
0.025-0.150
0.025-0.150
0.05-0.11
NOTE: Standard play = 0 mm
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
22B-1-2e
MANUAL TRANSMISSION (E-W) - Specifications
Items
Allowable range
Limit
Front differential case preload <W5M42> mm
Center differential case pinion backlash <W5M42> mm
Center differential case preload <W5M42> mm
Synchronizer ring back surface to gear clearance mm
NOTE: Standard play = 0 mm
0.05-0.11
0.025-0.150
0.05-0.11
-
-
-
-
0.5
SEALANTS AND ADHESIVES
TRANSMISSION
Items
Specified sealants and adhesives
Clutch housing-transmission case mating surface
Control housing-transmission case mating surface
MITSUBISHI genuine sealant part No. MD997740
or equivalent
Under cover-transmission case mating surface
<F5M42, W5M42>
Air breather
3M SUPER WEATHERSTRIP No. 8001 or
equivalent
Differential drive gear bolt <F5M41, F5M42>
Front differential drive gear bolt <W5M42>
3M STUD Locking No. 4170 or equivalent
Center differential drive gear bolt <W5M42>
Front bearing retainer bolt (countersink head bolt) <F5M41>
TRANSFER
Item
Specified sealant
Air breather
3M SUPER WEATHERSTRIP No. 8001 or
equivalent
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Added
E
MANUAL TRANSMISSION (E-W) - Specifications
22B-1-3
FORM-IN-PLACE GASKET
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the
gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too
thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of
the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the
metallic flange areas.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In some
cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with
a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined
surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget
to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt
hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened.
While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are
mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any
oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour)
has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
LUBRICANTS
TRANSMISSION
Items
Specified lubricants
Drive shaft oil seal lip area
Control shaft oil seal lip area
Input shaft oil seal lip area
Select lever shoe
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
MITSUBISHI genuine grease part No. 0101011 or
equivalent
TRANSFER
Items
Specified lubricants
Drive shaft oil seal lip area
Front differential oil seal lip area
Each O-ring
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-1-4
MANUAL TRANSMISSION (E-W) - Specifications
SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT
Part name
Thickness mm
Identification
symbol
Part No.
Snap ring
2.24
2.31
2.38
2.31
2.35
2.39
2.43
2.47
2.51
2.55
2.59
2.63
2.67
2.71
2.82
2.86
2.90
2.94
2.98
3.02
3.06
3.10
1.43
1.51
1.59
None
MD706537
MD706538
MD706539
MD747149
MD746561
MD746562
MD746563
MD746564
MD746565
MD746566
MD746567
MD746568
MD746569
MD746570
MD748015
MD748016
MD748017
MD748018
MD748019
MD748020
MD748021
MD748022
MD746708
MD746709
MD746710
(For adjustment of input shaft front bearing end
play)
Blue
Brown
Snap ring
Black (2)
(For adjustment of input shaft rear bearing end
play ....F5M41)
None
(For adjustment of output shaft rear bearing end
play ....F5M42, W5M42)
Blue
Brown
Green
White
Yellow
Black
Orange
Blue
Brown
Thrust plate: F5M42, W5M42
(For adjustment of input shaft 5th speed gear
end play)
-
-
-
-
-
-
-
-
Snap ring
Green (2)
White (2)
Yellow (2)
(For adjustment of output shaft front bearing end
play)
(For adjustment of input shaft rear bearing end
play ....F5M42, W5M42)
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Specifications
22B-1-5
Part name
Thickness mm
Identification
symbol
Part No.
Snap ring: F5M41
2.31
2.35
2.39
2.43
2.47
2.51
2.55
2.59
2.63
2.67
2.71
2.81
2.85
2.89
2.93
2.97
3.01
3.05
3.09
2.81
2.85
2.89
2.93
2.97
3.01
3.05
3.09
Black (2)
None
Blue
MD748800
MD748801
MD748802
MD748803
MD748804
MD748805
MD748806
MD748807
MD748808
MD748809
MD748810
MD748782
MD748783
MD748784
MD748785
MD748786
MD748787
MD748788
MD748789
MD745799
MD745800
MD745801
MD745802
MD745803
MD745804
MD745805
MD745806
(For adjustment of output shaft rear bearing end
play)
Brown
Green
White
Yellow
Black
Orange
Blue
Brown
Green
White
Yellow
Black
Orange
Red
Snap ring: F5M41
(For adjustment of output shaft 3rd speed gear
end play)
Pink
Blue
Snap ring: F5M42, W5M42
(For adjustment of output shaft 3rd speed gear
end play)
Green
White
Yellow
Black
Orange
Red
Pink
Blue
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-1-6
MANUAL TRANSMISSION (E-W) - Specifications
Part name
Thickness mm
Identification
symbol
Part No.
Spacer: F5M41
(For adjustment of differential case end play)
0.77
0.86
0.95
1.04
1.13
1.22
1.31
1.40
1.49
1.58
1.67
1.76
77
86
95
04
D
MD754476
MD720938
MD720941
MD720944
MD700270
MD700271
MD706574
MD706573
MD706572
MD706571
MD706570
MD706575
G
E
None
C
B
A
F
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Specifications
22B-1-7
Part name
Thickness mm
Identification
symbol
Part No.
Spacer: F5M42
(For adjustment of differential case preload)
0.71
0.74
0.77
0.80
0.83
0.86
0.89
0.92
0.95
0.98
1.01
1.04
1.07
1.10
1.13
1.16
1.19
1.22
1.25
1.28
1.31
71
74
77
80
83
86
89
92
95
98
01
04
07
J
MD754475
MD727660
MD754476
MD727661
MD720937
MD720938
MD720939
MD720940
MD720941
MD720942
MD720943
MD720944
MD720945
MD710454
MD700270
MD710455
MD710456
MD700271
MD710457
MD710458
MD706574
D
K
L
G
M
N
E
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-1-8
MANUAL TRANSMISSION (E-W) - Specifications
Part name
Thickness mm
Identification
symbol
Part No.
