MITSUBISHI
FRONT WHEEL DRIVE
MANUAL TRANSMISSION (E-W)
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures
for removal, disassembly, inspection,
adjustment, reassembly and installation, etc.
for service mechanics.
All information, illustrations and product
descriptions contained in this manual are
current as at the time of publication. We,
however, reserve the right to make changes
at any time without prior notice or obligation.
FILING INSTRUCTION
Please keep these manual pages in the binder
No. BN940001.
File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.
Added:
File the pages with this sign additionally in
your manual.
Revised, Deleted:
Replace the existing pages with the
corresponding pages with this sign.
Clutch
.........................................
F5MR1, F5MR2, F5MR3
Clutch
.........................................
F5M41, F5M42, W5M42
Manual Transmission
F5MR1, F5MR2, F5MR3
Manual Transmission
F5M41, F5M42, W5M42
Manual Transmission
F5M51
....................
....................
....................
21A
21B
22A
22B
22C
Missing sheets will be supplied upon request.
Mitsubishi Motors Corporation Jun. 2000
E
Pub. No. PWEE9508-G
INTRODUCTION
EXPLANATION OF MANUAL CONTENTS
Maintenance and Servicing Procedures
(1) A diagram of the component parts is
provided near the front of each section in
order to give the reader a better understanding of the installed condition of
component parts.
(2) The numbers provided with the diagram
indicate the sequence for maintenance and
servicing procedures.
: Indicates a non-reusable part.
The tightening torque is provided where
applicable.
Classification of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essentialmaintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points and explained in
detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.
D Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
D Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
D Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.
D Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for
lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagram of component parts, or
on the page following the component parts
page, and explained.
: Grease (multipurpose grease unless
there is a brand or type specified)
: Sealant or adhesive
: Brake fluid, automatic transmission fluid
: Gear oil
INTRODUCTION
Indicates the
group title.
Indicates the
section title.
Indicates the
group number.
Indicates the
section number.
Indicates the
page number.
Denotes tightening
torque.
Denotes non-reusable part.
Apply gear oil to all
moving parts before
installation.
This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.
Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.
Issue date
Publication number-Revision code
LIST OF EFFECTIVE PAGES
Page Revision
21A-0-1 May 1995
21A-1-1 B May 1996
21A-2-1 May 1995
21A-3-1 to 21A-3-3 May 1995
21A-4-1 and 21A-4-2 May 1995
21B-0-1 E Jun. 1998
21B-1-1 and 21B-1-2 E Jun. 1998
21B-2-1 and 21B-2-2 E Jun. 1998
21B-2-2a to 21B-2-2d E Jun. 1998
21B-2-3 E Jun. 1998
21B-2-4 C Jan. 1997
21B-2-4a E Jun. 1998
21B-2-4b C Jan. 1997
21B-3-1 E Jun. 1998
21B-3-2 C Jan. 1997
21B-3-2a C Jan. 1997
22A-0-1 B May 1996
22A-0-2 and 22A-0-3 May 1995
22A-0-4 B May 1996
22A-1-1 E Jun. 1998
22A-1-2 B May 1996
22A-2-1 to 22A-2-4 B May 1996
22A-3-1 and 22A-3-2 B May 1996
22A-3-2a and 22A-3-2b B May 1996
22A-3-3 May 1995
22A-3-4 to 22A-3-16 B May 1996
22A-4-1 to 22A-4-9 B May 1996
22A-5-1 to 22A-5-6 B May 1996
22A-6-1 to 22A-6-6 B May 1996
22A-7-1 to 22A-7-3 May 1995
22A-8-1 and 22A-8-2 B May 1996
22B-0-1 G Jun. 2000 Revised
22B-0-2 A Nov. 1995
22B-0-3 to 22B-0-6 F July 1999
22B-0-7 E Jun. 1998
22B-1-1 and 22B-1-2 F July 1999
22B-1-2a and 22B-1-2b F July 1999
22B-1-2c and 22B-1-2d G Jun. 2000 Revised
22B-1-2e G Jun. 2000 Added
22B-1-3 E Jun. 1998
22B-1-4 to 22B-1-9 F July 1999
22B-2-1 to 22B-2-4 E Jun. 1998
22B-3-1 to 22B-3-4 A Nov. 1995
22B-3-5 F July 1999
Code
Date Remarks Page Revision
Code
Date Remarks
22B-3-6 to 22B-3-9 A Nov. 1995
22B-4-1 F July 1999
22B-4-2 to 22B-4-8 E Jun. 1998
22B-5-1 and 22B-5-2 F July 1999
22B-5-2a and 22B-5-2b F July 1999
22B-5-3 to 22B-5-6 A Nov. 1995
22B-5-7 G Jun. 2000 Revised
22B-6-1 to 22B-6-5 E Jun. 1998
22B-6-6 G Jun. 2000 Revised
22B-7-1 and 22B-7-2 F July 1999
22B-7-2a and 22B-7-2b F July 1999
22B-7-3 and 22B-7-4 A Nov. 1995
22B-7-5 F July 1999
22B-7-6 G Jun. 2000 Revised
22B-7-7 F July 1999
22B-8-1 and 22B-8-2 F July 1999
22B-8-3 to 22B-8-8 E Jun. 1998
22B-8-9 G Jun. 2000 Revised
22B-8-10 E Jun. 1998
22B-9-1 E Jun. 1998
22B-10-1 A Nov. 1995
22B-11-1 A Nov. 1995
22B-12-1 E Jun. 1998
22B-12-2 C Jan. 1997
22B-12-2a C Jan. 1997
22B-13-1 and 22B-13-2 E Jun. 1998
22B-13-3 F July 1999
22B-14-1 A Nov. 1995
22B-14-2 F July 1999
22B-15-1 to 22B-15-4 E Jun. 1998
22B-16-1 to 22B-16-3 E Jun. 1998
22B-17-1 to 22B-17-3 E Jun. 1998
22C-0-1 to 22C-0-3 C Jan. 1997
22C-1-1 D Nov. 1997
22C-1-2 to 22C-1-6 C Jan. 1997
22C-2-1 to 22C-2-3 C Jan. 1997
22C-3-1 to 22C-3-8 C Jan. 1997
22C-4-1 to 22C-4-7 C Jan. 1997
22C-5-1 to 22C-5-8 C Jan. 1997
22C-6-1 C Jan. 1997
22C-7-1 C Jan. 1997
22C-8-1 C Jan. 1997
22C-9-1 to 22C-9-3 C Jan. 1997
22C-10-1 to 22C-10-3 C Jan. 1997
22C-11-1 and 22C-11-2 C Jan. 1997
22C-12-1 to 22C-12-3 C Jan. 1997
Missing sheets will be supplied upon request.
