Mitsubishi F5M41, F5M42, W5M42 User Manual

4.8 (18)

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

 

 

 

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 2000

PWEE9508-G

Revised

22B-0-2

NOTES

MANUAL TRANSMISSION (E - W) - General Information

22B-0-3

GENERAL INFORMATION

F5M41 <Types with single synchronizer ring for 2nd gear>

6

7

8

1

2

3

4

5

9

10

15

14

13

12

 

 

11

 

 

 

TFM0809

1.

Reverse gear meshing noise pre-

8.

Clutch housing

 

vention device

9.

Release bearing retainer

 

<Models with reverse brake>

10.

Input shaft

2.

5th-reverse speed synchronizer hub

11.

Differential

3.

5th speed gear

12.

1st speed gear

4.

4th speed gear

13.

1st-2nd speed synchronizer hub

5.

3rd-4th speed synchronizer hub

14.

2nd speed gear

6.

3rd speed gear

15.

Output shaft

7.

Transmission case

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

22B-0-4 MANUAL TRANSMISSION (E - W) - General Information

F5M41 <Types with double synchronizer ring for 2nd gear>

6

7

8

1

2

3

4

5

9

10

15 14 13 12

11

1.

Reverse gear meshing noise pre-

8.

Clutch housing

 

vention device

9.

Release bearing retainer

2.

5th-reverse speed synchronizer hub

10.

Input shaft

3.

5th speed gear

11.

Differential

4.

4th speed gear

12.

1st speed gear

5.

3rd-4th speed synchronizer hub

13.

1st-2nd speed synchronizer hub

6.

3rd speed gear

14.

2nd speed gear

7.

Transmission case

15.

Output shaft

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

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>

4

5

6

1

2

3

7

8

9

16

15

14

13

12

11

10

1.

Reverse idler gear

9.

Output shaft

2.

4th speed gear

10.

Differential

3.

3rd-4th speed synchronizer hub

11.

1st speed gear

4.

3rd speed gear

12.

1st-2nd speed synchronizer hub

5.

Transmission case

13.

2nd speed gear

6.

Clutch housing

14.

5th speed gear

7.

Release bearing retainer

15.

5th-reverse speed synchronizer hub

8.

Input shaft

16.

Reverse gear

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

Mitsubishi F5M41, F5M42, W5M42 User Manual

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

5

6

1

2

3

7

8

9

16

15

14

13

12

11

10

1.

Reverse idler gear

9.

Output shaft

2.

4th speed gear

10.

Differential

3.

3rd-4th speed synchronizer hub

11.

1st speed gear

4.

3rd speed gear

12.

1st-2nd speed synchronizer hub

5.

Transmission case

13.

2nd speed gear

6.

Clutch housing

14.

5th speed gear

7.

Release bearing retainer

15.

5th-reverse speed synchronizer hub

8.

Input shaft

16.

Reverse gear

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

MANUAL TRANSMISSION (E - W) - General Information

22B-0-7

W5M42

1

2

3

4

5

6

7

8

10

9

19 18 17 16 15 14

13

11

12

1.

Reverse idler gear

11.

Front differential

2.

4th speed gear

12.

Transfer driven gear

3.

3rd-4th speed synchronizer hub

13.

Center differential

4.

3rd speed gear

14.

1st speed gear

5.

Transmission case

15.

1st-2nd speed synchronizer hub

6.

Clutch housing

16.

2nd speed gear

7.

Release bearing retainer

17.

5th speed gear

8.

Input shaft

18.

5th-reverse speed synchronizer hub

9.

Output shaft

19.

Reverse gear

10.

Viscous coupling

 

 

E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Added

 

MANUAL TRANSMISSION (E - W) - Specifications

22B-1-1

1. SPECIFICATIONS

 

 

 

 

TRANSMISSION MODEL TABLE - MODEL 1996

 

 

 

 

 

 

 

 

 

Transmission model

Gear ratio

Speedometer

Final gear ratio

Vehicle model

Engine model

 

 

 

gear ratio

 

 

 

 

 

 

 

 

 

 

EUR

F5M41-1-B8A1

B

31/36

3.454

CJ4A

4G92-MVV

 

 

 

 

 

 

 

 

F5M41-1-F8A1

A

31/36

3.714

CJ4A, CK4A

4G92-MPI

 

 

 

 

 

 

 

 

F5M41-1-R8A

A

31/36

4.052

CJ1A, CK1A

4G13

 

 

 

 

 

 

 

EXP

F5M41-1-F8A1

A

31/36

3.714

CJ4A, CK4A

4G92-MPI

 

 

 

 

 

 

 

 

F5M41-1-R8A

A

31/36

4.052

CJ1A, CK1A

4G13

 

 

 

 

 

 

 

 

F5M41-1-R8A

A

31/36

4.052

CJ2A, CK2A

4G15

 

 

 

 

 

 

 

 