Spacer: W5M42
0.74
74
77
80
83
86
89
92
95
98
01
04
07
J
MD727660
MD745476
MD727661
MD720937
MD720938
MD720939
MD720940
MD720941
MD720942
MD720943
MD720944
MD720945
MD710454
MD700270
MD710455
MD710456
MD700271
MD710457
MD710458
MD706574
MA180862
MA180861
MA180860
MA180875
MA180876
MD744236
MD744235
MD744234
MD744233
MD744232
(For adjustment of center differential case
preload)
0.77
0.80
0.83
0.86
0.89
0.92
0.95
0.98
1.01
1.04
1.07
1.10
1.13
D
K
1.16
1.19
L
1.22
G
M
N
E
1.25
1.28
1.31
Spacer: F5M41, F5M42
(For adjustment of differential case backlash)
0.75-0.82
0.83-0.92
0.93-1.00
1.01-1.08
1.09-1.16
0.75 - 0.82
0.83 - 0.92
0.93 - 1.00
1.01 - 1.08
1.09 - 1.16
-
-
-
-
-
Spacer: W5M42
(For adjustment of center differential case pinion
backlash)
-
-
-
-
-
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Specifications
TORQUE SPECIFICATIONS
22B-1-9
TRANSMISSION
Items
Nm
6.9
30
Under cover mounting bolt <F5M42, W5M42>
Interlock plate bolt
Clutch housing-transmission case mounting bolt
Clutch release bearing retainer mounting bolt
Control housing mounting bolt
44
9.8
18
Shift cable bracket mounting bolt
18
Speedometer gear mounting bolt
3.9
22
Stopper bracket mounting bolt
Select lever mounting bolt
18
Select lever mounting nut
11
Front differential drive gear mounting bolt <W5M42>
Center differential flange mounting screw <W5M42>
Center differential drive gear mounting bolt <W5M42>
Differential drive gear mounting bolt <F5M41, F5M42>
Back-up lamp switch
132
3.9
132
132
32
Front bearing retainer mounting bolt
Poppet spring
18
32
Restrict ball <F5M41>
32
Reverse idler gear shaft mounting bolt
Reverse shift lever mounting bolt <F5M41>
Roll stopper bracket mounting bolt
Oil temperature sensor <For GDI engine only>
Connector bracket mounting bolt <For GDI engine except DA2A>
Clutch fluid line bracket mounting bolt <DA2A only>
48
18
69
32
19
19
TRANSFER
Items
Nm
23
Transfer cover mounting bolt
Transmission - transfer mounting bolt
69
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Added
E
MANUAL TRANSMISSION (E-W) - Special Tools
22B-2-1
2. SPECIAL TOOLS
TRANSMISSION
Tool
Number
Name
Use
MB990926
Installer adapter
Installation of clutch housing input shaft oil seal
MB990927
MB990930
MB990934
MB990935
MB990937
MB990938
MD998325
Installer adapter
Installer adapter
Installer adapter
Installer adapter
Installer adapter
Handle
Installation of sealing cap
Removal of center differential taper roller
bearing <W5M42>
Installation of roller bearing outer race
Installation of differential case taper roller
bearing outer race
Installation of center differential taper roller
bearing <W5M42>
Use with Installer adapter
Differential oil seal Installation of differential oil seal
installer <F5M41, F5M42>
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-2-2
MANUAL TRANSMISSION (E-W) - Special Tools
Tool
Number
Name
Use
MD998346
Bearing outer race Removal of roller bearing outer race
remover
MD998772
MD998801
MD998812
MD998813
MD998814
MD998816
MD998817
MD998818
Valve spring com- Removal of roller bearing outer race
pressor
Bearing remover
Installer cap
Installer-100
Installer-200
Installation and removal of gears, bearings and
sleeves
Use with Installer and Installer adapter
Use with Installer cap and Installer adapter
Use with Installer cap and Installer adapter
Installer adapter Installation of input shaft front bearing
(30) <F5M42, W5M42>
Installer adapter Installation of input shaft front bearing
(34)
<F5M41>, output shaft rear bearing <F5M42,
W5M42>
Installer adapter Installation of input shaft rear bearing, roller
(38)
bearing inner race, reverse gear, needle roller
bearing, reverse gear bearing sleeve <F5M42,
W5M42> and reverse bearing sleeve
<F5M41>
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Special Tools
22B-2-3
Tool
Number
Name
Use
MD998819
Installer adapter Installation of 5th-reverse speed synchronizer
(40)
hub, differential case bearing, 4th speed gear
and 5th speed gear sleeve <F5M42, W5M42>
MD998820
MD998822
MD998823
MD998824
MD998825
MD998826
MD998917
MD999566
Installer adapter Installation of 5th speed gear sleeve, 2nd
(42) speed gear sleeve <F5M41>
Installer adapter Installation of 1st speed gear sleeve,1st-2nd
(46)
speed synchronizer hub <F5M41>, 2nd speed
gear sleeve and 3rd speed gear <F5M42,
W5M42>
Installer adapter Installation of differential case taper roller
(48) bearing inner race <F5M42, W5M42>
Installer adapter Installation of 4th speed gear sleeve and 5th
(50) speed gear <F5M42, W5M42>
Installer adapter Installation of 1st-2nd speed synchronizer hub,
(52)
3rd-4th speed synchronizer hub and 1st speed
gear sleeve <F5M42, W5M42>
Installer adapter Installation of 3rd-4th speed synchronizer hub
(54)
<F5M41>
Bearing remover
Installation and removal of gears, bearings and
sleeves
Claw
Removal of differential case taper rollerbearing
outer race <F5M42, W5M42>
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-2-4
MANUAL TRANSMISSION (E-W) - Special Tools
TRANSFER
Tool
Number
Name
Use
MB990887
Arm bush remover Installation of transfer oil seal
and installer ring
MB990891
MB990933
MD998304
MD998800
Arm bush remover Installation of transfer oil seal
and installer base
Installer adapter
Oil seal installer
Oil seal installer
Installation of transfer cover oil seal
Installation of transfer extension housing oil
seal
Installation of transfer cover oil seal
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
22B-3-1
3. TRANSMISSION <F5M41>
DISASSEMBLY AND REASSEMBLY
18 Nm
32 Nm
9
11
12
5
3
2
7
10
8
4
3.9 Nm
6
69 Nm
69 Nm
1
1
TFM0718
Disassembly steps
1. Roll stopper bracket
2. Insulator washer
3. Shift cable bracket
4. Insulator washer
"MA 5. Select lever
"LA 6. Speedometer gear
7. Back-up lamp switch
8. Gasket
9. Restrict ball
10. Gasket
11. Poppet spring
12. Gasket
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-3-2
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
Lubricate all internal
parts with gear oil dur-
ing reassembly.
15
30 Nm
18 Nm
16
13
14
19
20
44 Nm
25
28
18
17
26
48 Nm
27
18 Nm
24
21
23
22
TFM0719
Disassembly steps
13. Interlock plate bolt
14. Gasket
AC" "GA 21. Reverse idler gear shaft
22. Reverse idler gear
23. Reverse shift lever shoe
24. Reverse shift lever
"FA 25. Oil guide
"KA 15. Control housing
16. Neutral return spring
"JA 17. Reverse idler gear shaft bolt
18. Gasket
26. Magnet holder
AA" "IA 19. Sealing cap
AB" "HA 20. Transmission case
27. Magnet
"EA 28. Spacer
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
22B-3-3
Lubricate all internal
parts with gear oil dur-
ing reassembly.
30
36
32
29
41
31
33
35
45
40
34
39
38
46
37
18 Nm
42
44
43
TFM0720
Disassembly steps
"DA 29. Spring pin
AD" "CA 38. Reverse interlock rail
AD" "CA 39. Steel ball
30. 1st-2nd speed shift rail
31. 1st-2nd speed shift fork
AD" "CA 40. 3rd-4th speed shift rail
AD" "CA 41. 3rd-4th speed shift fork
"BA 42. Front bearing retainer
AE" "AA 43. Input shaft
AE" "AA 44. Output shaft
45. Differential
"DA 32. Spring pin
"DA 33. Spring pin
AD" "CA 34. 5th speed shift rail
AD" "CA 35. 5th speed shift fork
AD" "CA 36. Reverse shift lug
AD" "CA 37. Snap ring
46. Clutch housing
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-3-4
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
DISASSEMBLY SERVICE POINTS
AA" SEALING CAP REMOVAL
Sealing cap
AB" TRANSMISSION CASE REMOVAL
Expand the snap ring to remove it from the snap ring groove
of the ball bearing.
NOTE
Expansion of the snap ring causes the snap ring groove to
get out of position because of the output shaft’s own weight.
Snap ring
AC" REVERSE IDLER GEAR SHAFT REMOVAL
3rd-4th speed syn-
chronizer sleeve
Shift the 3rd-4th speed synchronizer sleeve toward the 4th
speed side.
AD" 3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED
SHIFT FORK / 5TH SPEED SHIFT FORK / SNAP
RING / REVERSE SHIFT LUG / 5TH SPEED
SHIFT RAIL / STEEL BALL / REVERSE
INTERLOCK RAIL REMOVAL
Reverse shift lug
(1) While sliding the reverse shift lug in the direction shown,
remove the 5th speed shift fork, 5th speed shift rail, reverse
shift lug, snap ring, steel ball and reverse interlock rail.
(2) While sliding the 3rd-4th speed shift rail in the direction
shown, remove it together with the shift fork.
3rd-4th
speed
shift rail
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
22B-3-5
AE" INPUT SHAFT / OUTPUT SHAFT REMOVAL
Remove the input and output shafts together.
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR DIFFERENTIAL CASE END
PLAY ADJUSTMENT
(1) Put solders (about 10 mm long, 1.6 mm in diameter) in
the illustrated positions of the transmission case and install
the differential.
(2) Install the clutch housing and tighten the bolts to the
specified torque.
(3) If the solders are not crushed, put larger diameter solders
and repeat Steps (1) and (2).
(4) Measure the thickness (T) of the crushed solder with a
micrometer and select a spacer according to the following
equation.
Spacer thickness:
(T - 0.05 mm) to (T - 0.17 mm)
REASSEMBLY SERVICE POINTS
Detent
"AA OUTPUT SHAFT / INPUT SHAFT INSTALLATION
<F5M41 with reverse brake>
While placing the reverse brake cone detent in the illustrated
position, install the input and output shafts together.