E
Jun. 2000Mitsubishi Motors Corporation Revised
PWEE9508-G
CLUTCH
F5MR1, F5MR2
21A-0-1
1. SPECIFICATIONS 21A-1-1........................................
GENERAL SPECIFICATIONS 21A-1-1............................
SERVICE SPECIFICATIONS 21A-1-1.............................
TORQUE SPECIFICATIONS 21A-1-1.............................
LUBRICANTS 21A-1-1..........................................
2. SPECIAL TOOLS 21A-2-1........................................
3. CLUTCH 21A-3-1................................................
4. CLUTCH RELEASE CYLINDER 21A-4-1...........................
CONTENTS
21209000032
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May 1995Mitsubishi Motors Corporation
PWEE9508
21A-0-2
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9508
1. SPECIFICATIONS
GENERAL SPECIFICATIONS
CLUTCH -
Specifications
21A-1-1
Items
Clutch operating method Hydraulic type Hydraulic type Hydraulic type
Clutch disc type Single dry disc
Clutch disc size O.D. ´ I.D. mm 200 ´ 137 215 ´ 147 215 ´ 145
Clutch cover type Diaphragm
Clutch cover setting load Nm 4,000 4,400 4,400
Clutch release cylinder I.D. mm 20.64 20.64 20.64
F5MR1 F5MR2 F5MR3
type
spring strap
drive type
Single dry disc
type
Diaphragm
spring strap
drive type
Single dry type
Diaphragm
spring strap
drive type
SERVICE SPECIFICATIONS
Items
Facing rivet sink mm 0.3
Diaphragm spring end height difference mm 0.5
Specifications (Limit)
TORQUE SPECIFICATIONS
Items Nm
Clutch cover bolt 30
Release cylinder mounting bolt 30
Clutch tube flare nut 15
Clutch tube bracket mounting bolt 48
Release cylinder union bolt 23
Release cylinder bleeder plug 11
LUBRICANTS
Items Specified lubricants Quantity
Piston and cup surface Rubber grease As required
Clutch disc spline Mitsubishi genuine grease As required
Part No.0101011 or equiv-
Clutch release bearing to release fork contact surface
alent
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9508
CLUTCH -
Special Tools
21A-2-1
2. SPECIAL TOOLS
Tool
Number Name Use
MD998126 Clutch disc center
21200060015
Aligning clutch disc center hole
guide
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May 1995Mitsubishi Motors Corporation
PWEE9508
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9508
CLUTCH -
Clutch
21A-3-1
3. CLUTCH
REMOVAL AND INSTALLATION
4
5
21200100038
8
30 Nm
1
2
7
6
Removal steps
1. Clutch tube
2. Clutch tube bracket
3. Clutch release cylinder
"BA
"BA
"AA
4. Clutch cover
5. Clutch disc
6. Clutch release bearing
7. Release fork
8. Release fork boot
30 Nm
3
15 Nm
15 Nm
48 Nm
E
May 1995Mitsubishi Motors Corporation
PWEE9508
21A-3-2
CLUTCH -
Clutch
INSTALLATION SERVICE POINTS
"AA
Specified grease:
GREASE APPLICATION TO RELEASE FORK
Mitsubishi genuine grease Part No.0101011 or
equivalent
Flywheel
MD998126
Clutch disc
Clutch cover
assembly
"BA
CLUTCH DISC/CLUTCH COVER ASSEMBLY
INSTALLATION
(1) Apply specified grease to clutch disc splines and squeeze
it in place with a brush.
Specified grease:
Mitsubishi genuine grease Part No.0101011 or
equivalent
(2) Using special tool, position clutch disc on flywheel.
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May 1995Mitsubishi Motors Corporation
PWEE9508
CLUTCH -
Clutch
21A-3-3
Rivet sink
CLUTCH INSPECTION
CLUTCH COVER ASSEMBLY
Check the diaphragm spring end for wear and uneven
D
height.
Replace if wear is evident or height difference exceeds
the limit.
Limit: 0.5 mm
Check the pressure plate surface for wear, cracks and
D
seizure.
Check the strap plate rivets for looseness and replace
D
the clutch cover assembly if loose.
CLUTCH DISC
Check the facing for loose rivets, uneven contact,
D
deterioration due to seizure, adhesion of oil or grease,
and replace the clutch disc if defective.
Measure the rivet sink and replace the clutch disc if it
D
is out of specification.
21200110031
Limit: 0.3 mm
Check torsion spring for play and damage and replace
D
the clutch disc if defective.
Combine the clutch disc with the input shaft, and check
D
sliding condition and play in the rotating direction. If it
does not slide smoothly or the play is excessive, check
after cleaning and reassembling. If the play is excessive,
replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
Caution
Release bearing is packed with grease. Therefore do not
wash it in cleaning solvent or the like.
Check bearing for seizure, damage, noise, or improper
D
rotation. Check also diaphragm spring contact surface
for wear.
Replace bearing if its release fork contact surface is
D
abnormally worn.
RELEASE FORK
Replace release fork if its bearing contact surface is
D
abnormally worn.
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May 1995Mitsubishi Motors Corporation
PWEE9508
CLUTCH -
Clutch Release Cylinder
21A-4-1
4. CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
4
11 Nm
7
6
3
5
21200150033
1
2
Piston
Cup
13
Disassembly steps
1. Push rod
AA"
AA"
2. Boot
3. Piston cup
4. Piston
5. Conical spring
6. Cap
7. Bleeder plug
8. Union bolt
12
11
Grease: Rubber grease
9
10
9
23 Nm
8
9. Gasket
10. Union
11. Valve plate
12. Compressor spring
13. Release cylinder
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May 1995Mitsubishi Motors Corporation
PWEE9508
21A-4-2
CLUTCH -
Clutch Release Cylinder
DISASSEMBLY SERVICE POINTS
AA"
Remove the piston from the release cylinder using compressed
air.
Caution
1. Cover with shop towel to prevent the piston from
2. Apply compressed air slowly to prevent brake fluid
PISTON AND PISTON CUP REMOVAL
popping out.
from splashing.
CLUTCH RELEASE CYLINDER INSPECTION
21200160036
(1) Check the inner surface of the release cylinder for
scratches or irregular wear.
(2) Replace if the piston cup outer circumference is scratched
or shows signs of fatigue, or if there is excessive wear
of the lip where indicated in the figure.