F5M42-1-Y8A

C

31/36

4.058

CK4A

4G92-MIVEC

 

 

 

 

 

 

 

TRANSMISSION MODEL TABLE - MODEL 1997

 

 

 

 

 

 

 

 

Transmission model

Gear ratio

Speedometer

Final gear ratio

Vehicle model

Engine model

 

 

 

gear ratio

 

 

 

 

 

 

 

 

 

 

EUR

F5M42-1-F7N

D

30/36

3.722

EA2A, EA2W

4G63

 

 

 

 

 

 

 

 

F5M42-2-F6N2

D

29/36

3.722

EA5A, EA5W

6A13

 

 

 

 

 

 

 

 

F5M42-2-F6N5

E

29/36

3.722

EA6A, EA6W

4D68

 

 

 

 

 

 

 

EXP

F5M42-1-F6N4

D

29/36

3.722

EA2A

4G63-MPI

 

 

 

 

 

 

 

 

F5M42-1-F7N

D

30/36

3.722

EA2A

4G63-MPI

 

 

 

 

 

 

 

 

F5M42-1-R6N2

D

29/36

4.058

EA1A

4G93

 

 

 

 

 

 

 

 

F5M42-1-R6N3

D

29/36

4.058

EA2A

4G63-CARB

 

 

 

 

 

 

 

 

F5M42-2-F6N2

D

29/36

3.722

EA5A

6A13

 

 

 

 

 

 

 

 

F5M42-2-V6N

D

29/36

4.312

EA4A

6A12

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

22B-1-2

MANUAL TRANSMISSION (E - W) - Specifications

 

TRANSMISSION MODEL TABLE - MODEL 1998

 

 

 

 

 

 

 

 

 

 

Transmission model

 

Gear ratio

Speedometer

Final gear ratio

Vehicle model

Engine model

 

 

 

 

gear ratio

 

 

 

 

 

 

 

 

 

 

EUR

F5M41-1-B8A2

B

31/36

3.454

CJ4A

4G92

 

 

 

 

 

 

 

 

F5M41-1-F8A5

A

31/36

3.714

CJ4A

4G92

 

 

 

 

 

 

 

 

F5M41-1-R8A1

A

31/36

4.052

CK1A, CJ1A

4G13

 

 

 

 

 

 

 

 

F5M42-1-F71

D

30/36

3.722

EA2A, EA2W

4G63

 

 

 

 

 

 

 

 

F5M42-1-F8A4

D

31/36

3.722

DA2A

4G93-GDI

 

 

 

 

 

 

 

 

F5M42-2-F6NA

E

29/36

3.722

EA6A, EA6W

4D68

 

 

 

 

 

 

 

 

F5M42-2-F6N7

F

29/36

3.722

EA5A, EA5W

6A13

 

 

 

 

 

 

 

EXP

F5M41-1-F8A5

A

31/36

3.714

CJ4A, CK4A

4G92

 

 

 

 

 

 

 

 

F5M41-1-R8A1

A

31/36

4.052

CJ1A, CK1A

4G13

 

 

 

 

 

 

 

 

F5M41-1-R8A1

A

31/36

4.052

CJ2A, CK2A

4G15

 

 

 

 

 

 

 

 

F5M42-1-R6N6

D

29/36

4.052

EA1A

4G93

 

 

 

 

 

 

 

 

F5M42-2-R6N7

D

29/36

3.722

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-2-R6N8

D

29/36

3.722

EA6A

4D68

 

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

 

MANUAL TRANSMISSION (E - W) - Specifications

22B-1-2a

TRANSMISSION MODEL TABLE - MODEL 1999

 

 

 

 

 

 

 

 

 

Transmission model

Gear ratio

Speedometer

Final gear ratio

Vehicle model

Engine model

 

 

 

gear ratio

 

 

 

 

 

 

 

 

 

 

EUR

F5M42-1-V5A4

D

28/36

4.312

N61W

4G93-GDI

 

 

 

 

 

 

 

 

F5M42-2-R5A3

G

28/36

4.058

N84W

4G64-GDI

 

 

 

 

 

 

 

 

W5M42-1-V5A1

H

28/36

4.352

N94W

4G64-GDI

 

 

 

 

 

 

 

 

F5M42-1-F8A

G

31/36

3.722

DA2A

4G93-GDI

 

 

 

 

 

 

 

 

F5M42-2-F7N2

D

30/36

3.722

EA2A, EA2W

4G93

 

 

 

 

 

 

 

 

F5M42-2-F6NC

G

29/36

3.722

EA3A, EA3W

4G64-GDI

 

 

 

 

 

 

 

 

F5M42-2-F6N7

F

29/36

3.722

EA5A, EA5W

6A13

 

 

 

 

 

 

 

 

F5M42-2-F6NA

E

29/36

3.722

EA6A, EA6W

4D65

 

 

 

 

 

 

 

EXP

F5M42-1-R6N6

D

29/36

4.058

EA1A

4G93

 