"BA FRONT BEARING RETAINER INSTALLATION
Apply a sealant to the front bearing retainer mounting bolts
(countersunk bolts only).
Specified sealant:
3M STUD Locking No. 4170 or equivalent
5 mm
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-3-6
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
"CA REVERSE INTERLOCK RAIL / STEEL BALL /
3rd-4th
speed
shift
5TH SPEED SHIFT RAIL / REVERSE SHIFT LUG
/ SNAP RING / 5TH SPEED SHIFT FORK /
3RD-4TH SPEED SHIFT FORK / 3RD-4TH SPEED
SHIFT RAIL INSTALLATION
3rd-4th
speed
shift rail
fork
(1) Install the 3rd-4th shift rail and fork.
(2) Install the reverse interlock rail, steel ball, 5th speed shift
rail, 5th speed shift fork, reverse shift lug and snap ring
in the illustrated positions.
5th speed shift fork
5th
speed
shift rail
Reverse interlock
rail
Steel ball
(inside)
Reverse shift lug
Snap ring
Reverse
shift lug
Reverse
interlock rail
Snap ring
Steel ball
5th speed shift rail
(3) While sliding the reverse shift lug in the direction shown,
install the 5th speed shift fork, 5th speed shift rail, reverse
shift lug, snap ring, steel ball and reverse interlock rail.
Reverse
shift lug
"DA SPRING PIN INSTALLATION
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
22B-3-7
"EA SPACER INSTALLATION
Install the spacer selected in the section “ADJUSTMENT
BEFORE REASSEMBLY”.
"FA OIL GUIDE INSTALLATION
Oil guide
"GAREVERSE IDLER GEAR SHAFT INSTALLATION
(1) Shift the 3rd-4th speed synchronizer sleeve toward the
4th speed side.
3rd-4th speed synchronizer sleeve
(2) Face the threaded hole of the reverse idler gear shaft
toward the direction shown.
Reverse
idler gear
shaft
"HA TRANSMISSION CASE INSTALLATION
(1) Apply a 1.5 mm bead of sealant to the illustrated positions
of the transmission case.
Specified sealant:
MITSUBISHI genuine sealant part No. MD997740
or equivalent
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-3-8
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
(2) Install the transmission case and expand the snap ring.
(3) Tighten the transmission case mounting bolts to the
specified torque.
NOTE
Place the transmission upside down and let the snap ring
fit in the groove by taking advantage of the output shaft’s
own weight.
Snap ring
"IA SEALING CAP INSTALLATION
Sealing cap
Press-fit the sealing cap all the way up tothe illustratedposition.
MB990938
MB990927
"JA REVERSE IDLER GEAR SHAFT BOLT
INSTALLATION
Using a screwdriver (8 mm in shaft diameter), center the bolt
hole.
"KA CONTROL HOUSING INSTALLATION
Apply a 1.5 mm bead of sealant to the illustrated position
of the transmission case.
Specified sealant:
MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Caution
Squeeze out the sealant uniformly, while making sure that
it is not broken or excessively applied.
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M41>
22B-3-9
"LA SPEEDOMETER GEAR INSTALLATION
O-ring
Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
"MASELECT LEVER INSTALLATION
Control shaft
Apply grease to the control shaft sliding portion of the select
lever shoe.
Select
lever
shoe
Specified grease:
MITSUBISHI genuine grease part No. 0101011 or
equivalent
INSPECTION
BACK-UP LAMP SWITCH
Check for continuity between terminals.
Switch condition
Pressed
Continuity
Not exist
Exists
Released
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>22B-4-1
4. TRANSMISSION <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
18 Nm
moving parts before
installation.
32 Nm
5
4
9
7
10
8
3.9 Nm
69 Nm
32 Nm
6
15
14
3
13
2
11
19 Nm
3
12
69 Nm
1
69 Nm
Disassembly steps
1. Transfer <W5M42>
2. O-ring <W5M42>
3. Roll stopper bracket
4. Shift cable bracket
"KA 5. Select lever
"JA 6. Speedometer gear
7. Back-up lamp switch
8. Gasket
9. Poppet spring
10. Gasket
11. Connector bracket <For GDI engine except DA2A>
12. Clutch fluid line blacket <DA2A only>
13. Oil temperature sensor harness <For GDI engine only>
14. Oil temperature sensor <For GDI engine only>
15. Gasket <For GDI engine only>
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-4-2 MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>
Apply gear oil to all
moving parts before
installation.
18
18 Nm
30 Nm
19
16
17
24
25
44 Nm
27
26
21
22
48 Nm
23
28
29
20
6.9 Nm
TFM0597
Disassembly steps
16. Interlock plate bolt
17. Gasket
"IA 18. Control housing
19. Neutral return spring
"HA 20. Under cover
21. Reverse idler gear shaft bolt
22. Gasket
23. Reverse idler gear
AA" "GA 24. Sealing cap
AB" "FA 25. Transmission case
"EA 26. Outer race
"DA 27. Spacer
28. Magnet holder
29. Magnet
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>22B-4-3
Apply gear oil to all
moving parts before
installation.
31
33
34
30
32
42
36
37
38
35
43
18 Nm
39
41
40
TFM0598
Disassembly steps
"CA 30. Spring pin
31. 1st-2nd speed shift rail
32. 1st-2nd speed shift fork
"CA 33. Spring pin
"CA 34. Spring pin
AC" "BA 35. 3rd-4th speed shift rail
AC" "BA 36. 3rd-4th speed shift fork
AC" "BA 37. 5th-reverse speed shift rail
AC" "BA 38. 5th-reverse speed shift fork
39. Front bearing retainer
AD" "AA 40. Input shaft
AD" "AA 41. Output shaft
42. Differential
43. Clutch housing
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-4-4 MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>
DISASSEMBLY SERVICE POINTS
AA" SEALING CAP REMOVAL
Sealing cap
Drive a screwdriver into the sealing cap at the center, then
pry off the sealing cap with the screwdriver.
AB" TRANSMISSION CASE REMOVAL
Expand the snap ring to remove it from the snap ring groove
of the ball bearing.
NOTE
Expansion of the snap ring causes the snap ring groove to
get out of position because of the output shaft’s own weight.
Snap ring
AC" 3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED
SHIFT FORK / 5TH-REVERSE SPEED SHIFT RAIL
/ 5TH-REVERSE SPEED SHIFT FORK REMOVAL
3rd-4th speed
shift fork
(1) Shift the 3rd-4th speed shift fork and 5th-reverse speed
shift fork in the direction shown.
5th-reverse
speed shift
fork
(2) Slide the 3rd-4th speed shift rail and 5th-reverse speed
shift rail in the direction shown and remove them together
with the shift fork.
5th-reverse
speed shift rail
3rd-4th speed
shift rail
AD" INPUT SHAFT / OUTPUT SHAFT REMOVAL
Input shaft
Remove the input and output shafts together.
Output shaft
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>22B-4-5
ADJUSTMENT BEFORE REASSEMBLY
Solders
SPACER SELECTION FOR DIFFERENTIAL CASE
PRELOAD ADJUSTMENT
(1) Put solders (about 10 mm long, 1.6 mm in diameter) in
the illustrated positions of the transmission case and install
the bearing outer race and differential.
(2) Install the clutch housing and tighten the bolts to the
specified torque.
(3) If the solders are not crushed, put larger diameter solders
and repeat Steps (1) and (2).
(4) Measure the thickness (T) of the crushed solder with a
micrometer and select a spacer according to the following
equation.
Spacer thickness:
(T + 0.05 mm) to (T + 0.11 mm)
REASSEMBLY SERVICE POINTS
"AA OUTPUT SHAFT / INPUT SHAFT INSTALLATION
Input shaft
Output shaft
Install the input and output shafts together.
"BA 5TH-REVERSE SPEED SHIFT FORK /
5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
RAIL INSTALLATION
3rd-4th
speed
synchro-
nizer
sleeve
(1) Shift the 3rd-4th speed synchronizer sleeve and
5th-reverse speed synchronizer sleeve in the direction
shown.
5th-reverse
speedsynchro-
nizer sleeve
(2) Install the 3rd-4th speed shift rail and fork and the
5th-reverse speed shift rail and fork.