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May 1995Mitsubishi Motors Corporation
PWEE9508
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9508
21B-0-1
CLUTCH
F5M41, F5M42, W5M42
CONTENTS
1. SPECIFICATIONS 21B-1-1
GENERAL SPECIFICATIONS 21B-1-1
SERVICE SPECIFICATIONS 21B-1-1
TORQUE SPECIFICATIONS 21B-1-2
LUBRICANTS 21B-1-2
2. CLUTCH 21B-2-1
3. CLUTCH RELEASE CYLINDER 21B-3-1
..................................................
...................................
....................................
.....................................
....................................................
............................................................
...................................
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
21B-0-2
NOTES
E
Nov. 1995Mitsubishi Motors Corporation Added
PWEE9508-A
1. SPECIFICATIONS
GENERAL SPECIFICATIONS
CLUTCH -
Specifications
21B-1-1
Items
Clutch operating method Hydraulic type Hydraulic type Hydraulic type
Clutch disc type Single dry disc type Single dry disc type Single dry disc type
Clutch disc size O.D. x I.D. mm 184 x 127 200 x 130 215 x 140
Clutch cover type Diaphragm spring type Diaphragm spring type Diaphragm spring type
Clutch cover setting load N 3256 4193 4539
Clutch release cylinder I.D. mm 20.64 20.64 20.64
Items F5M42-4G93, 4G63 F5M42-4G64, 6A12,
Clutch operating method Hydraulic type Hydraulic type Hydraulic type
Clutch disc type Single dry disc type Single dry disc type Single dry disc type
Clutch disc size O.D. x I.D. mm 215 x 140 225 x 150 225 x 150
Clutch cover type Diaphragm spring type Diaphragm spring type Diaphragm spring type
Clutch cover setting load N 4511 4511 5198
F5M41-4G13, 4G15 F5M41-4G92 F5M42-4G92
F5M42-6A13
4D68
Clutch release cylinder I.D. mm 20.64 20.64 20.64
Items F5M51 F5M42-4G64-GDI, W5M42
Clutch operating method Hydraulic type Hydraulic type
Clutch disc type Single dry disc type Single dry disc type
Clutch disc size O.D. x I.D. mm 225 x 150 230 x 150
Clutch cover type Diaphragm spring type Diaphragm spring type
Clutch cover setting load N 5864 4511
Clutch release cylinder I.D. mm 20.64 20.64
SERVICE SPECIFICATIONS
Items
Clutch disc facing rivet sink mm 0.3
Diaphragm spring end height difference mm
<F5M41, F5M42, W5M42>
Release cylinder I.D. to piston O.D. clearance mm 0.15
Specifications (limit)
0.5
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Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
21B-1-2
TORQUE SPECIFICATIONS
CLUTCH -
Specifications
Items
Clutch damper mounting bolt Nm <F5M41, F5M42, W5M42> 18
Clutch fluid line bracket Nm 18
Clutch release cylinder air bleeder Nm 11
Clutch release cylinder mounting bolt Nm <F5M41, F5M42, W5M42> 18
Clutch release cylinder union bolt Nm 22
Clutch tube flare nut Nm 15
Clutch release cylinder and clutch damper mounting bolt Nm <F5M51> 18
Fulcrum Nm <F5M41, F5M42, W5M42> 35
Release fork shaft mounting bolt Nm <F5M51> 9.8
Specified torque
LUBRICANTS
Items
Clutch release bearing inner surface MITSUBISHI genuine grease Part No. 0101011 or
Release fork and fulcrum contact surface
<F5M41, F5M42, W5M42>
Specified lubricants
equivalent
Release fork and release bearing contact surface
Release fork and release cylinder push rod contact surface
Release fork and release fork shaft contact surface <F5M51>
Piston and piston cup outer surface Brake fluid SAE J1703 (DOT3)
Release cylinder inner surface
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
CLUTCH -
2. CLUTCH
REMOVAL AND INSTALLATION <F5M41>
18 Nm
2
3
15
Clutch
35 Nm
21B-2-1
1
14
10
Removal steps
1. Clutch fluid line bracket
2. Insulator
3. Washer
4. Clutch tube
5. Union bolt
6. Union
7. Gasket
8. Clutch release cylinder
9
12
4
5
11
13
7
22 Nm
6
15 Nm
18 Nm
8
TFM0595
9. Clutch cover
10. Clutch disc
11. Return clip
"BA 12. Clutch release bearing
AA""AA 13. Release fork
14. Release fork boot
15. Fulcrum
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
21B-2-2
CLUTCH -
Clutch
REMOVAL AND INSTALLATION
<F5M42-4G92-MIVEC, 4G64-GDI, 6A12-MIVEC, 6A13, W5M42>
18Nm
2
1
3
35 Nm
12
13
15
14
16
18
22 Nm
7
9
10
11
17
15 Nm
18 Nm
6
4
5
8
15 Nm
18 Nm
TFM0900
Removal steps
1. Clutch fluid line bracket
2. Insulator
3. Washer
4. Clutch tube (A)
5. Tube clip
6. Clutch tube
7. Union bolt
8. Union
9. Gasket
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
AA""AA 16. Release fork
10. Clutch release cylinder
11. Clutch damper
12. Clutch cover
13. Clutch disc
14. Return clip
"BA 15. Clutch release bearing
17. Release fork boot
18. Fulcrum
CLUTCH -
Clutch
REMOVAL AND INSTALLATION
<F5M42-4G93, 4G93-GDI (For SPACE RUNNER), 4G63, 4G64, 4D68>
18Nm
2
1
3
35 Nm
21B-2-1
21B-2-2a
9
10
12
11
13
15
22 Nm
14
4
5
7
6
15 Nm
8
18 Nm
Removal steps
1. Clutch fluid line bracket
2. Insulator
3. Washer
4. Clutch tube
5. Union bolt
6. Union
7. Gasket
8. Clutch release cylinder
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
AA""AA 13. Release fork
"BA 12. Clutch release bearing
9. Clutch cover
10. Clutch disc
11. Return clip
14. Release fork boot
15. Fulcrum
21B-2-2
b
CLUTCH -
Clutch
REMOVAL AND INSTALLATION <F5M42-4G93-GDI (For CARISMA)>
35 Nm
6
7
9
12
11
1
10
22 Nm
8
2
4
3
15 Nm
5
18 Nm
Removal steps
1. Clutch tube
2. Union bolt
3. Union
4. Gasket
5. Clutch release cylinder
6. Clutch cover
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
AA""AA 10. Release fork
"BA 9. Clutch release bearing
7. Clutch disc
8. Return clip
11. Release fork boot
12. Fulcrum
CLUTCH -
REMOVAL AND INSTALLATION <F5M51>
15
18Nm
Clutch
4
15 Nm
12
18 Nm
21B-2-1
21B-2-2c
5
15 Nm
13
14
2
1
3
9.8 Nm
11
16
10
9
7
8
6
22 Nm
24
23
22
20
20
25
21
18
17
19
Removal steps
1. Clutch fluid line bracket
2. Insulator
3. Washer
4. Clutch tube (A)
5. Clutch tube
6. Union bolt
7. Union
8. Gasket
9. Valve
10. Valve spring
11. Clutch release cylinder
12. Clutch damper
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Jun. 1998Mitsubishi Motors Corporation Added
PWEE9508-E
13. Clutch cover
14. Clutch disc
"EA 15. Sealing cap
16. Release fork shaft
17. Support spring (L)
18. Packing
"DA 19. Release fork
"CA 20. Bushing
"BA 21. Clutch release bearing
22. Packing
23. Support spring (R)
24. Release fork boot
25. Maintenance hole cover
21B-2-2
d
CLUTCH -
Clutch
Intentionally blank
E
Jun. 1998Mitsubishi Motors Corporation Added
PWEE9508-E
Release Fork
CLUTCH - Clutch
21B-2-3
REMOVAL SERVICE POINT
AA"
Move the release fork in the direction shown to remove the
clip from the fulcrum.