 

 

 

 

 

 

 

F5M42-1-R6N7

D

29/36

4.058

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-1-F6N9

D

29/36

3.722

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-1-F7N1

D

30/36

3.722

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-2-V6N1

D

29/36

4.352

EA4A

6A12-MIVEC

 

 

 

 

 

 

 

 

F5M42-2-F6N7

F

29/36

3.722

EA5A

6A13

 

 

 

 

 

 

 

 

F5M42-2-R6N8

E

29/36

4.058

EA6A

4D56

 

 

 

 

 

 

 

 

F5M42-2-R5A2

D

28/36

4.058

N84W

4G64

 

 

 

 

 

 

 

MMAL

F5M41-1-F8A5

D

31/36

3.722

CJ2A, CK2A

4G15

 

 

 

 

 

 

 

 

F5M42-1-F8A7

D

31/36

3.722

CJ5A, CK5A

4G93

 

 

 

 

 

 

 

 

F5M42-2-R5A2

D

28/36

4.058

N84W

4G64

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

22B-1-2b

MANUAL TRANSMISSION (E - W) - Specifications

 

TRANSMISSION MODEL TABLE - MODEL 2000

 

 

 

 

 

 

 

 

 

 

Transmission model

 

Gear ratio

Speedometer

Final gear ratio

Vehicle model

Engine model

 

 

 

 

gear ratio

 

 

 

 

 

 

 

 

 

 

EUR

F5M41-1-R8A1

A

31/36

4.052

CJ1A

4G13

 

 

 

 

 

 

 

 

F5M41-1-F8A5

A

31/36

3.714

CJ4A

4G92

 

 

 

 

 

 

 

 

F5M41-1-B8A2

B

31/36

3.454

CJ4A

4G92-MVV

 

 

 

 

 

 

 

 

F5M42-1-R7A2

D

30/36

4.058

DA2A

4G93-GDI

 

 

 

 

 

 

 

 

F5M42-1-V5A4

D

28/36

4.312

N61W

4G93-GDI

 

 

 

 

 

 

 

 

F5M42-2-R5A3

G

28/36

4.058

N64W, N84W

4G64-GDI

 

 

 

 

 

 

 

 

W5M42-1-V5A1

H

28/36

4.352

N94W

4G64-GDI

 

 

 

 

 

 

 

EXP

F5M41-1-R8A1

A

31/36

4.052

CJ1A, CK1A

4G13

 

 

 

 

 

 

 

 

F5M41-1-F8A5

A

31/36

3.714

CJ4A, CK4A

4G92

 

 

 

 

 

 

 

 

F5M42-1-R6N6

D

29/36

4.058

EA1A

4G93

 

 

 

 

 

 

 

 

F5M42-1-R6N7

D

29/36

4.058

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-1-F6N9

D

29/36

3.722

EA2A, EA2W

4G63

 

 

 

 

 

 

 

 

F5M42-2-F6N7

F

29/36

3.722

EA5A

6A13

 

 

 

 

 

 

 

 

F5M42-2-R5A2

D

28/36

4.058

N84W

4G64

 

 

 

 

 

 

 

MMAL

F5M42-2-R5A2

D

28/36

4.058

N84W

4G64

 

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

 

MANUAL TRANSMISSION (E-W) - Specifications

22B-1-2c

 

 

 

 

 

 

 

TRANSMISSION MODEL TABLE - MODEL 2001

 

 

 

 

 

 

 

 

 

Transmission model

Gear ratio

Speedometer

Final gear ratio

Vehicle model

Engine model

 

 

 

gear ratio

 

 

 

 

 

 

 

 

 

 

EUR

F5M41-1-R8A1

A

31/36

4.052

CJ1A

4G13

 

 

 

 

 

 

 

 

F5M41-1-F8A5

A

31/36

3.714

CJ4A

4G92

 

 

 

 

 

 

 

 

F5M41-1-F8AC

B

31/36

3.454

DG5A

4G93

 

 

 

 

 

 

 

 

F5M42-2-R7A2

D

30/36

4.058

DA2A

4G93

 

 

 

 

 

 

 

 

F5M42-2-F7N2

D

30/36

3.722

EA2A, W

4G63

 

 

 

 

 

 

 

 

F5M42-2-F6NC

G

29/36

3.722

EA3A, W

4G64

 

 

 

 

 

 

 

 

F5M42-2-F6N7

F

29/36

3.722

EA5A, W

6A13

 

 

 

 

 

 

 

 

F5M42-2-V5A

D

28/36

4.352

N63W

4G63

 

 

 

 

 

 

 

 

F5M42-2-R5A3

G

28/36

4.058

N64W

4G64

 

 

 

 

 

 

 

EXP

F5M41-1-R8A1

A

31/36

4.052

CJ1A

4G13

 

 

 

 

 

 

 

 

F5M41-1-F8A5

A

31/36

3.714

CJ4A

4G92

 