3rd-4th speed shift rail
3rd-4th speed shift fork
5th-reverse
speed shift rail
5th-reverse
speed shift
fork
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-4-6 MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>
(3) While fitting each shift fork in the sleeve, slide the shift
rails in the direction shown and install.
5th-reverse
speed shift rail
3rd-4th speed
shift rail
"CA SPRING PIN INSTALLATION
Shift fork
2.5 mm
Shift rail
Install the spring pin such that its slit may face in the axial
direction of the shift rail.
Spring pin
Slit
"DA SPACER INSTALLATION
Install the spacer selected in the section “ADJUSTMENT
BEFORE REASSEMBLY”.
"EA OUTER RACE INSTALLATION
Use the special tools to install the outer race.
MB990938
MB990935
"FA TRANSMISSION CASE INSTALLATION
(1) Apply a 1.5 mm bead of sealant to the illustrated position
of the transmission case.
Specified sealant:
MITSUBISHI genuine sealant part No. MD997740
or equivalent
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>22B-4-7
(2) Install the transmission case and expand the snap ring.
(3) Tighten the transmission case to the specified torque.
NOTE
Place the transmission upside down and let the snap ring
fit in the groove by taking advantage of the output shaft’s
own weight.
Snap ring
"GASEALING CAP INSTALLATION
Sealing cap
Press-fit the sealing cap all the way up tothe illustratedposition.
MB990938
MB990927
"HA UNDER COVER INSTALLATION
Apply a 1.5 mm bead of sealant to the illustrated position
of the transmission case.
Specified sealant:
MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Caution
Squeeze out the sealant uniformly, while making sure that
it is not broken or excessively applied.
"IA CONTROL HOUSING INSTALLATION
Apply a 1.5 mm bead of sealant to the illustrated position
of the transmission case.
Specified sealant:
MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Caution
Squeeze out the sealant uniformly, while making sure that
it is not broken or excessively applied.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-4-8 MANUAL TRANSMISSION (E-W) - Transmission <F5M42, W5M42>
"JA SPEEDOMETER GEAR INSTALLATION
O-ring
Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
"KA SELECT LEVER INSTALLATION
Control shaft
Apply grease to the control shaft sliding portion of the select
lever shoe.
Specified grease:
Select
lever shoe
MITSUBISHI genuine grease part No. 0101011 or
equivalent
INSPECTION
BACK-UP LAMP SWITCH
(1) Check for continuity between terminals.
Switch condition
Pressed
Continuity
Not exist
Exists
Released
(2) If the above requirements are not met, replace the back-up
lamp switch with a new one.
OIL TEMPERATURE SENSOR <For GDI engine only>
(1) Check for continuity between terminals.
Temperature (°C)
Standard value (kW)
2.31 - 2.59
20
110
0.1451 - 0.1491
(2) If the standard value is not met, replace the oil temperature
sensor with a new one.
Transmission oil
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
22B-5-1
5. INPUT SHAFT <F5M41>
DISASSEMBLY AND REASSEMBLY <Models with reverse brake>
15
Apply gear oil to all
moving parts before
installation.
17
19
20
23
22
24
16
25
18
1
2
21
4
5
27
6
28
7
29
14
3
13
25
26
8
9
11
10
12
13
TFM0834
Disassembly steps
"MA 1. Snap ring
AA" "LA 2. Ball bearing
AB" "KA 3. Reverse brake sleeve
4. Needle roller bearing
15. 4th speed gear
16. Needle roller bearing
AE" "GA 17. 4th speed gear sleeve
18. Synchronizer ring
5. Reverse brake cone
"DA 19. Synchronizer spring
"FA 20. Synchronizer sleeve
6. Reverse brake ring
"DA 7. Synchronizer spring
"JA 8. Synchronizer sleeve
"EA 21. 3rd-4th speed synchronizer hub
22. Synchronizer ring
AC" "IA 9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"DA 23. Synchronizer spring
24. 3rd speed gear
"DA 11. Synchronizer spring
12. 5th speed gear
25. Needle roller bearing
"CA 26. Snap ring
13. Needle roller bearing
AF" "BA 27. Ball bearing
"AA 28. Oil seal
AD" "HA 14. 5th speed gear sleeve
29. Input shaft
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-5-2
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
DISASSEMBLY AND REASSEMBLY <Except models with reverse brake>
14
15
Apply gear oil to all
16
moving parts before
installation.
17
19
18
20
21
2
23
24
5
9
25
7
1
21
3
10
22
11
12
4
13
6
8
9
Disassembly steps
"MA 1. Snap ring
14. Synchronizer ring
AA" "LA 2. Ball bearing
3. Collar
"DA 15. Synchronizer spring
"FA 16. Synchronizer sleeve
"EA 17. 3rd-4th speed synchronizer hub
18. Synchronizer ring
"JA 4. Synchronizer sleeve
AC" "IA 5. 5th-reverse speed synchronizer hub
6. Synchronizer ring
"DA 19. Synchronizer spring
20. 3rd speed gear
"DA 7. Synchronizer spring
8. 5th speed gear
21. Needle roller bearing
9. Needle roller bearing
"CA 22. Snap ring
AD" "HA 10. 5th speed gear sleeve
11. 4th speed gear
AF" "BA 23. Ball bearing
"AA 24. Oil seal
12. Needle roller bearing
25. Input shaft
AE" "GA 13. 4th speed gear sleeve
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
22B-5-2a
DISASSEMBLY SERVICE POINTS
AA" BALL BEARING REMOVAL
MD998801
AB" REVERSE BRAKE SLEEVE REMOVAL
MD998801
Mount a special tool on the 5th speed gear and remove the
reverse brake sleeve.
AC" 5TH-REVERSE SPEED SYNCHRONIZER HUB
MD998917
REMOVAL
Mount a special tool on the 5th speed gear and remove the
5th-reverse synchronizer hub.
AD" 5TH SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the 4th speed gear and remove the
5th speed gear sleeve.
MD998917
AE" 4TH SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the 3rd speed gear and remove the
4th speed gear sleeve.
MD998801
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Added
E
22B-5-2b MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
Intentionally blank
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Added
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
22B-5-3
AF" BALL BEARING REMOVAL
MD998801
REASSEMBLY SERVICE POINTS
"AA OIL SEAL INSTALLATION
3.5 mm
Oil seal
Drive in the oil seal all the way up to the illustrated dimension.
"BA BALL BEARING INSTALLATION
MD998812
MD998813
MD998817
MD998801
"CA SNAP RING INSTALLATION
Select and install a snap ring so that the input shaft front
bearing end play will have the standard value.
Standard value:
-0.01-0.12 mm
Snap ring
"DA SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely up to the illustrated
position of the synchronizer ring.
Synchronizer spring
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-5-4
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
"EA 3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 3rd-4th speed synchronizer hub in such a way that
it will be oriented in the direction shown.
Rear of
trans-
mission
Identification mark
Caution
MD998812
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998813
MD998826
MD998801
"FA SYNCHRONIZER SLEEVE INSTALLATION
Identification
groove
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
Rear of
transmission
(2) When the synchronizer sleeve is installed, make sure that
the deep groove portion of the synchronizer hub is aligned
with the projecting portion of the sleeve.
Synchronizer
sleeve
Synchronizer hub
"GA4TH SPEED GEAR SLEEVE INSTALLATION
MD998812
MD998813
MD998824
MD998801
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
22B-5-5
"HA 5TH SPEED GEAR SLEEVE INSTALLATION
MD998812
MD998813
MD998820
MD998801
"IA 5TH-REVERSE SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 5th-reverse speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Rear of
transmission
Identification mark
Caution
MD998812
MD998819
When the 5th-reverse speed synchronizer hub is installed,
make sure that the synchronizer ring is not caught.
MD998801
"JA SYNCHRONIZER SLEEVE INSTALLATION
Identification
groove
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
Rear of
transmission
(2) When the synchronizer sleeve is installed, make sure that
the deep groove portion of the synchronizer hub is aligned
with the projecting portion of the sleeve.