RELEASE FORK REMOVAL
Apply grease
Pack grease
<F5M41, F5M42, W5M42>
Pack grease
INSTALLATION SERVICE POINTS
"AA
Apply/pack grease to the illustrated positions of the release
fork.
"BA
Apply grease to the illustrated position of the clutch release
bearing.
RELEASE FORK INSTALLATION
Specified grease:
MITSUBISHI genuine grease part No. 0101011 or
equivalent
CLUTCH RELEASE BEARING INSTALLATION
Specified grease:
MITSUBISHI genuine grease Part No. 0101011 or
equivalent.
TFM0917
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
21B-2-4
<F5M51>
TFM0918
CLUTCH -
Clutch
Bushing
TFM0710
Apply grease
"CA
BUSHING INSTALLATION
Press in the bushing into the release fork to the position shown
in the illustration.
"DA
RELEASE FORK INSTALLATION
Apply/pack grease to the illustrated positions of the release
fork.
Specified grease:
MITSUBISHI genuine grease Part No. 0101011 or
equivalent
Apply grease
E
Pack grease
TFM0919
2mm
"EA
Press in the sealing cap to the position shown in the illustration.
SEALING CAP INSTALLATION
Be sure that it is not installed aslant.
TFM0712
Jan. 1997Mitsubishi Motors Corporation Revised
PWEE9508-C
21B-2-3
CLUTCH -
Clutch
21B-2-4a
INSPECTION
CLUTCH COVER
Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the
limit. <F5M41, F5M42, W5M42>
Limit: 0.5 mm
Check the pressure plate surface for wear, cracks and
discoloration.
Check the rivets of the strap plate for looseness. If loose,
replace the clutch cover.
Rivet sink
CLUTCH DISC
Caution
Don’t clean the clutch disc in a cleaning fluid.
Check the facing for loose rivets, uneven contact, evidence
of seizure, or deposited oils and greases. If defective, replace
the clutch disc.
Measure the rivet sink and replace the clutch disc if it is out
of specification.
Limit: 0.3 mm
Check the torsion spring for looseness and damage. If
defective, replace the clutch disc.
Combine the clutch disc with the input shaft and check for
sliding condition and play in the rotating direction. If poor
sliding condition is evident, clean, reassemble, and recheck.
If excessive looseness is evident, replace the clutch disc and/or
input shaft.
CLUTCH RELEASE BEARING
Caution
Release bearing is packed with grease. Therefore, do
not wash it in a cleaning fluid and the like.
Check for seizure, damage, noise or improper rotation.
Check for wear on the surface which contacts with the
diaphragm spring. <F5M41, F5M42, W5M42>
Check for wear on the surface which contacts with release
fork. If abnormally worn, replace.
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
21B-2-4
b
CLUTCH -
Clutch
<F5M51>
Check the pull ring for wear and replace the clutch release
bearing if necessary. <F5M51>
TFM0920
RELEASE FORK
If the surface which contacts with the bearing is abnormally
worn, replace.
RELEASE FORK SHAFT <F5M51>
Check the release fork shaft for bend and wear, and replace
if necessary.
E
Jan. 1997Mitsubishi Motors Corporation Added
PWEE9508-C
CLUTCH -
Clutch Release Cylinder
3. CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY <F5M41, F5M42, W5M42>
4
6
21B-3-1
8
Disassembly steps
1. Cap
2. Air bleeder
3. Push rod
4. Boot
7
11 Nm
5
2
1
AA""AA
AA""AA
3
TFM0594
5. Piston cup
6. Piston
7. Conical spring
8. Release cylinder
E
E
Nov. 1995Mitsubishi Motors Corporation Added
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-A
PWEE9508-E
21B-3-2
CLUTCH -
Clutch Release Cylinder
DISASSEMBLY AND REASSEMBLY <F5M51>
4
3
1
2
11 Nm
8
Disassembly steps
1. Cap
2. Air bleeder
3. Push rod
4. Boot
6
7
5
AA""AA
AA""AA
TFM0709
5. Piston cup
6. Piston
7. Conical spring
8. Release cylinder
DISASSEMBLY SERVICE POINT
AA"
Remove the piston from the release cylinder using compressed
air.
Caution
1. Cover with shop towel to prevent the piston from
2. Apply compressed air slowly to prevent brake fluid
E
E
Nov. 1995Mitsubishi Motors Corporation Added
Jan. 1997Mitsubishi Motors Corporation Revised
PISTON CUP / PISTON REMOVAL
popping out.
from splashing.
PWEE9508-A
PWEE9508-C
CLUTCH -
21B-3-1
Clutch Release Cylinder
21B-3-2a
REASSEMBLY SERVICE POINT
"AA
After applying brake fluid to the inside wall surface of the
release cylinder and all the circumferential surfaces of the
piston and piston cup, insert the piston and piston cup into
the cylinder.
PISTON / PISTON CUP INSTALLATION
Specified brake fluid:
Brake fluid SAE J1703 (DOT3)
INSPECTION
RELEASE CYLINDER
Check the inside wall surface of the release cylinder for rust
and damage.