 

 

 

 

 

 

 

F5M42-1-F6N9

D

29/36

3.722

EA2W

4G63

 

 

 

 

 

 

 

 

F5M42-1-F7N1

D

30/36

3.722

EA2W

4G63

 

 

 

 

 

 

 

 

F5M42-1-R6N6

D

29/36

4.058

EA1A

4G93

 

 

 

 

 

 

 

 

F5M42-1-F6N7

F

29/36

3.722

EA1A

4G93

 

 

 

 

 

 

 

 

F5M42-1-R6N7

D

29/36

4.058

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-1-F6N9

D

29/36

3.722

EA2A

4G63

 

 

 

 

 

 

 

 

F5M42-1-F6N7

F

29/36

3.722

EA5A

6A13

 

 

 

 

 

 

 

 

F5M42-2-R6N8

E

29/36

4.058

EA6A

4D68

 

 

 

 

 

 

 

 

F5M42-2-R5A2

D

28/36

4.058

N84W

4G64

 

 

 

 

 

 

 

MMAL

F5M41-1-F8A5

A

31/36

3.714

CJ2A

4G15

 

 

 

 

 

 

 

 

F5M42-1-F8A7

F

31/36

3.722

CJ5A

4G93

 

 

 

 

 

 

 

 

F5M42-2-R5A2

D

31/36

4.058

N84W

4G64

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 2000

PWEE9508-G

Revised

22B-1-2d

MANUAL TRANSMISSION (E-W) - Specifications

 

 

 

 

 

 

 

 

 

GEAR RATIO TABLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

B

C

D

E

F

G

 

 

 

 

 

 

 

 

1st

3.583

3.727

3.071

3.583

3.583

3.583

3.583

 

 

 

 

 

 

 

 

2nd

1.947

1.947

1.947

1.947

1.947

1.947

1.947

 

 

 

 

 

 

 

 

3rd

1.343

1.343

1.379

1.379

1.379

1.379

1.266

 

 

 

 

 

 

 

 

4th

0.976

0.976

1.030

1.030

1.030

1.030

0.970

 

 

 

 

 

 

 

 

5th

0.804

0.804

0.820

0.820

0.733

0.767

0.767

 

 

 

 

 

 

 

 

Reverse

3.416

3.416

3.363

3.363

3.363

3.363

3.363

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1st

3.583

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2nd

1.947

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3rd

1.266

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4th

0.970

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5th

0.767

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Reverse

3.363

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Transfer

0.3018

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SERVICE SPECIFICATIONS

Items

Allowable range

Limit

 

 

 

 

Input shaft front bearing end play mm

-0.01

- 0.12

-

 

 

 

 

Input shaft rear bearing end play <F5M41> mm

-0.01

- 0.09

-

 

 

 

 

Input shaft rear bearing end play <F5M42, W5M42> mm

-0.01

- 0.12

-

 

 

 

 

Input shaft 5th speed gear end play <F5M42, W5M42> mm

-0.01

- 0.09

-

 

 

 

 

Output shaft front bearing end play mm

-0.01

- 0.12

-

 

 

 

 

Output shaft rear bearing end play mm

-0.01

- 0.09

-

 

 

 

 

Output shaft 3rd speed gear end play mm

-0.01

- 0.09

-

 

 

 

Differential case end play <F5M41> mm

0.05- 0.17

-

 

 

 

 

Differential case pinion backlash <F5M41, F5M42> mm

0.025

- 0.150

-

 

 

 

 

Front differential case backlash <W5M42> mm

0.025

- 0.150

-

 

 

 

Differential case preload <F5M42> mm

0.05- 0.11

-

 

 

 

 

NOTE: Standard play = 0 mm

E Mitsubishi Motors Corporation

Jun. 2000

PWEE9508-G

Revised

MANUAL TRANSMISSION (E-W) - Specifications

22B-1-2e

 

 

 

 

 

 

Items

Allowable range

Limit

 

 

 

Front differential case preload <W5M42> mm

0.05- 0.11

-

 

 

 

Center differential case pinion backlash <W5M42> mm

0.025- 0.150

-

 

 

 

Center differential case preload <W5M42> mm

0.05- 0.11

-

 

 

 

Synchronizer ring back surface to gear clearance mm

-

0.5

 

 

 

NOTE: Standard play = 0 mm

 

 

SEALANTS AND ADHESIVES

 

 

TRANSMISSION

 

 

 

 

Items

Specified sealants and adhesives

 

 

Clutch housing-transmission case mating surface

MITSUBISHI genuine sealant part No. MD997740

 

or equivalent

 

Control housing-transmission case mating surface

 

 

 

 

 

 

Under cover-transmission case mating surface

 

 

<F5M42, W5M42>

 

 

 

 

Air breather

3M SUPER WEATHERSTRIP No. 8001 or

 

equivalent

 

 

 

Differential drive gear bolt <F5M41, F5M42>

3M STUD Locking No. 4170 or equivalent

 