Synchronizer
sleeve
Synchronizer hub
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-5-6
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
"KA REVERSE BRAKE SLEEVE INSTALLATION
MD998812
MD998818
MD998801
"LA BALL BEARING INSTALLATION
MD998812
MD998818
MD998801
"MASNAP RING INSTALLATION
Select and install a snap ring so that the input shaft rear
bearing end play will have the standard value.
Standard value:
-0.01-0.09 mm
INSPECTION
INPUT SHAFT
(1) Check theoutside diameterof theneedle bearingmounting
portion for damage, abnormal wear and seizure.
(2) Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the input shaft, sleeve and
gear are combined and made to rotate, they rotate
smoothly without noise.
(2) Check to ensure that the cage is not deformed.
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-5-7
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M41>
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance “A”. If “A” is less than the limit, replace.
A
Limit: 0.5 mm
Synchronizer ring
Gear
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M42, W5M42> 22B-6-1
6. INPUT SHAFT <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
9
10
11
12
14
13
15
16
2
19
18
4
20
6
7
1
8
3
16
17
5
TFM0591
Disassembly steps
"LA 1. Snap ring
"FA 11. Synchronizer sleeve
AA" "KA 2. Ball bearing
"EA 12. 3rd-4th speed synchronizer hub
13. Synchronizer ring
"JA 3. Thrust plate stopper
"IA 4. Thrust plate
"DA 14. Synchronizer spring
15. 3rd speed gear
AB" "HA 5. 5th speed gear
6. 4th speed gear
16. Needle roller bearing
"CA 17. Snap ring
7. Needle roller bearing
AC" "GA 8. 4th speed gear sleeve
9. Synchronizer ring
AD" "BA 18. Ball bearing
"AA 19. Oil seal
"DA 10. Synchronizer spring
20. Input shaft
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-6-2 MANUAL TRANSMISSION (E-W) - Input Shaft <F5M42, W5M42>
DISASSEMBLY SERVICE POINTS
MD998801
AA" BALL BEARING REMOVAL
Use the special tool to remove the ball bearing.
AB" 5TH SPEED GEAR REMOVAL
MD998801
Use the special tool to remove the 5th speed gear.
AC" 4TH SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the 3rd gear and remove the 4th
speed gear sleeve.
MD998801
AD" BALL BEARING REMOVAL
Use the special tool to remove the ball bearing.
MD998801
REASSEMBLY SERVICE POINTS
"AA OIL SEAL INSTALLATION
3.5 mm
Oil seal
Drive in the oil seal all the way up to the illustrated dimension.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M42, W5M42> 22B-6-3
"BA BALL BEARING INSTALLATION
MD998812
Use the special tools to install the ball bearing.
MD998813
MD998816
MD998801
"CA SNAP RING INSTALLATION
Select and install a snap ring so that the input shaft front
bearing end play will have the standard value.
Standard value:
-0.01-0.12 mm
Snap ring
"DA SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely up to the illustrated
position of the synchronizer ring.
Synchronizer spring
"EA 3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 3rd-4th speed synchronizer hub in such a way that
it will be oriented in the direction shown.
Rear of
trans-
mission
Identification mark
Caution
MD998812
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998813
MD998825
MD998801
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-6-4 MANUAL TRANSMISSION (E-W) - Input Shaft <F5M42, W5M42>
"FA SYNCHRONIZER SLEEVE INSTALLATION
Identification
groove
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
Rear of trans-
mission
Synchronizer sleeve
(2) When the synchronizer sleeve is installed, make sure that
the deep groove portion of the synchronizer hub is aligned
with the projecting portion of the sleeve.
Synchronizer hub
"GA4TH SPEED GEAR SLEEVE INSTALLATION
MD998812
Use the special tools to install the 4th speed gear sleeve.
MD998813
MD998824
MD998801
"HA 5TH SPEED GEAR INSTALLATION
MD998812
Use the special tools to install the 5th speed gear.
MD998813
MD998824
MD998801
"IA THRUST PLATE INSTALLATION
Select and install a thrust plate so that the input shaft 5th
speed gear end play will have the standard value.
Standard value:
-0.01-0.09 mm
Thrust plate
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M42, W5M42> 22B-6-5
"JA THRUST PLATE STOPPER INSTALLATION
Thrust plate stopper
When the thrust plate is installed, make sure that it is not
tilted.
Thrust plate
"KA BALL BEARING INSTALLATION
MD998812
Use the special tools to install the ball bearing.
MD998818
MD998801
"LA SNAP RING INSTALLATION
Select and install a snap ring so that the input shaft rear
bearing end play will have the standard value.
Standard value:
-0.01-0.12 mm
Snap ring
INSPECTION
INPUT SHAFT
(1) Check theoutside diameterof theneedle bearingmounting
portion for damage, abnormal wear and seizure.
(2) Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the input shaft and gear are
combined and made to rotate, they rotate smoothly without
looseness and noise.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-6-6
MANUAL TRANSMISSION (E-W) - Input Shaft <F5M42, W5M42>
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
A
clearance “A”. If “A” is less than the limit, replace.
Limit: 0.5 mm
Synchronizer ring
Gear
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
22B-7-1
7. OUTPUT SHAFT <F5M41>
DISASSEMBLY AND REASSEMBLY
<Types with single synchronizer ring for 2nd gear>
Apply gear oil to all
moving parts before
installation.
19
1
14
22
16
15
17
18
21
6
9
3
2
11
4
12
20
5
13
7
10
8
9
TFM0715
Disassembly steps
"JA 1. Snap ring
AA" "IA 2. Ball bearing
3. Collar
"DA 12. Synchronizer spring
"FA 13. Synchronizer sleeve
"EA 14. 1st-2nd speed synchronizer hub
15. Synchronizer ring
4. 5th speed gear
5. 4th speed gear
"DA 16. Synchronizer spring
17. 1st speed gear
"HA 6. Snap ring
7. 3rd speed gear
18. Needle roller bearing
8. 2nd speed gear
AC" "CA 19. 1st speed gear sleeve
"BA 20. Snap ring
9. Needle roller bearing
AB" "GA 10. 2nd speed gear sleeve
11. Synchronizer ring
AD" "AA 21. Roller bearing inner race
22. Output shaft
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-7-2
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
DISASSEMBLY AND REASSEMBLY
<Types with double synchronizer ring for 2nd gear>
Apply gear oil to all
moving parts before
installation.
21
24
1
16
18
17
19
6
23
20
9
3
2
11
4
22
15
13
5
7
10
8
9
12
14
Disassembly steps
"JA 1. Snap ring
13. Outer synchronizer ring
AA" "IA 2. Ball bearing
3. Collar
"KA 14. Synchronizer spring
"FA 15. Synchronizer sleeve
4. 5th speed gear
5. 4th speed gear
"HA 6. Snap ring
7. 3rd speed gear
8. 2nd speed gear
"EA 16. 1st-2nd speed synchronizer hub
17. Synchronizer ring
"DA 18. Synchronizer spring
19. 1st speed gear
20. Needle roller bearing
9. Needle roller bearing
AB" "GA 10. 2nd speed gear sleeve
11. Inner synchronizer ring
AC" "CA 21. 1st speed gear sleeve
"BA 22. Snap ring
AD" "AA 23. Roller bearing inner race
24. Output shaft
12. Synchronizer cone
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41> 22B-7-2a
DISASSEMBLY SERVICE POINTS
AA" BALL BEARING REMOVAL
MD998801
AB" 2ND SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the synchronizer sleeve and remove
the 2nd speed gear sleeve.
MD998917
AC" 1ST SPEED GEAR SLEEVE REMOVAL
MD998801
AD" ROLLER BEARING INNER RACE REMOVAL
Inner race
MD998917
REASSEMBLY SERVICE POINTS
MD998812
"AA ROLLER BEARING INNER RACE INSTALLATION
MD998801
MD998818
Inner
race
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Added
E
22B-7-2b MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
Intentionally blank
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Added
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
22B-7-3
"BA SNAP RING INSTALLATION
Select and install a snap ring so that the output shaft front
bearing end play will have the standard value.
Standard value:
-0.01-0.12 mm
Snap ring
"CA 1ST SPEED GEAR SLEEVE INSTALLATION
MD998812
MD998814
MD998822
Sleeve
"DA SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely up to the illustrated
position of the synchronizer ring.