Using a cylinder gauge, measure the inside diameter of the
release cylinder at about three positions (the deepest, middle
and brim positions). If the clearance from the outside diameter
of the piston exceeds the limit, replace the release cylinder
as an assembly.
Limit: 0.15 mm
E
E
Nov. 1995Mitsubishi Motors Corporation Added
Jan. 1997Mitsubishi Motors Corporation Added
PWEE9508-A
PWEE9508-C
NOTES
22A-0-1
MANUAL
TRANSMISSION
F5MR1, F5MR2, F5MR3
GENERAL INFORMATION 22A-0-3....................................
1. SPECIFICATIONS 22A-1-1.........................................
GENERAL SPECIFICATIONS 22A-1-1.............................
TORQUE SPECIFICATIONS 22A-1-1..............................
LUBRICANTS 22A-1-2...........................................
SEALANTS AND ADHESIVES 22A-1-2............................
2. SPECIAL TOOLS 22A-2-1.........................................
3. TRANSMISSION 22A-3-1..........................................
4. OUTPUT SHAFT 22A-4-1..........................................
5. DIFFERENTIAL 22A-5-1...........................................
6. CLUTCH HOUSING 22A-6-1.......................................
CONTENTS
7. CONTROL LEVER 22A-7-1........................................
8. INPUT SHAFT 22A-8-1............................................
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
22A-0-2
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9508
MANUAL TRANSMISSION (E- W) -
General Information
GENERAL INFORMATION
F5MR1, F5MR2 - Five-speed front wheel drive transmission
8765 4 3
22A-0-3
1
2
9101112 13 14151617
1. Clutch housing
2. Input shaft
3. Input shaft bearing
4. Transmission case
5. Input shaft bearing
6. Rear cover
7. 5th speed gear
8. 5th speed synchronizer assembly
9. 5th gear wheel
10. Output shaft
11. Output shaft bearing
12. 4th speed gear
13. 3rd - 4th speed synchronizer
assembly
25
24
2322
21201918
14. 3rd speed gear
15. 2nd speed gear
16. 1st - 2nd speed synchronizer
assembly
17. 1st speed gear
18. Guard ring
19. Spring ring
20. Differential bearing
21. Differential
22. Differential bearing
23. Snap ring
24. Snap ring
25. Output shaft bearing
E
May 1995Mitsubishi Motors Corporation
PWEE9508
22A-0-4
MANUAL TRANSMISSION (E- W) -
General Information
F5MR3 - Five-speed front wheel drive transmission
876 5 4
9
1
2
3
24
10 11 12 13 14 15 16 17
1. Clutch housing
2. Input shaft
3. Guide bushing
4. Input shaft bearing
5. Transmission case
6. Input shaft bearing
7. Rear cover
8. 5th speed gear
9. 5th speed synchronizer assembly
10. 5th gear wheel
11. Output shaft
12. Output shaft bearing
13. 4th speed gear
18
22
212019
23
RMT0001
14. 3rd - 4th speed synchronizer assembly
15. 3rd speed gear
16. 2nd speed gear
17. 1st - 2nd speed synchronizer assembly
18. 1st speed gear
19. Differential bearing
20. Differential
21. Differential bearing
22. Shim
23. Lock nut
24. Output shaft bearing
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Added
MANUAL TRANSMISSION (E- W) -
1. SPECIFICATIONS
GENERAL SPECIFICATIONS
Specifications
22A-1-1
Items
Model F5MR1 <For CARIS-
Type Manual, 5-speed,
Gear ratio 1st 3.363 3.727 3.727
2nd 2.047 2.047 2.047
3rd 1.321 1.321 1.321
4th 0.966 0.966 0.971
5th 0.794 0.794 0.756
Reverse 3.545 3.545 3.545
Final reduction ratio 4.066 4.214 3.437
Specifications
MA>, F5MR2
front wheel drive
F5MR1
<For SPACE STAR>
Manual, 5-speed,
front wheel drive
F5MR3
Manual, 5-speed,
front wheel drive
TORQUE SPECIFICATIONS
Items Specifications (Nm)
Bearing housing bolts 25
Input shaft lock nut 135
Output shaft bolt 80
Cover bolts 25
Locating pin 24
Back-up lamp switch 22
Drain plug 22
Filler/level plug 2.25
Sealing plugs 25
Guide bushing bolts <F5MR3> 25
Differential nut <F5MR3> 130
E
Jun. 1998Mitsubishi Motors Corporation Revised
PWEE9508-E
22A-1-2
LUBRICANTS
MANUAL TRANSMISSION (E- W) -
Specifications
Items
Transmission oil 3.4 L Elf Tranself TRX 75W - 80W (XT3556)
Rear cover O-ring As required Elf Tranself TRX 75W - 80W (XT3556)
All internal parts As required Elf Tranself TRX 75W - 80W (XT3556)
Shift lever As required Lithium MoS2
Shift lever bearing bush As required Lithium MoS2
Selector shaft oil seal As required Lithium MoS2
Speedometer driven gear As required Multi-purpose grease
Differential side gear As required Multi-purpose grease
Differential pinion gear As required Multi-purpose grease
Differential pinion washer As required Multi-purpose grease
Differential side oil seal As required Multi-purpose grease
Quantity Specified lubricant
SEALANTS AND ADHESIVES
Items
Specified sealants and adhesives
5th gear wheel on output shaft Loctite 242
5th gear wheel bolt Loctite 242
Plastic cover on release fork ball and socket joint Loctite 415
Transmission case mating surface Loctite 518
Locating pin for 5th gear Loctite 572
Back-up lamp switch Loctite 572
Differential nut <F5MR3> Loctite 270
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
MANUAL TRANSMISSION (E-W) -
2. SPECIAL TOOLS
Special Tools
22A-2-1
Tool
Number Name Use
MB990926 Installer Fitting shift rail assembly oil seal
MB990927 Installer Removing input shaft front bearing <F5MR1,
F5MR2>
MB990930 Installer Removing small differential bearing <F5MR1,
F5MR2>
MB990931 Installer Fitting output shaft bearing
MB990932 Installer Fitting input and output shaft rear bearings
MB990933 Installer Fitting input and output shaft rear bearing cups
<F5MR3>
MB990934 Installer Fitting small differential bearing <F5MR1,
F5MR2>
MB990938 Handle Various installers