 

 

Front differential drive gear bolt <W5M42>

 

 

 

 

 

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

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 2000

PWEE9508-G

Added

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

Hypoid gear oil SAE 75W-85W conforming to API

 

classification GL-4 or higher

Control shaft oil seal lip area

 

 

 

Input shaft oil seal lip area

MITSUBISHI genuine grease part No. 0101011 or

 

equivalent

Select lever shoe

 

 

 

TRANSFER

Items

Specified lubricants

 

 

Drive shaft oil seal lip area

Hypoid gear oil SAE 75W-85W conforming to API

 

classification GL-4 or higher

Front differential oil seal lip area

 

 

 

Each O-ring

 

 

 

E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Revised

22B-1-4

MANUAL TRANSMISSION (E - W) - Specifications

 

SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT

 

 

 

 

 

 

 

Part name

 

Thickness mm

Identification

 

Part No.

 

 

 

symbol

 

 

 

 

 

 

 

 

Snap ring

 

2.24

None

 

MD706537

(For adjustment of input shaft front bearing end

 

 

 

 

2.31

Blue

 

MD706538

play)

 

 

 

 

 

 

 

 

 

 

2.38

Brown

 

MD706539

 

 

 

 

 

 

Snap ring

 

2.31

Black (2)

 

MD747149

(For adjustment of input shaft rear bearing end

 

 

 

 

2.35

None

 

MD746561

play ....F5M41)

 

 

(For adjustment of output shaft rear bearing end

 

 

 

 

2.39

Blue

 

MD746562

play ....F5M42, W5M42)

 

 

 

 

 

 

 

 

 

2.43

Brown

 

MD746563

 

 

 

 

 

 

 

 

2.47

Green

 

MD746564

 

 

 

 

 

 

 

 

2.51

White

 

MD746565

 

 

 

 

 

 

 

 

2.55

Yellow

 

MD746566

 

 

 

 

 

 

 

 

2.59

Black

 

MD746567

 

 

 

 

 

 

 

 

2.63

Orange

 

MD746568

 

 

 

 

 

 

 

 

2.67

Blue

 

MD746569

 

 

 

 

 

 

 

 

2.71

Brown

 

MD746570

 

 

 

 

 

Thrust plate: F5M42, W5M42

2.82

-

 

MD748015

(For adjustment of input shaft 5th speed gear

 

 

 

 

2.86

-

 

MD748016

end play)

 

 

 

 

 

 

 

 

 

 

2.90

-

 

MD748017

 

 

 

 

 

 

 

 

2.94

-

 

MD748018

 

 

 

 

 

 

 

 

2.98

-

 

MD748019

 

 

 

 

 

 

 

 

3.02

-

 

MD748020

 

 

 

 

 

 

 

 

3.06

-

 

MD748021

 

 

 

 

 

 

 

 

3.10

-

 

MD748022

 

 

 

 

 

 

Snap ring

 

1.43

Green (2)

 

MD746708

(For adjustment of output shaft front bearing end

 

 

 

 

1.51

White (2)

 

MD746709

play)

 

 

(For adjustment of input shaft rear bearing end

 

 

 

 

1.59

Yellow (2)

 

MD746710

play ....F5M42, W5M42)

 

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

MANUAL TRANSMISSION (E - W) - Specifications

22B-1-5

 

 

 

 

 

Part name

Thickness mm

Identification

 

Part No.

 

 

symbol

 

 

 

 

 

 

 

Snap ring: F5M41

2.31

Black (2)

 

MD748800

(For adjustment of output shaft rear bearing end

 

 

 

 

2.35

None

 

MD748801

play)

 

 

 

 

 

 

 

2.39

Blue

 

MD748802

 

 

 

 

 

 

2.43

Brown

 

MD748803

 

 

 

 

 

 

2.47

Green

 

MD748804

 

 

 

 

 

 

2.51

White

 

MD748805

 

 

 

 

 

 

2.55

Yellow

 

MD748806

 

 

 

 

 

 

2.59

Black

 

MD748807

 

 

 

 

 

 

2.63

Orange

 

MD748808

 

 

 

 

 

 

2.67

Blue

 

MD748809

 

 

 

 

 

 

2.71

Brown

 

MD748810

 

 

 

 

 

Snap ring: F5M41

2.81

Green

 

MD748782

(For adjustment of output shaft 3rd speed gear

 

 

 

 

2.85

White

 

MD748783

end play)

 

 

 

 

 

 

 

2.89

Yellow

 

MD748784

 

 

 

 

 

 

2.93

Black

 

MD748785

 

 

 

 

 

 

2.97

Orange

 

MD748786

 

 

 

 

 

 

3.01

Red

 

MD748787

 

 

 

 

 

 

3.05

Pink

 

MD748788

 

 

 

 

 

 

3.09

Blue

 

MD748789

 

 

 

 

 