Synchronizer spring
"EA 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 1st-2nd speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Rear of trans-
mission
Identification mark
Caution
MD998812
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998814
MD998822
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-7-4
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
"FA SYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
Rear of
transmission
(2) When the synchronizer sleeve is installed, make sure that
Synchronizer sleeve
the deep groove portion of the synchronizer hub is aligned
with the projecting portion of the sleeve.
Synchronizer hub
"GA2ND SPEED GEAR SLEEVE INSTALLATION
MD998812
MD998813
MD998820
"HA SNAP RING INSTALLATION
Select and install a snap ring so that the output shaft 3rd
speed gear end play will have the standard value.
Standard value:
-0.01-0.09 mm
Snap ring
"IA BALL BEARING INSTALLATION
MD998812
MD998817
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
22B-7-5
"JA SNAP RING INSTALLATION
Select and install a snap ring so that the output shaft rear
bearing end play will have the standard value.
Standard value:
-0.01-0.09 mm
"KA SYNCHRONIZER SPRING INSTALLATION
Installthesynchronizerspringsecurelyintheillustratedposition
of the outer synchronizer ring.
Synchronizer
spring
INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the bearing sleeve and gear
are combined and made to rotate, they rotate smoothly
without looseness and noise.
(2) Check to ensure that the cage is not deformed.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-7-6
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
(3) Press the synchronizer ring against the gear and check
A
clearance “A”. If “A” is less than the limit, replace.
Limit: 0.5 mm
Synchronizer ring
Gear
OUTER SYNCHRONIZER RING / INNER
SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surfaces and
cone surfaces are not damaged and broken.
(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
than the limit, replace.
Gear
A
Limit: 0.5 mm
Outer ring
Cone
Caution
When the outer ring, inner ring or cone has to be
replaced, make sure that the outer ring, inner ring
and cone are replaced as a set.
Inner ring
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M41>
22B-7-7
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Added
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42> 22B-8-1
8. OUTPUT SHAFT <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY <Types with single synchronizer ring for 1st
gear and double synchronizer ring for 2nd gear>
18
Apply gear oil to all
moving parts before
installation.
19
20
21
22
23
24
25
26
28
27
29
30
31
4
1
34
5
33
32
13
2
3
4
12
15
6
7
17
8
9
11
14
10
13
16
Disassembly steps
"PA 1. Snap ring
18. 2nd speed gear
19. Needle roller bearing
AA" "OA 2. Ball bearing
AB" "NA 3. Reverse gear bearing sleeve
"NA 4. Needle roller bearing
"NA 5. Reverse gear
AE" "HA 20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
6. Synchronizer ring
"DA 7. Synchronizer spring
"FA 8. Synchronizer sleeve
23. Outer synchronizer ring
"GA 24. Synchronizer spring
"FA 25. Synchronizer sleeve
"EA 26. 1st-2nd speed synchronizer hub
27. Synchronizer ring
AC" "MA 9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"DA 11. Synchronizer spring
12. 5th speed gear
"DA 28. Synchronizer spring
29. 1st speed gear
13. Needle roller bearing
30. Needle roller bearing
"LA 14. 5th speed gear sleeve
"KA 15. 4th speed gear
AF" "CA 31. 1st speed gear sleeve
"BA 32. Snap ring
"JA 16. Snap ring
AG" "AA 33. Roller bearing inner race
34. Output shaft
AD" "IA 17. 3rd speed gear
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
22B-8-2
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY
<Types with double synchronizer ring for both 1st and 2nd gears, types with
double synchronizer ring for 1st gear and triple synchronizer ring for 2nd gear>
Apply gear oil to all
moving parts before
installation.
19
18
20
31
21
22
32
23
5
4
33
24
25
26
30
36
29
28
6
27
13
1
2
3
12
14
15
17
35
16
7
4
34
8
9
11
10
13
Disassembly steps
"PA 1. Snap ring
18. 2nd speed gear
AA" "OA 2. Ball bearing
19. Needle roller bearing
AB" "NA 3. Reverse gear bearing sleeve
"NA 4. Needle roller bearing
"NA 5. Reverse gear
AE" "HA 20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
6. Synchronizer ring
"DA 7. Synchronizer spring
"FA 8. Synchronizer sleeve
23. Outer synchronizer ring
"GA 24. Synchronizer spring
"FA 25. Synchronizer sleeve
AC" "MA 9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"EA 26. 1st-2nd speed synchronizer hub
27. Inner synchronizer ring
28. Synchronizer cone
"DA 11. Synchronizer spring
12. 5th speed gear
29. Outer synchronizer ring
"GA 30. Synchronizer spring
31. 1st speed gear
13. Needle roller bearing
"LA 14. 5th speed gear sleeve
"KA 15. 4th speed gear
32. Needle roller bearing
"JA 16. Snap ring
AF" "CA 33. 1st speed gear sleeve
"BA 34. Snap ring
AD" "IA 17. 3rd speed gear
AG" "AA 35. Roller bearing inner race
36. Output shaft
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42> 22B-8-3
DISASSEMBLY SERVICE POINTS
AA" BALL BEARING REMOVAL
Ball bearing
MD998917
MD998801
MD998801
Use the special tool to remove the ball bearing.
AB" REVERSE GEAR BEARING SLEEVE REMOVAL
Sleeve
Mount a special tool on the reverse gear and remove the
reverse gear bearing sleeve.
AC" 5TH-REVERSE SPEED SYNCHRONIZER HUB
Synchronizer hub
REMOVAL
Mount a special tool on the 4th speed gear and remove the
5th-reverse speed synchronizer hub.
AD" 3RD SPEED GEAR REMOVAL
Mount a special tool on the 2nd speed gear and remove the
3rd speed gear.
3rd speed gear
MD998917
AE" 2ND SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the 1st speed gear and remove the
2nd speed gear sleeve.
Sleeve
MD998917
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-8-4
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42>
AF" 1ST SPEED GEAR SLEEVE REMOVAL
Use the special tool to remove the 1st speed gear sleeve.
Sleeve
MD998801
AG"ROLLER BEARING INNER RACE REMOVAL
Inner race
MD998917
Use the special tool to remove the roller bearing inner race.
REASSEMBLY SERVICE POINTS
MD998812
"AA ROLLER BEARING INNER RACE INSTALLATION
MD998801
MD998818
Use the special tools to install the roller bearing inner race.
Inner race
"BA SNAP RING INSTALLATION
Select and install a snap ring so that the output shaft front
bearing end play will have the standard value.
Standard value:
-0.01-0.12 mm
Snap ring
"CA 1ST SPEED GEAR SLEEVE INSTALLATION
MD998812
Use the special tools to install the 1st speed gear sleeve.
MD998814
MD998825
Sleeve
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42> 22B-8-5
"DA SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely up to the illustrated
position of the synchronizer ring.
Synchronizer spring
"EA 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 1st-2nd speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Rear of
trans-
mission
Identification mark
Caution
MD998812
When the hub is installed, make sure that the synchronizer
ring is not caught.
MD998814
MD998825
Synchronizer hub
"FA SYNCHRONIZER SLEEVE INSTALLATION
Identification
groove
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
Rear of trans-
mission
Synchronizer sleeve
(2) When the synchronizer sleeve is installed, make sure that
the deep groove portion of the synchronizer hub is aligned
with the projecting portion of the sleeve.
Synchronizer hub
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-8-6
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42>
"GASYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely up to the illustrated
position of the synchronizer ring.
Synchronizer spring
"HA 2ND SPEED GEAR SLEEVE INSTALLATION
MD998812
Use the special tools to install the 2nd speed gear sleeve.
MD998814
MD998822
Sleeve
"IA 3RD SPEED GEAR INSTALLATION
MD998812
Use the special tools to install the 3rd speed gear.
MD998814
MD998822
3rd speed gear
"JA SNAP RING INSTALLATION
Select and install a snap ring so that the output shaft 3rd
speed gear end play will have the standard value.
Standard value:
-0.01-0.09 mm
Snap ring
"KA 4TH SPEED GEAR INSTALLATION
MD998812
MD998813
Use the special tools to install the 4th speed gear.
MD998819
4th speed gear
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42> 22B-8-7
"LA 5TH SPEED GEAR SLEEVE INSTALLATION
MD998812
Use the special tools to install the 5th speed gear sleeve.