MB996000 Spindle Fitting large and small bearing cups <F5MR3>
May 1996
E
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-2-2
MANUAL TRANSMISSION (E-W) -
Tool UseNameNumber
MB996001 Bearing puller Removing output shaft front bearing
MB996003 Socket wrench Removing and installing differential gear
MB996004 Bearing drift Fitting large and small bearing cups <F5MR3>
MB996005 Counterhold Removing and installing differential gear
Special Tools
<F5MR3>
<F5MR3>
MB996006 Bracket Removing output shaft front bearing
MB996007 Bearing bush drift Fitting selector shaft bushes
MB996008 Bearing drift Fitting large and small bearing cups <F5MR3>
MB996010 Oil seal drift Fitting differential gear assembly oil seal
MB996011 Bearing drift Fitting input shaft bearing cup <F5MR3>
May 1996
E
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E-W) -
Tool UseNameNumber
MB996012 Mounting plate Calculate the pre-tention of input and output
MB996013 Bearing drift Fitting output shaft bearing <F5MR3>
MD998019 Spring pin extractor Removing spring pins
MD998020 Bearing puller Removing 5th gear synchronizer hub
Special Tools
shafts with new bearings <F5MR3>
22A-2-3
MD998245 Spring pin installer Installation of spring pin and lock pin
MD998348 Bearing and gear
Removing 5th gear wheel
puller
MD998717 Installer Fitting input shaft front bearing <F5MR1,
F5MR2>
MD998801 Bearing remover Removing input and output shaft bearings
<F5MR3>
MD998812 Installer cap Fitting 4th gear wheel bearing bush <F5MR3>
May 1996
E
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
AddedPWEE9508-BMitsubishi Motors Corporation
22A-2-4
MANUAL TRANSMISSION (E-W) -
Tool UseNameNumber
MD998813 Installer - 100 Fitting 4th gear wheel bearing bush <F5MR3>
Special Tools
MD998819 Installer adapter
(40)
Fitting 4th gear wheel bearing bush <F5MR3>
May 1996
E
E
May 1996Mitsubishi Motors Corporation
PWEE9508-B
Revised
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
3. TRANSMISSION
DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2>
Transmission
22A-3-1
21
20
10
19
80 Nm
9
18
15
17
38 Nm
22
3
2
14
16
8
24 Nm
135 Nm
11
12
5
4
25
24
13
23
1
22 Nm
7
6
25 Nm
22 Nm
Lubricate all internal
parts with gear oil
during reassembly.
"ZA
AA""YA
AA""YA
AA""YA
AB""WA
AB""WA
AB""WA
AC""XA
AC""VA
E
E
Disassembly steps
1. Back-up lamp switch
2. Drain plug
3. Gasket
4. Filler plug
5. Gasket
6. Bolt
7. Rear cover
8. O-ring
9. Bolt
10. Shim
11. Lock nut
12. Spring pin
13. 5th speed shift fork
May 1996
May 1995Mitsubishi Motors Corporation
PWEE9508
AC""VA
AD""VA
AD""VA
AD""TA
AD""TA
AD""TA
AD""TA
AE""UA
AF""SA
AG""RA
AG""RA
AG""RA
14. Synchronizer sleeve
15. Synchronizer spring
16. Synchronizer hub
17. Synchronizer ring
18. 5th speed gear
19. Bearing sleeve
20. Retaining ring
21. 5th gear wheel
22. Locating pin
23. Cover plate
24. Poppet spring
25. Poppet ball
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-3-2
MANUAL TRANSMISSION (E- W) -
41
Transmission
28
39
33
34
36
40
26
25 Nm
32
35
30
42
27
38
37
29
45
44
43
31
Lubricate all internal
parts with gear oil
during reassembly.
46
Disassembly steps
26. Bolt
AH""QA
AH""QA
AH""QA
AI""PA
AI""NA
AJ""JA
AJ""JA
AK""KA
AL""JA
AL""HA
27. Transmission case
28. Poppet spring
29. Poppet ball
30. Magnet
31. 5th gear shift rail assembly
32. Spring pin
33. 1st and 2nd shift rail assembly
34. Reverse idler gear shaft
35. Spring pin
36. 3rd and 4th shift rail assembly
AL""HA
AL""HA
AN""FA
AO""EA
AP""DA
AP""DA
AQ""CA
AR""AA
AR""AA
AR""AA
37. Output shaft
38. Input shaft
39. Interlock plungers
40. Plastic cover
41. Breather unit
42. Breather hose
43. Oil guide
44. Output shaft rear bearing
45. Input shaft rear bearing
46. Snap ring
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY AND REASSEMBLY <F5MR3>
Transmission
22A-3-2a
Lubricate all internal
parts with gear oil
during reassembly.
21
20
10
19
80 Nm
9
18
17
15
16
8
14
135 Nm
11
13
7
12
6
25 Nm
1
22 Nm
Disassembly steps
"ZA
AA""YA
AA""YA
AA""YA
AB""WA
AB""WA
AB""WA
AC""XA
AC""VA
1. Backup lamp switch
2. Drain plug
3. Gasket
4. Filler plug
5. Gasket
6. Bolt
7. Rear cover
8. O-ring
9. Bolt
10. Shim
11. Lock nut
12. Spring pin
13. 5th speed shift fork
3
2
38 Nm
22
24 Nm
AC""VA
AD""VA
AD""VA
AD""TA
AD""TA
AD""TA
AD""TA
AE""UA
AF""SA
AG""RA
AG""RA
AG""RA
5
4
22 Nm
25
23
24
14. Synchronizer sleeve
15. Synchronizer spring
16. Synchronizer hub
17. Synchronizer ring
18. 5th speed gear
19. Bearing sleeve
20. Retaining ring
21. 5th gear wheel
22. Locating pin
23. Cover plate
24. Poppet spring
25. Poppet ball
RMT0002
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-3-2b
Lubricate all internal
parts with gear oil
during reassembly.
MANUAL TRANSMISSION (E- W) -
41
Transmission
28
39
33
34
36
40
32
35
30
42
27
29
45
44
38
37
43
31
26
25 Nm
Disassembly steps
26. Bolt
AH""QA
AH""QA
AH""QA
AI""PA
AI""NA
AJ"
AJ"
AK""LA
27. Transmission case
28. Poppet spring
29. Poppet ball
30. Magnet
31. 5th gear shift rail assembly
32. Spring pin
33. 1st - 2nd gear shift rail assembly
34. Reverse idler gear shaft
35. Spring pin
"OA
AM""MA
AM""IA
AN""GA
AO""EA
AP""DA
AP""DA
AQ""CA
AS""BA
AS""BA
RMT0003
36. 3rd - 4th gear shift rail assembly
37. Output shaft
38. Input shaft
39. Interlock plungers
40. Plastic cover
41. Breather unit
42. Breather hose
43. Oil guide
44. Output shaft rear bearing cup
45. Input shaft rear bearing cup
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY SERVICE POINTS
AA"
(1) Remove the bolts and lift off the rear cover carefully to
(2) Remove the O-ring.
