Mitsubishi F5M41, F5M42, W5M42 Service manual
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-1-2f. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 22B-1-2f. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANTS AND ADHESIVES 22B-1-2g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
Mar . 2002Mitsubishi Motors Corporation Revised
PWEE9508-I
22B-0-2
NOTES
MANUAL TRANSMISSION (E-W) -
General Information
GENERAL INFORMATION
F5M41 <Types with single synchronizer ring for 2nd gear>
22B-0-3
67
2
1
3
5
4
8
9
10
15
1214 13
11
TFM0809
1. Reverse gear meshing noise prevention device
<Models with reverse brake>
2. 5th-reverse speed synchronizer hub
3. 5th speed gear
4. 4th speed gear
5. 3rd-4th speed synchronizer hub
6. 3rd speed gear
7. Transmission case
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
8. Clutch housing
9. Release bearing retainer
10. Input shaft
11. Differential
12. 1st speed gear
13. 1st-2nd speed synchronizer hub
14. 2nd speed gear
15. Output shaft
22B-0-4
MANUAL TRANSMISSION (E-W) -
General Information
F5M41 <Types with double synchronizer ring for 2nd gear>
12
34
6
7
8
5
9
10
15
1214 13
11
1. Reverse gear meshing noise prevention device
2. 5th-reverse speed synchronizer hub
3. 5th speed gear
4. 4th speed gear
5. 3rd-4th speed synchronizer hub
6. 3rd speed gear
7. Transmission case
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
8. Clutch housing
9. Release bearing retainer
10. Input shaft
11. Differential
12. 1st speed gear
13. 1st-2nd speed synchronizer hub
14. 2nd speed gear
15. Output shaft
MANUAL TRANSMISSION (E–W) – General Information
22B-0-4a
F5M41 <Types with single synchronizer ring for 2nd gear and synchronizer lever
for 5th gear>
1234
5
6
7
8
9
14
13
12
11
10
1. 5th-reverse speed synchronizer hub
2. 5th speed gear
3. 4th speed gear
4. 3rd-4th speed synchronizer hub
5. 3rd speed gear
6. Transmission case
7. Clutch housing
E
Dec. 2000Mitsubishi Motors Corporation Added
PWEE9508-H
8. Release bearing retainer
9. Input shaft
10. Differential
11. 1st speed gear
12. 1st-2nd speed synchronizer hub
13. 2nd speed gear
14. Output shaft
22B-0-4b
MANUAL TRANSMISSION (E–W) – General Information
Intentionally blank
E
Dec. 2000Mitsubishi Motors Corporation Added
PWEE9508-H
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
1
2
3
5
6
7
8
9
111214 131516
10
1. Reverse idler gear
2. 4th speed gear
3. 3rd-4th speed synchronizer hub
4. 3rd speed gear
5. Transmission case
6. Clutch housing
7. Release bearing retainer
8. Input shaft
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
9. Output shaft
10. Differential
11. 1st speed gear
12. 1st-2nd speed synchronizer hub
13. 2nd speed gear
14. 5th speed gear
15. 5th-reverse speed synchronizer hub
16. Reverse gear
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
1
2
3
5
6
7
8
9
16
15
14
13
1112
10
1. Reverse idler gear
2. 4th speed gear
3. 3rd-4th speed synchronizer hub
4. 3rd speed gear
5. Transmission case
6. Clutch housing
7. Release bearing retainer
8. Input shaft
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
9. Output shaft
10. Differential
11. 1st speed gear
12. 1st-2nd speed synchronizer hub
13. 2nd speed gear
14. 5th speed gear
15. 5th-reverse speed synchronizer hub
16. Reverse gear
W5M42
MANUAL TRANSMISSION (E-W) -
General Information
22B-0-7
1
2
3
4
56
7
8
9
16
171819
15
14
10
13
1. Reverse idler gear
2. 4th speed gear
3. 3rd-4th speed synchronizer hub
4. 3rd speed gear
5. Transmission case
6. Clutch housing
7. Release bearing retainer
8. Input shaft
9. Output shaft
10. Viscous coupling
11
12
11. Front differential
12. Transfer driven gear
13. Center differential
14. 1st speed gear
15. 1st-2nd speed synchronizer hub
16. 2nd speed gear
17. 5th speed gear
18. 5th-reverse speed synchronizer hub
19. Reverse gear
E
Jun. 1998Mitsubishi Motors Corporation Added
PWEE9508-E
MANUAL TRANSMISSION (E–W) – Specifications
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE – MODEL 1996
22B-1-1
Transmission model Gear ratio Speedometer
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 4.625 CK4A 4G92-MIVEC
Final gear ratio Vehicle model Engine model