Snap ring: F5M42, W5M42

2.81

Green

 

MD745799

(For adjustment of output shaft 3rd speed gear

 

 

 

 

2.85

White

 

MD745800

end play)

 

 

 

 

 

 

 

2.89

Yellow

 

MD745801

 

 

 

 

 

 

2.93

Black

 

MD745802

 

 

 

 

 

 

2.97

Orange

 

MD745803

 

 

 

 

 

 

3.01

Red

 

MD745804

 

 

 

 

 

 

3.05

Pink

 

MD745805

 

 

 

 

 

 

3.09

Blue

 

MD745806

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

22B-1-6

MANUAL TRANSMISSION (E - W) - Specifications

 

 

 

 

 

 

 

Part name

 

Thickness mm

Identification

 

Part No.

 

 

 

symbol

 

 

 

 

 

 

 

 

Spacer: F5M41

 

0.77

77

 

MD754476

(For adjustment of differential case end play)

 

 

 

 

0.86

86

 

MD720938

 

 

 

 

 

 

 

 

 

 

 

0.95

95

 

MD720941

 

 

 

 

 

 

 

 

1.04

04

 

MD720944

 

 

 

 

 

 

 

 

1.13

D

 

MD700270

 

 

 

 

 

 

 

 

1.22

G

 

MD700271

 

 

 

 

 

 

 

 

1.31

E

 

MD706574

 

 

 

 

 

 

 

 

1.40

None

 

MD706573

 

 

 

 

 

 

 

 

1.49

C

 

MD706572

 

 

 

 

 

 

 

 

1.58

B

 

MD706571

 

 

 

 

 

 

 

 

1.67

A

 

MD706570

 

 

 

 

 

 

 

 

1.76

F

 

MD706575

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

 

MANUAL TRANSMISSION (E - W) - Specifications

22B-1-7

 

 

 

 

 

 

Part name

 

Thickness mm

Identification

 

Part No.

 

 

 

symbol

 

 

 

 

 

 

 

 

Spacer: F5M42

 

0.71

71

 

MD754475

(For adjustment of differential case preload)

 

 

 

 

0.74

74

 

MD727660

 

 

 

 

 

 

 

 

 

 

 

0.77

77

 

MD754476

 

 

 

 

 

 

 

 

0.80

80

 

MD727661

 

 

 

 

 

 

 

 

0.83

83

 

MD720937

 

 

 

 

 

 

 

 

0.86

86

 

MD720938

 

 

 

 

 

 

 

 

0.89

89

 

MD720939

 

 

 

 

 

 

 

 

0.92

92

 

MD720940

 

 

 

 

 

 

 

 

0.95

95

 

MD720941

 

 

 

 

 

 

 

 

0.98

98

 

MD720942

 

 

 

 

 

 

 

 

1.01

01

 

MD720943

 

 

 

 

 

 

 

 

1.04

04

 

MD720944

 

 

 

 

 

 

 

 

1.07

07

 

MD720945

 

 

 

 

 

 

 

 

1.10

J

 

MD710454

 

 

 

 

 

 

 

 

1.13

D

 

MD700270

 

 

 

 

 

 

 

 

1.16

K

 

MD710455

 

 

 

 

 

 

 

 

1.19

L

 

MD710456

 

 

 

 

 

 

 

 

1.22

G

 

MD700271

 

 

 

 

 

 

 

 

1.25

M

 

MD710457

 

 

 

 

 

 

 

 

1.28

N

 

MD710458

 

 

 

 

 

 

 

 

1.31

E

 

MD706574

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

22B-1-8

MANUAL TRANSMISSION (E - W) - Specifications

 

 

 

 

 

 

 

Part name

 

Thickness mm

Identification

 

Part No.

 

 

 

symbol

 

 

 

 

 

 

 

 

Spacer: W5M42

 

0.74

74

 

MD727660

(For adjustment of center differential case

 

 

 

 

0.77

77

 

MD745476

preload)

 

 

 

 

 

 

 

 

 

 

0.80

80

 

MD727661

 

 

 

 

 

 

 

 

0.83

83

 

MD720937

 

 

 

 

 

 

 

 

0.86

86

 

MD720938

 

 

 

 

 

 

 

 

0.89

89

 

MD720939

 

 

 

 

 

 

 

 

0.92

92

 

MD720940

 

 

 

 

 

 

 

 

0.95

95

 

MD720941

 

 

 

 

 

 

 

 

0.98

98

 

MD720942

 

 

 

 

 

 

 

 

1.01

01

 

MD720943

 

 

 

 

 

 

 

 

1.04

04

 

MD720944

 

 

 

 

 

 

 

 

1.07

07

 

MD720945

 

 

 

 

 

 

 

 

1.10

J

 

MD710454

 

 

 

 

 

 

 

 

1.13

D

 

MD700270

 

 

 

 

 

 

 

 

1.16

K

 

MD710455

 

 

 

 

 

 

 

 