BOLT/REAR COVER/O-RING REMOVAL
avoid damaging the oil pipe on the rear cover.
Transmission
22A-3-3
3
5
6
MD998019
1
2
MD998020
AB"
BOLT/SHIM/LOCK NUT REMOVAL
(1) Engage two gears: first engage reverse gear and then
push the 5th gear synchronizer sleeve over the 5th speed
gear.
(2) Remove the bolt 1, shim 2 and lock nut 3.
AC"
SPRING PIN/5TH SPEED SHIFT FORK/
SYNCHRONIZER SLEEVE REMOVAL
(1) Support the shift rail assembly and remove the spring
pin with spring pin extractor MD998019.
(2) Tap the 5th speed shaft fork 4 together with the
synchronizer 5 off the shift rail assembly.
NOTE
Do not lose the spring pin.
AD"
SYNCHRONIZER HUB/SYNCHRONIZER RING/
SYNCHRONIZER SPRING/5TH SPEED GEAR/
7
BEARING SLEEVE/RETAINING RING REMOVAL
(1) Locate bearing puller MD998020 with attachments No.85
8
under the teeth of the synchronizer hub.
(2) Pull the synchronizer hub off the shaft.
(3) Remove the 5th speed gear 6, bearing sleeve 7 and
retaining ring 8.
AE"
5TH GEAR WHEEL REMOVAL
(1) Locate gear puller MD998348 over the 5th gear wheel.
MD998348
E
May 1995Mitsubishi Motors Corporation
(2) Pull the gear wheel off the shaft.
PWEE9508
22A-3-4
MANUAL TRANSMISSION (E- W) -
Transmission
<F5MR1, F5MR2>
AF"
LOCATING PIN REMOVAL
Unscrew and remove the locating pin.
NOTE
Do not lose the adjusting ring (if fitted).
AG"
COVER PLATE/POPPET SPRING/POPPET BALL
REMOVAL
Remove the cover plate and withdraw the poppet spring and
ball.
NOTE
Do not lose the poppet spring and ball.
<F5MR3>
RMT0004
9
AH"
TRANSMISSION CASE/POPPET BALL/POPPET
SPRING REMOVAL
(1) Remove the retaining bolts.
(2) Tap lightly to separate the transmission case and clutch
housing.
(3) Remove the transmission case; note the shim on the
output shaft.
NOTE
When removing the transmission case, hold the poppet
springs and balls of both selector shafts in position with
two hex nut drivers.
AI"
MAGNET/5TH GEAR SHIFT RAIL ASSEMBLY
REMOVAL
(1) Remove the magnet from the clutch housing.
(2) Remove the shift rail assembly 9 from the transmission
case.
NOTE
Catch the poppet spring and ball and put them to one
side.
May 1996
May 1996
E
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Transmission
22A-3-5
<F5MR1, F5MR2>
MD998019
<F5MR3>
10
MD998019
<F5MR1, F5MR2>
10
RMT0005
AJ"
SPRING PIN/1ST AND 2ND GEAR SHIFT RAIL
ASSEMBLY REMOVAL
(1) Cover the differential drive gear with a cleaning rag.
(2) Tap out the spring pin as far as possible with spring pin
extractor MD998019.
(3) Move 3rd and 4th gear into neutral.
(4) Raise the reverse gear shaft as high as possible and
remove the shift rail assembly 10.
AK"
REVERSE IDLER GEAR SHAFT REMOVAL
(1) Raise the input and output shafts.
(2) Take the reverse idler gear shaft out of the clutch housing.
NOTE
Hold the output shaft at the bottom.
<F5MR3>
<F5MR1, F5MR2>
RMT0006
(3) Inspect the reverse idler gear shaft.
NOTE
The shaft must always be renewed in the event of wear
or damage. The shaft cannot be reconditioned.
May 1996
May 1996
E
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-3-6
<F5MR3>
MANUAL TRANSMISSION (E- W) -
RMT0007
Transmission
AL"
SPRING PIN/3RD AND 4TH SHIFT RAIL ASSEMBLY/
INPUT SHAFT/OUTPUT SHAFT REMOVAL
(1) Remove the spring pin from the 3rd and 4th gear selector
fork.
(2) Take both shafts together with the shift rail assembly
out of the clutch housing.
(3) Inspect the input shaft.
NOTE
The shaft must always be renewed in the event of wear
or damage. The shaft cannot be reconditioned.
AM"
INPUT SHAFT/OUTPUT SHAFT REMOVAL
(1) Take the two shafts out of the clutch housing together.
RMT0008
(2) Inspect the input shaft.
NOTE
The shaft must always be replaced in the event of wear
or damage. The shaft cannot be reconditioned.
RMT0009
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Transmission
22A-3-7
<F5MR1, F5MR2>
AN"
INTERLOCK PLUNGERS REMOVAL
Remove the three interlock plungers and the small interlock
plunger from the 1st and 2nd gear shift rail assembly.
AO"
PLASTIC COVER REMOVAL
Remove the plastic cover from the release fork ball and socket
joint.
<F5MR3>
RMT0010
11
AP"
BREATHER UNIT/BREATHER HOSE REMOVAL
Take the breather unit out of the transmission case. Carefully
remove the breather hose.
AQ"
OIL GUIDE REMOVAL
Push in the lug 11 and withdraw the oil guide from the
transmission case.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-3-8
MANUAL TRANSMISSION (E- W) -
Transmission
MB990938
MB990931
RMT0011
AR"
OUTPUT SHAFT REAR BEARING/INPUT SHAFT
REAR BEARING/SNAP RING REMOVAL
(1) Open the snap rings with a pair of pliers.
(2) Tap out the bearings towards the inside of the transmission
case with a plastic-tip hammer.
(3) Remove the two snap rings.
AS"
REAR BEARING CUP OUTPUT SHAFT/REAR
BEARING CUP INPUT SHAFT REMOVAL
(1) Tap the bearing cups out of the transmission case with
handle MB990938 and bearing installer MB990931.