MD998813
MD998819
Sleeve
"MA5TH-REVERSE SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 5th-reverse speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Rear of
trans-
mission
Identification mark
Caution
MD998812
When the 5th-reverse speed synchronizer hub is installed,
make sure that the synchronizer ring is not caught.
MD998813
MD998819
Synchronizer hub
"NA REVERSE GEAR / NEEDLE ROLLER BEARING /
REVERSE GEAR BEARING SLEEVE
INSTALLATION
MD998812
MD998818
Use the special tools to install the reverse gear, needle roller
bearing and reverse gear bearing sleeve.
Reverse gear
Sleeve
"OABALL BEARING INSTALLATION
MD998812
MD998818
Use the special tools to install the ball bearing.
Ball bearing
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-8-8
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42>
"PA SNAP RING INSTALLATION
Select and install a snap ring so that the output shaft rear
bearing end play will have the standard value.
Standard value:
-0.01-0.09 mm
Snap ring
INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the bearing sleeve and gear
are combined and made to rotate, they rotate smoothly
without looseness and noise.
(2) Check to ensure that the cage is not deformed.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
A
clearance “A”. If “A” is less than the limit, replace.
Limit: 0.5 mm
Synchronizer ring
Gear
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42> 22B-8-9
OUTER SYNCHRONIZER RING / INNER
SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surfaces and
cone surfaces are not damaged and broken.
F5M42-2-R5A3
only
(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
than the limit, replace.
<Double synchronizer ring>
Gear
A
Limit: 0.5 mm <Double synchronizer ring>
0.3 mm <Triple synchronizer ring>
Outer ring
Cone
Caution
When the outer ring, inner ring or cone has to be
replaced, make sure that the outer ring, inner ring
and cone are replaced as a set.
Inner ring
<Triple synchronizer ring>
Gear
A
Outer ring
Cone
Inner ring
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
Mitsubishi Motors Corporation
Jun. 2000
PWEE9508-G
Revised
E
22B-8-10
MANUAL TRANSMISSION (E-W) - Output Shaft <F5M42, W5M42>
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces are
not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
MANUAL TRANSMISSION (E-W) - Reverse Idler Gear <F5M42, W5M42> 22B-9-1
9. REVERSE IDLER GEAR <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
1
5
2
3
4
TFM0590
Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Checktoensurethatwhentheshaft andgear arecombined
and made to rotate, they rotate smoothly withoutlooseness
and noise.
(2) Check to ensure that the cage is not deformed.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Speedometer Gear
22B-10-1
10. SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
Lubricate all internal
parts with gear oil dur-
ing reassembly.
4
2
3
1
TFM0593
Disassembly steps
1. e-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Select Lever
22B-11-1
11. SELECT LEVER
DISASSEMBLY AND REASSEMBLY
6
5
7
1
11 Nm
8
2
9
3
4
10
TFM0589
Disassembly steps
"AA 1. Dust cover
2. Nut
6. Select lever shoe
7. Select lever
3. Spring washer
4. Washer
8. Select lever bushing
"AA 9. Dust cover
5. Select lever bushing
10. Select lever shaft
REASSEMBLY SERVICE POINT
Dust cover
"AA DUST COVER INSTALLATION
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
MANUAL TRANSMISSION (E-W) - Control Housing
22B-12-1
12. CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
13
7
12
8
1
9
6
2
5
15
4
16
17
3
14
20
11
10
19
18
22 Nm
TFM0916
Disassembly steps
AA" "FA 1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
12. Control shaft (Except up to MODEL
1998 of F5M42-1-F6N4, F7N,
R6N3, F5M42-2-F6N2, F6N5 and
MODEL 1999)
5. Return spring
6. Stopper plate
"EA 7. Spring pin
"DA 8. Spring pin
9. Stopper body
10. Neutral return spring
11. Spacer
13. Control shaft (Up to MODEL 1998
of F5M42-1-F6N4, F7N, R6N3,
F5M42-2-F6N2, F6N5 and MODEL
1999)
"CA 14. Air breather
15. Control shaft boot
"BA 16. Oil seal
"AA 17. Needle bearing
18. Spring washer
19. Stopper bracket
20. Control housing
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-12-2
MANUAL TRANSMISSION (E-W) - Control Housing
DISASSEMBLY SERVICE POINT
AA" LOCK PIN REMOVAL
Lock pin
Drive the lock pin out of position from the direction shown.
Control finger
REASSEMBLY SERVICE POINTS
"AA NEEDLE BEARING INSTALLATION
Control housing
Press fit the needle bearing up the illustrated dimension, while
making sure that the model number stamped side is oriented
in the direction shown.
Needle
bearing
Model
number
stamped
side
2 mm
"BA OIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
TFM0859
"CA AIR BREATHER INSTALLATION
(1) Apply asealanttotheoutsidecircumferenceoftheinserting
portion.
Specified sealant:
3M SUPER WEATHERSTRIP No. 8001 or equivalent
(2) Make sure that the projecting portion is oriented in the
direction shown.
Mitsubishi Motors Corporation
Jan. 1997
PWEE9508-C
Revised
E
22B-12-2a
MANUAL TRANSMISSION (E-W) - Control Housing
"DA SPRING PIN INSTALLATION
"EA SPRING PIN INSTALLATION
"FA LOCK PIN INSTALLATION
Stopper body
Control shaft
Installation
direction
Slit
TFM0860
Spring pin
Spring pin
45°
TFM0861
Drive in the lock pin in the direction shown in the illustration.
Lock pin
Control finger
Mitsubishi Motors Corporation
Jan. 1997
PWEE9508-C
Added
E
MANUAL TRANSMISSION (E-W) - Clutch Housing
22B-13-1
13. CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
4
7*
8
5
3
6
2
1
9.8 Nm
TFM0759
Disassembly steps
1. Clutch release bearing retainer
"EA 2. Oil seal
"DA 3. Oil seal <F5M41, F5M42>
AA" "CA 4. Outer race <F5M42, W5M42>
AB" "BA 5. Outer race
6. Oil guide <F5M41>
"AA 7. Bushing*
8. Clutch housing
NOTE:
Referring to INSTALLATION SERVICE POINTS is required only when the clutch housing is replaced.
DISASSEMBLY SERVICE POINTS
AA" OUTER RACE REMOVAL <F5M42, W5M42>
MD999566
Use the special tool to remove the outer race.
Outer race
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
22B-13-2
MANUAL TRANSMISSION (E-W) - Clutch Housing
AB" OUTER RACE REMOVAL
MD998772
MD998346
Use the special tools to remove the outer race.
REASSEMBLY SERVICE POINTS
"AA BUSHING INSTALLATION
Air purge groove
Split ends
Press fit the bushing up to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
the air purge groove.
1 mm
"BA OUTER RACE INSTALLATION
(1) Install the outer race so that the model number stamped
side will be oriented in the direction shown.
Model number
stamped side
(2) Use the special tools to install the outer race.
MB990938
MB990934
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Clutch Housing
22B-13-3
"CA OUTER RACE INSTALLATION
MB990938
MB990935
"DA OIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Specified oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
MD998325
"EA OIL SEAL INSTALLATION
Pack grease in the oil seal lip area.
Specified grease:
MITSUBISHI genuine grease part No. 0101011 or
equivalent
MB990938
MB990926
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
MANUAL TRANSMISSION (E-W) - Transmission Case
22B-14-1
14. TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY
1
2
5
6
3
4
TFM0600
Disassembly steps
"CA 1. Oil seal
"BA 2. Needle bearing
3. Oil guide
4. Snap ring
"AA 5. Bushing
6. Transmission case
REASSEMBLY SERVICE POINTS
Split ends
"AA BUSHING INSTALLATION
Press fit the bushing up to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
the air purge groove.
Air purge groove
Mitsubishi Motors Corporation
Nov. 1995
PWEE9508-A
Added
E
22B-14-2
MANUAL TRANSMISSION (E-W) - Transmission Case
1 mm
"BA NEEDLE BEARING INSTALLATION
Press fit the needle bearing until it is flush with the case,
while making sure that the model number stamped side is
oriented in the direction shown.