TRANSMISSION MODEL TABLE – MODEL 1997
Transmission model Gear ratio Speedometer
gear ratio
EUR F5M42-1-F7N D 30/36 3.722 EA2A, EA2W 4G63
F5M42-2-F6N2 F 29/36 3.722 EA5A, EA5W 6A13
F5M42-2-F6N5 E 29/36 3.722 EA6A, EA6W 4D68
Final gear ratio Vehicle model Engine model
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 F 29/36 3.722 EA5A 6A13
F5M42-2-V6N D 29/36 4.312 EA4A 6A12
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
22B-1-2
MANUAL TRANSMISSION (E–W) – Specifications
TRANSMISSION MODEL TABLE – MODEL 1998
Transmission model Gear ratio Speedometer
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
F5M42-2-F7N2 D 30/36 3.722 EA2A, EA2W 4G63
F5M42-1-F8A4 G 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 4.058 EA1A 4G93
F5M42-1–F6N9 D 29/36 3.722 EA2A 4G63
F5M42-2-R6N8 E 29/36 4.058 EA6A 4D68
Final gear ratio Vehicle model Engine model
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
MANUAL TRANSMISSION (E–W) – Specifications
TRANSMISSION MODEL TABLE – MODEL 1999
22B-1-2a
Transmission model Gear ratio Speedometer
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-F8A4 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 4.312 EA4A 6A12-MIVEC
Final gear ratio Vehicle model Engine model
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 A 31/36 3.714 CJ2A, CK2A 4G15
F5M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93
F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
22B-1-2b
MANUAL TRANSMISSION (E–W) – Specifications
TRANSMISSION MODEL TABLE – MODEL 2000
Transmission model Gear ratio Speedometer
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 G 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
Final gear ratio Vehicle model Engine model
F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
MMAL F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
MANUAL TRANSMISSION (E–W) – Specifications
TRANSMISSION MODEL TABLE – MODEL 2001
22B-1-2c
Transmission model Gear ratio Speedometer
gear ratio
EUR F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13
F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92
F5M42-1-F8AC I 31/36 3.722 DG5A 4G93
F5M42-1-R7A2 G 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 4.312 N63W 4G63
F5M42-2-R5A3 G 28/36 4.058 N64W 4G64
EXP F5M41-1-R8A1 A 31/36 4.052 CJ1A, CJ2A 4G13, 4G15
F5M41-1-R7B A 30/36 4.052 CS1A, CS3A 4G13, 4G18
F5M41-1-R8B A 31/36 4.052 CS1A, CS3A 4G13, 4G18
F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92
Final gear ratio Vehicle model Engine model
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
F5M42-2-R6N7 D 29/36 4.058 EA2A 4G63
F5M42-1-F6N9 D 29/36 3.722 EA2A 4G63
F5M42-2-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, CK2A 4G15
F5M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93
F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
22B-1-2d
MANUAL TRANSMISSION (E–W) – Specifications
TRANSMISSION MODEL TABLE – MODEL 2002
Transmission model Gear ratio Speedometer
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-R8B A 31/36 4.052 CS3A 4G18
F5M42-1-F8AC I 31/36 3.722 DG5A 4G93
F5M42-1-R7A2 G 30/36 4.058 DA2A 4G93
F5M42-2-V5A D 28/36 4.312 N83W 4G63
F5M42-2-R5A3 G 28/36 4.058 N84W 4G64
W5M42-1-V5A1 H 28/36 4.352 N94W 4G64
EXP F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92
F5M41-1-R8A1 A 31/36 4.052 CJ1A, CJ2A 4G13, 4G15
F5M42-2-F6N7 F 29/36 3.722 EA5A 6A13
F5M42-1-R6N6 D 29/36 4.058 EA1A 4G93
F5M42-1-R6N7 D 29/36 4.058 EA2A 4G63
Final gear ratio Vehicle model Engine model
F5M42-1-F6N9 D 29/36 3.722 EA2A, W 4G63
F5M42-2-R6N8 E 29/36 4.058 EA6A 4D68
F5M41-1-R7B A 30/36 4.052 CS1A, CS3A 4G13, 4G18
F5M41-1-R8B A 31/36 4.052 CS1A, CS3A 4G13, 4G18
F5M41-1-V7B A 30/36 4.333 CS1A 4G13
F5M41-1-V8B1 A 31/36 4.333 CS1A 4G13
F5M42-1-R7A2 G 30/36 4.058 DA3A 4G93
F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
MMAL F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
F5M41-1-F8A5 A 31/36 3.714 CJ2A 4G15
F4M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93
E
Mar . 2002Mitsubishi Motors Corporation Revised
PWEE9508-I
MANUAL TRANSMISSION (E–W) – Specifications