1.19

L

 

MD710456

 

 

 

 

 

 

 

 

1.22

G

 

MD700271

 

 

 

 

 

 

 

 

1.25

M

 

MD710457

 

 

 

 

 

 

 

 

1.28

N

 

MD710458

 

 

 

 

 

 

 

 

1.31

E

 

MD706574

 

 

 

 

 

Spacer: F5M41, F5M42

0.75- 0.82

-

 

MA180862

(For adjustment of differential case backlash)

 

 

 

 

0.83- 0.92

-

 

MA180861

 

 

 

 

 

 

 

 

 

 

 

0.93- 1.00

-

 

MA180860

 

 

 

 

 

 

 

 

1.01- 1.08

-

 

MA180875

 

 

 

 

 

 

 

 

1.09- 1.16

-

 

MA180876

 

 

 

 

 

 

Spacer: W5M42

 

0.75 - 0.82

-

 

MD744236

(For adjustment of center differential case pinion

 

 

 

 

0.83 - 0.92

-

 

MD744235

backlash)

 

 

 

 

 

 

 

 

 

 

0.93 - 1.00

-

 

MD744234

 

 

 

 

 

 

 

 

1.01 - 1.08

-

 

MD744233

 

 

 

 

 

 

 

 

1.09 - 1.16

-

 

MD744232

 

 

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Revised

MANUAL TRANSMISSION (E - W) - Specifications

22B-1-9

TORQUE SPECIFICATIONS

 

 

TRANSMISSION

 

 

 

 

 

Items

Nm

 

 

 

 

Under cover mounting bolt <F5M42, W5M42>

6.9

 

 

 

 

Interlock plate bolt

30

 

 

 

 

Clutch housing-transmission case mounting bolt

44

 

 

 

 

Clutch release bearing retainer mounting bolt

9.8

 

 

 

 

Control housing mounting bolt

18

 

 

 

 

Shift cable bracket mounting bolt

18

 

 

 

 

Speedometer gear mounting bolt

3.9

 

 

 

 

Stopper bracket mounting bolt

22

 

 

 

 

Select lever mounting bolt

18

 

 

 

 

Select lever mounting nut

11

 

 

 

 

Front differential drive gear mounting bolt <W5M42>

132

 

 

 

 

Center differential flange mounting screw <W5M42>

3.9

 

 

 

 

Center differential drive gear mounting bolt <W5M42>

132

 

 

 

 

Differential drive gear mounting bolt <F5M41, F5M42>

132

 

 

 

 

Back-up lamp switch

32

 

 

 

 

Front bearing retainer mounting bolt

18

 

 

 

 

Poppet spring

32

 

 

 

 

Restrict ball <F5M41>

32

 

 

 

 

Reverse idler gear shaft mounting bolt

48

 

 

 

 

Reverse shift lever mounting bolt <F5M41>

18

 

 

 

 

Roll stopper bracket mounting bolt

69

 

 

 

 

Oil temperature sensor <For GDI engine only>

32

 

 

 

 

Connector bracket mounting bolt <For GDI engine except DA2A>

19

 

 

 

 

Clutch fluid line bracket mounting bolt <DA2A only>

19

 

 

 

 

TRANSFER

 

 

 

 

 

Items

Nm

 

 

 

 

Transfer cover mounting bolt

23

 

 

 

 

Transmission - transfer mounting bolt

69

 

 

 

 

E Mitsubishi Motors Corporation

July 1999

PWEE9508-F

Added

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

Installer adapter

Installation of sealing cap

 

 

 

MB990930

Installer adapter

Removal of center differential taper roller

 

 

bearing <W5M42>

 

 

 

MB990934

Installer adapter

Installation of roller bearing outer race

 

 

 

MB990935

Installer adapter

Installation of differential case taper roller

 

 

bearing outer race

 

 

 

MB990937

Installer adapter

Installation of center differential taper roller

 

 

bearing <W5M42>

 

 

 

MB990938

Handle

Use with Installer adapter

 

 

 

 

MD998325

Differential oil seal

Installation of differential oil seal

 

 

installer

<F5M41, F5M42>

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Revised

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

Valve spring com-

Removal of roller bearing outer race

 

pressor

 

 

 

 

MD998801

Bearing remover

Installation and removal of gears, bearings and

 

 

sleeves

 

 

 

MD998812

Installer cap

Use with Installer and Installer adapter

 

 

 

MD998813

Installer-100

Use with Installer cap and Installer adapter

 

 

 

MD998814

Installer-200

Use with Installer cap and Installer adapter

 

 

 

MD998816

Installer

adapter

Installation of input shaft front bearing

 

(30)

 

<F5M42, W5M42>

 

 

 

 

MD998817

Installer

adapter

Installation of input shaft front bearing

 

(34)

 

<F5M41>, output shaft rear bearing <F5M42,

 

 

 

W5M42>

 

 

 

 

 

MD998818

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>

 

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Revised

 