Model number
stamped side
"CA OIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Specified oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher
MD998325
Mitsubishi Motors Corporation
July 1999
PWEE9508-F
Revised
E
Differential <F5M41, F5M42>,
MANUAL TRANSMISSION (E-W) - Front Differential <W5M42>
22B-15-1
15. DIFFERENTIAL <F5M41, F5M42>,
FRONT DIFFERENTIAL <W5M42>
DISASSEMBLY AND REASSEMBLY
3
Apply gear oil to all
moving parts before
installation.
1
7
4
2
6
5
8
3
132 Nm
9
6
9
7
10
2
TFM0760
Disassembly steps
"EA 1. Differential drive gear
AA" "DA 2. Ball bearing <F5M41>
AB" "CA 3. Taper roller bearing <F5M42, W5M42>
"BA 4. Lock pin
"AA 5. Pinion shaft
"AA 6. Pinion
"AA 7. Washer
"AA 8. Side gear
"AA 9. Spacer
10. Differential case
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
Differential <F5M41, F5M42>,
MANUAL TRANSMISSION (E-W) - Front Differential <W5M42>
22B-15-2
DISASSEMBLY SERVICE POINTS
AA" BALL BEARING REMOVAL <F5M41>
Use the special tool to remove the ball bearing.
MD998801
AB" TAPER ROLLER BEARING REMOVAL <F5M42>
MD998801
Use the special tool to remove the taper roller bearing.
REASSEMBLY SERVICE POINTS
"AA SPACER / SIDE GEAR / WASHER / PINION /
PINION SHAFT INSTALLATION
(1) After a spacer has been mounted on the back surface
of the side gear, install the side gear in the differential
case.
NOTE
When a new side gear is to be installed, mount a medium
thickness spacer (0.93-1.00 mm).
(2) Set the washer on the back of each pinion, and put both
pinions simultaneously in mesh with the side gears. While
rotating them, install them in position.
(3) Insert the pinion shaft.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
Differential <F5M41, F5M42>,
MANUAL TRANSMISSION (E-W) - Front Differential <W5M42>
22B-15-3
(4) Measure the backlash between the side gear and pinion.
Standard value:
0.025-0.150 mm
(5) If the backlash is out of specification, select a spacer
and re-measure the backlash.
NOTE
Adjust until the backlashes on both sides are equal.
"BA LOCK PIN INSTALLATION
Install the lock pin in such a way that it will be oriented in
the direction shown.
"CA TAPER ROLLER BEARING INSTALLATION
<F5M42>
MD998812
MD998819
Use the special tools to install the taper roller bearing.
Taper roller
bearing
"DA BALL BEARING INSTALLATION <F5M41>
MD998812
MD998819
Use the special tools to install the ball bearing.
Ball bearing
"EA DIFFERENTIAL DRIVE GEAR INSTALLATION
(1) Apply a sealant to the entire threaded portion of the bolt.
Specified sealant:
3M STUD Locking No. 4170 or equivalent
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
Differential <F5M41, F5M42>,
MANUAL TRANSMISSION (E-W) - Front Differential <W5M42>
22B-15-4
(2) Tighten to the specified torque in the illustrated sequence.
3
1
5
8
7
6
2
4
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Revised
E
MANUAL TRANSMISSION (E-W) - Center Differential <W5M42>
22B-16-1
16. CENTER DIFFERENTIAL <W5M42>
DISASSEMBLY AND REASSEMBLY
1
3
2
Apply gear oil to all
moving parts before
installation.
5
6
12
7
11
132 Nm
12
4
17
14
10
9
12
13
11
12
8
9
16
15
Disassembly steps
"CA 10. Pinion shaft holder
"CA 11. Pinion
"DA 1. Center differential drive gear
"CA 2. Center differential flange
AA" "BA 3. Taper roller bearing
"CA 4. Snap ring
"CA 12. Washer
"CA 13. Side gear
"CA 14. Spacer
"CA 5. Front output shaft
"CA 6. Spacer
AB" "AA 15. Taper roller bearing
16. Speedometer drive gear
17. Differential case
"CA 7. Side gear
"CA 8. Lock pin
"CA 9. Pinion shaft
DISASSEMBLY SERVICE POINTS
AA" TAPER ROLLER BEARING REMOVAL
Use the special tool to remove the taper roller bearing.
MD998917
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
22B-16-2 MANUAL TRANSMISSION (E-W) - Center Differential <W5M42>
AB" TAPER ROLLER BEARING REMOVAL
MD998917
Use the special tools to remove the taper roller bearing.
MD990930
REASSEMBLY SERVICE POINTS
MB990937
"AA TAPER ROLLER BEARING INSTALLATION
Use the special tool to install the taper roller bearing.
"BA TAPER ROLLER BEARING INSTALLATION
Use the special tools to install the taper roller bearing.
MD998812
MD998823
"CA SPACER/SIDE GEAR/WASHER/PINION/PINION
HOLDER/PINION SHAFT/LOCK PIN/FRONT
OUTPUT SHAFT/SNAP RING/CENTER
DIFFERENTIAL FLANGE INSTALLATION
(1) Install the side gear in the center differential case with
the spacer attached.
NOTE:
If a new side gear is to be installed, select a spacer with
medium thickness (0.93 - 1.00 mm).
(2) Fit the washer on the back of each pinion. Engage the
Differential case
4 pinions simultaneously in the side gear.
Lock pin
Rotate the gears to place them in position, then install
the pinion shaft holder.
(3) Insert the pinion shafts.
(4) Install the lock pins in the illustrated direction.
Pinion shaft
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
MANUAL TRANSMISSION (E-W) - Center Differential <W5M42> 22B-16-3
(5) Install the front output shaft to the side gear and fit the
snap ring.
(6) Attach the spacer on the other side gear, then install the
side gear in the center differential case.
NOTE:
If a new side gear is to be installed, select a spacer with
medium thickness (0.93 - 1.00 mm).
(7) Install the center differential flange on the case while
aligning the mating marks, then secure it temporarily with
machine screw.
(8) Measure the backlash between the side gear and the
pinion.
Standard value: 0.025-0.150 mm
(9) If the measurement deviates from the standard value,
correct the backlash using a spacer of different thickness
and check it again.
NOTE:
The backlash must be the same on both sides.
"DA CENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Apply sealant to the entire threaded portion of the bolt.
Specified sealant:
3M STUD Locking No. 4170 or equivalent
(2) Tighten the bolts to the specified torque in the illustrated
1
3
10
sequence.
5
8
7
6
9
4
2
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
MANUAL TRANSMISSION (E-W) - Transfer <W5M42>
22B-17-1
17. TRANSFER <W5M42>
DISASSEMBLY AND REASSEMBLY
1
3
5
2
6
4
8
11
7
Apply gear oil to all
moving parts before
installation.
9
10
23 Nm
Disassembly steps
"FA 1. Air breather
2. Dust seal guard
"EA 3. Oil seal
"DA 4. Oil seal
"AA 5. O-ring
"AA 6. O-ring
"CA 7. Oil seal
"BA 8. Oil seal
"AA 9. O-ring
10. Transfer cover
11. Transfer
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
22B-17-2
MANUAL TRANSMISSION (E-W) - Transfer <W5M42>
REASSEMBLY SERVICE POINTS
"AA O-RING INSTALLATION
Apply transmission oil to the O-ring.
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher.
"BA OIL SEAL INSTALLATION
MD998800
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
Hypoid gear oil SAE 75W-85W conforming to API
classification GL-4 or higher.
(2) By using the special tool, install the oil seal.
"CA OIL SEAL INSTALLATION
MB990938
Use the special tools to install the oil seal.
MB990933
"DA OIL SEAL INSTALLATION
MB990891
Use the special tools to install the oil seal.
MB990887
"EA OIL SEAL INSTALLATION
Use the special tool to install the oil seal.
MD998304
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
MANUAL TRANSMISSION (E-W) - Transfer <W5M42>
22B-17-3
"FA AIR BREATHER INSTALLATION
Apply sealant to the air breather.
Specified sealant:
3M SUPER WEATHERSTRIP No. 8001 or
equivalent.
Mitsubishi Motors Corporation
Jun. 1998
PWEE9508-E
Added
E
NOTES
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