TRANSMISSION MODEL TABLE – MODEL 2003
22B-1-2e
Transmission model Gear ratio Speedometer
gear ratio
EUR F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92
F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13
F5M42-2-V5A D 28/36 4.312 N83W 4G64
F5M42-2-R5A3 G 28/36 4.058 N84W 4G64
W5M42-1-V5A1 H 28/36 4.325 N94W 4G64
F5M42-1-R7A2 G 30/36 4.058 DA2A 4G93
EXP F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92
F5M41-1-R8A1 A 31/36 4.052 CJ1A, CJ2A 4G13, 4G15
F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
F5M41-1-R7B1 A 30/36 4.052 CS1A, CS3A 4G13, 4G18
F5M41-1-R8B1 A 31/36 4.052 CS1A, CS3A 4G13, 4G18
MMAL F5M41-1-F8A5 A 31/36 3.714 CJ2A 4G15
F5M42-1-F8A7 F 31/36 3.722 CJ5A, CK5A 4G93
Final gear ratio Vehicle model Engine model
F5M42-2-R5A2 D 28/36 4.058 N84W 4G64
F5M42-1-F8B2 F 31/36 3.722 CS6A 4G93
E
Mar . 2002Mitsubishi Motors Corporation Revised
PWEE9508-I
22B-1-2f
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 0.767 0.820 0.733 0.767 0.767
Reverse 3.416 3.416 3.363 3.363 3.363 3.363 3.363
H I
1st 3.583 3.583
2nd 1.947 1.947
3rd 1.266 1.266
4th 0.970 0.970
5th 0.767 0.820
Reverse 3.363 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 0–0.150 –
Differential case preload <F5M42> mm 0.05–0.11 –
NOTE: Standard play = 0 mm
E
Mar . 2002Mitsubishi Motors Corporation Revised
PWEE9508-I
MANUAL TRANSMISSION (E–W) – Specifications
t
Items Allowable range Limit
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
22B-1-2g
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 equivalen
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
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
Mar . 2002Mitsubishi Motors Corporation Added
PWEE9508-I
22B-1-2h
MANUAL TRANSMISSION (E–W) – Specifications
Intentionally blank
E
Mar . 2002Mitsubishi Motors Corporation Added
PWEE9508-I
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
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
22B-1-4
(For adjustment o input sha t ront bearing end
(For adjustment o input sha t rear bearing end
(For adjustment of output shaft rear bearing end
(For adjustment o input sha t 5th speed gear
(For adjustment o output sha t ront bearing end
(For adjustment o input sha t rear bearing end
MANUAL TRANSMISSION (E–W) – Specifications
SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT
Part name Thickness mm Identification
symbol
Snap ring
f
play)
Snap ring
f
play ....F5M41)
f
play ....F5M42, W5M42)
f
f
f
f
2.24 None MD706537
2.31 Blue MD706538
2.38 Brown MD706539
2.31 Black (2) MD747149
2.35 None MD746561
2.39 Blue MD746562
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
Part No.
2.71 Brown MD746570
Thrust plate: F5M42, W5M42
f
end play)
Snap ring
f
play)
f
play ....F5M42, W5M42) 1.59 Yellow (2) MD746710
f
f
f
f
2.82 0 MD748015
2.86 2 MD748016
2.90 3 MD748017
2.94 5 MD748018
2.98 6 MD748019
3.02 7 MD748020
3.06 8 MD748021
3.10 9 MD748022
1.43 Green (2) MD746708
1.51 White (2) MD746709
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
MANUAL TRANSMISSION (E-W) -
Specifications
22B-1-5
Part name Part No.Identification
Snap ring: F5M41 2.31 Black (2) MD748800
(For adjustment of output shaft rear bearing end
play)
Snap ring: F5M41 2.81 Green MD748782
(For adjustment of output shaft 3rd speed gear
end play)
Thickness mm
symbol
2.35 None MD748801
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
2.85 White MD748783
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
end play)
2.85 White MD745800
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
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
22B-1-6
MANUAL TRANSMISSION (E-W) -
Specifications
Part name Part No.Identification
Spacer: F5M41 0.77 77 MD754476
(For adjustment of differential case end play)
Thickness mm
symbol
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
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
MANUAL TRANSMISSION (E–W) – Specifications
(For adjustment o di erential case preload)
22B-1-7
Part name Thickness mm Identification
symbol
Spacer: F5M42
f
ff
0.71 71 MD754475
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
Part No.