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

Installer

adapter

Installation of 5th speed gear sleeve, 2nd

 

(42)

 

speed gear sleeve <F5M41>

 

 

 

 

MD998822

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>

 

 

 

 

MD998823

Installer

adapter

Installation of differential case taper roller

 

(48)

 

bearing inner race <F5M42, W5M42>

 

 

 

 

MD998824

Installer

adapter

Installation of 4th speed gear sleeve and 5th

 

(50)

 

speed gear <F5M42, W5M42>

 

 

 

 

MD998825

Installer

adapter

Installation of 1st-2nd speed synchronizer hub,

 

(52)

 

3rd-4th speed synchronizer hub and 1st speed

 

 

 

gear sleeve <F5M42, W5M42>

 

 

 

 

MD998826

Installer

adapter

Installation of 3rd-4th speed synchronizer hub

 

(54)

 

<F5M41>

 

 

 

 

MD998917

Bearing remover

Installation and removal of gears, bearings and

 

 

sleeves

 

 

 

 

MD999566

Claw

Removal of differential case taper roller bearing

 

 

 

outer race <F5M42, W5M42>

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Revised

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

Arm bush remover

Installation of transfer oil seal

 

and installer base

 

 

 

 

MB990933

Installer adapter

Installation of transfer cover oil seal

 

 

 

MD998304

Oil seal installer

Installation of transfer extension housing oil

 

 

seal

 

 

 

 

MD998800

Oil seal installer

Installation of transfer cover oil seal

 

 

 

 

E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Added

MANUAL TRANSMISSION (E - W) - Transmission <F5M41> 22B-3-1

3. TRANSMISSION <F5M41>

DISASSEMBLY AND REASSEMBLY

18 Nm

32 Nm

3

2

5

9

 

 

 

11

 

 

 

 

7

 

 

 

 

 

 

10

 

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

E Mitsubishi Motors Corporation

Nov. 1995

PWEE9508-A

Added

22B-3-2 MANUAL TRANSMISSION (E - W) - Transmission <F5M41>

Lubricate all internal parts with gear oil during reassembly.

15

30 Nm

18 Nm

16

13

14

 

19

 

 

 

 

 

44 Nm

25

20

28

18

17

 

26

 

 

 

 

 

 

48 Nm

 

 

 

 

 

27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

18 Nm

 

24

 

 

 

 

 

 

 

23

 

21

 

 

 

 

 

 

22

 

 

 

TFM0719

Disassembly steps

 

 

13.

Interlock plate bolt

AC" "GA 21.

Reverse idler gear shaft

14.

Gasket

22.

Reverse idler gear

"KA 15.

Control housing

23.

Reverse shift lever shoe

16.

Neutral return spring

24.

Reverse shift lever

"JA 17.

Reverse idler gear shaft bolt

"FA 25. Oil guide

18.

Gasket

26.

Magnet holder

AA" "IA 19.

Sealing cap

27.

Magnet

AB" "HA 20.

Transmission case

"EA 28.

Spacer

E Mitsubishi Motors Corporation

Nov. 1995

PWEE9508-A

Added

MANUAL TRANSMISSION (E - W) - Transmission <F5M41> 22B-3-3

Lubricate all internal parts with gear oil during reassembly.

 

30

 

 

 

 

 

 

 

32

 

 

 

 

 

 

 

 

 

31

29

 

41

33

 

 

 

 

 

 

45

 

 

 

 

 

 

 

 

 

 

40

 

 

 

35

 

 

 

 

 

 

 

 

 

 

 

 

 

36

 

 

 

 

 

 

34

 

 

 

 

39

 

 

 

 

 

46

38

 

 

 

 

37

 

 

 

 

 

 

 

 

 

42

 

 

18 Nm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

44

43

TFM0720

Disassembly steps

"DA 29. Spring pin

30.1st-2nd speed shift rail

31.1st-2nd speed shift fork "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

AD" "CA 38. Reverse interlock rail AD" "CA 39. Steel ball

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

46.Clutch housing

E Mitsubishi Motors Corporation

Nov. 1995

PWEE9508-A

Added

22B-3-4 MANUAL TRANSMISSION (E - W) - Transmission <F5M41>

Sealing cap

Snap ring

3rd-4th speed synchronizer sleeve

Reverse shift lug

DISASSEMBLY SERVICE POINTS

AA"SEALING CAP REMOVAL

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.

AC"REVERSE IDLER GEAR SHAFT REMOVAL

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

(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 3rd-4th shown, remove it together with the shift fork.

speed shift rail

E Mitsubishi Motors Corporation

Nov. 1995

PWEE9508-A

Added

MANUAL TRANSMISSION (E - W) - Transmission <F5M41> 22B-3-5

Detent

5 mm

E Mitsubishi Motors Corporation

JulyNov. 19995

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

"AAOUTPUT 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.

"BAFRONT 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

PWEE9508--AF

RevisAdded

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