1.10 J MD710454
1.13 D MD700270
1.16 K MD710455
1.19 L MD710456
1.22 G MD700271
1.25 M MD710457
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
22B-1-8
(For adjustment o center di erential case
(For adjustment o di erential case backlash)
(For adjustment o center di erential case pinion
MANUAL TRANSMISSION (E–W) – Specifications
Part name Part No.Identification
Spacer: W5M42
f
preload)
ff
Thickness mm
symbol
0.74 74 MD727660
0.77 77 MD745476
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
Spacer: F5M41, F5M42
f
ff
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
0.72 – 0.79 – MA180862
0.85 – 0.90 – MA180861
0.94 – 0.98 – MA180860
1.02 – 1.06 – MA180875
1.06 – 1.10 – MR581570
1.12 – 1.16 – MA180876
1.16 – 1.20 – MR581571
Spacer: W5M42
f
backlash)
E
ff
Dec. 2000Mitsubishi Motors Corporation Revised
0.48 – 0.55 – MD744236
0.56 – 0.65 – MD744235
0.66 – 0.73 – MD744234
0.74 – 0.81 – MD744233
0.82 – 0.89 – MD744232
PWEE9508-H
MANUAL TRANSMISSION (E–W) – Specifications
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 19
Select lever mounting bolt 18
Select lever mounting nut 11
22B-1-9
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 70
Oil temperature sensor <For GDI engine only> 22
Connector bracket mounting bolt <For GDI engine except DA2A> 18
Clutch fluid line bracket mounting bolt <DA2A only> 18
TRANSFER
Items Nm
Transfer cover mounting bolt 23
Transmission – transfer mounting bolt 69
E
Dec. 2000Mitsubishi Motors Corporation Revised
PWEE9508-H
MANUAL TRANSMISSION (E-W) -
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
Special Tools
bearing <W5M42>
22B-2-1
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
installer
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
Installation of differential oil seal
<F5M41, F5M42>
22B-2-2
Tool UseNameNumber
MANUAL TRANSMISSION (E-W) -
Special Tools
MD998346 Bearing outer race
remover
MD998772 Valve spring com-
pressor
MD998801 Bearing remover Installation and removal of gears, bearings and
MD998812 Installer cap Use with Installer and Installer adapter
Removal of roller bearing outer race
Removal of roller bearing outer race
sleeves
MD998813 Installer-100 Use with Installer cap and Installer adapter
MD998814 Installer-200 Use with Installer cap and Installer adapter
MD998816 Installer adapter
(30)
MD998817 Installer adapter
(34)
Installation of input shaft front bearing
<F5M42, W5M42>
Installation of input shaft front bearing
<F5M41>, output shaft rear bearing <F5M42,
W5M42>
MD998818 Installer adapter
(38)
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
Installation of input shaft rear bearing, roller
bearing inner race, reverse gear, needle roller
bearing, reverse gear bearing sleeve <F5M42,
W5M42> and reverse bearing sleeve
<F5M41>
MANUAL TRANSMISSION (E-W) -
Tool UseNameNumber
Special Tools
22B-2-3
MD998819 Installer adapter
(40)
MD998820 Installer adapter
(42)
MD998822 Installer adapter
(46)
MD998823 Installer adapter
(48)
Installation of 5th-reverse speed synchronizer
hub, differential case bearing, 4th speed gear
and 5th speed gear sleeve <F5M42, W5M42>
Installation of 5th speed gear sleeve, 2nd
speed gear sleeve <F5M41>
Installation of 1st speed gear sleeve,1st-2nd
speed synchronizer hub <F5M41>, 2nd speed
gear sleeve and 3rd speed gear <F5M42,
W5M42>
Installation of differential case taper roller
bearing inner race <F5M42, W5M42>
MD998824 Installer adapter
(50)
MD998825 Installer adapter
(52)
MD998826 Installer adapter
(54)
MD998917 Bearing remover Installation and removal of gears, bearings and
Installation of 4th speed gear sleeve and 5th
speed gear <F5M42, W5M42>
Installation of 1st-2nd speed synchronizer hub,
3rd-4th speed synchronizer hub and 1st speed
gear sleeve <F5M42, W5M42>
Installation of 3rd-4th speed synchronizer hub
<F5M41>
sleeves
MD999566 Claw Removal of differentialcase taper roller bearing
outer race <F5M42, W5M42>
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
22B-2-4
MANUAL TRANSMISSION (E-W) -
TRANSFER
Tool Number Name Use
Special Tools
MB990887 Arm bush remover
and installer ring
MB990891 Arm bush remover
and installer base
MB990933 Installer adapter Installation of transfer cover oil seal
MD998304 Oil seal installer Installation of transfer extension housing oil
Installation of transfer oil seal
Installation of transfer oil seal
seal
MD998800 Oil seal installer Installation of transfer cover oil seal
E
Jun. 1998Mitsubishi Motors Corporation Added
PWEE9508-E
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