MB996012
RMT0012
ADJUSTMENT BEFORE REASSEMBLY
<F5MR3>
CALCULATE THE PRE-TENSION OF THE INPUT AND
OUTPUT SHAFTS WITH NEW BEARINGS
(1) Introduce the input shaft and the output shaft in the clutch
housing.
(2) Place the transmission case on the clutch housing, insert
a few retaining bolts around the shafts and tighten the
bolts.
(3) Locate the mounting plate MB996012 on the tripod joint
housing and secure it with a bolt.
(4) Locate the magnetic base together with clock gauge on
the mounting plate.
Input shaft
(5) Rotate the input shaft a few times.
(6) Raise the input shaft at the clutch end and read off the
value indicated by the clock gauge.
Repeat this operation several times.
Example A B
new used
bearings bearings
pre-tension
value 0.00 mm -0.03 mm
shim thickness +0.60 mm +0.60 mm
measured value +0.46 mm +0.46 mm
=1.06 mm =1.03 mm
Select:
A: a shim with a thickness of 1.10 mm
B: a shim with a thickness of 1.50 mm
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Output shaft
(7) Rotate the output shaft a few times.
(8) Raise the output shaft at the clutch end and read off
the value indicated by the clock gauge.
Repeat this operation several times.
Transmission
22A-3-9
MB996012
MB990938
MB990932
1
RMT0013
Example A B
new used
bearings bearings
pre-tension
value 0.26 mm 0.06 mm
shim thickness +1.60 mm +1.60 mm
measured value +0.28 mm +0.28 mm
=2.14 mm =1.94 mm
Select:
A: a shim with a thickness of 2.15 mm
B: a shim with a thickness of 1.95 mm
NOTE
Always use the thickest shim in order to obtain the required
pre-tension value.
(9) Remove the transmission case and the input shaft and
output shaft.
REASSEMBLY SERVICE POINTS
"AA
(1) Coat the mating faces in the transmission case with the
(2) Locate the two snap rings 1.
(3) Introduce the bearings from the outside of the transmission
(4) Open the snap rings with a pair of pliers and tap in the
(5) Remove the pliers.
(6) Now tap the bearings further into the transmission case
SNAP RING/INPUT SHAFT REAR BEARING/OUTPUT
SHAFT REAR BEARING INSTALLATION
specified sealant.
case with the groove facing up.
bearings with a plastic-tip hammer until they are projecting
about 3 mm above the transmission case.
with handle MB990938 and bearing installer set
MB990932 until the snap rings slip into the grooves.
E
E
MB990938
MB990933
May 1996
May 1995Mitsubishi Motors Corporation
RMT0014
"BA
INPUT SHAFT REAR BEARING CUP/OUTPUT
SHAFT REAR BEARING CUP INSTALLATION
(1) Coat the mating faces in the transmission case with the
specified sealant.
(2) Introduce the bearing cups from the inside of the
transmission case.
(3) Tap the bearing cup into the transmission case as far
as the stop with handle MB990938 and installer
MB990933.
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-3-10
MANUAL TRANSMISSION (E- W) -
Transmission
<F5MR1, F5MR2>
"CA
OIL GUIDE INSTALLATION
Locate the oil guide in the transmission case.
Caution
2
Make sure that the locking lug 2 of the oil guide is
correctly positioned.
"DA
BREATHER HOSE/BREATHER UNIT INSTALLATION
Push the breather hose into the transmission case. Fit the
breather unit.
"EA
PLASTIC COVER INSTALLATION
(1) Thoroughly clean the ball and socket joint.
(2) Apply Loctite 415 to the ball joint.
(3) Fit a new plastic cover on the ball and socket joint (press
down firmly).
<F5MR3>
RMT0010
"FA
INTERLOCK PLUNGERS INSTALLATION
Fit the three interlock plungers.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Transmission
22A-3-11
3
RMT0015
RMT0016
4
5
"GA
INTERLOCK PLUNGER INSTALLATION
(1) Fit the dowel pin.
(2) Fit the two short interlock plungers.
"HA
INPUT SHAFT/OUTPUT SHAFT/3RD AND 4TH SHIFT
RAIL ASSEMBLY INSTALLATION
(1) Locate the 1st and 2nd gear selector fork 3 in the
synchronizer hub.
(2) Locate the shift rail assembly 4 together with the selector
fork 5 in the synchronizer sleeve.
(3) Locate the three shafts in the clutch housing.
NOTE
When fitting the input shaft, take care not to damage
the oil seal.
"IA
INPUT SHAFT INSTALLATION
NOTE
When fitting the input shaft, take care not to damage the
oil seal.
RMT0017
"JA
1ST AND 2ND SHIFT RAIL ASSEMBLY/SPRING PIN
INSTALLATION
6
(1) Fit the small interlock plunger 6 in the shift rail assembly.
(2) Introduce the shift rail assembly 7 through the selector
fork in the housing.
7
(3) Check the operation of the interlock plungers.
(4) Fit a new (short) spring pin in the selector fork.
NOTE
The slit in the spring pin must be in axial alignment with
the shift rail assembly.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-3-12
MANUAL TRANSMISSION (E- W) -
Transmission
"KA
REVERSE IDLER GEAR SHAFT INSTALLATION
(1) Raise the input and output shafts slightly.
(2) Locate the reverse idler gear shaft 8.
(3) Put the shafts into neutral so that the interlock plungers
are lying clear.
8
"LA
REVERSE IDLER GEAR SHAFT INSTALLATION
(1) Raise the input shaft slightly.
(2) Locate the reverse idler gear shaft.
RMT0018
"MA
OUTPUT SHAFT INSTALLATION
(1) Fit the small dowel pin in the shift rail assembly.
(2) Raise the reverse idler gear shaft slightly and push the
long dowel pin into the hole.
(3) Locate the shift rail assembly together with the 1st and
2nd gear shift fork in the synchronizer sleeve.
(4) Locate the two shafts in the clutch housing.
E
E
May 1996
May 1995Mitsubishi Motors Corporation
RMT0019
9
RMT0020
"NA
5TH GEAR SHIFT RAIL ASSEMBLY INSTALLATION
(1) Locate the shift rail assembly 9.
(2) Fit the poppet spring and ball.
(3) Depress the ball and raise the shift rail assembly until
the ball engages the second recess (neutral position).
NOTE
Put the shift rail assembly into neutral so that the interlock
plungers are lying clear.
"OA
3RD/4TH GEAR SHIFT RAIL ASSEMBLY
INSTALLATION
(1) Raise the reverse idler gear shaft slightly.
(2) Locate the shift rail assembly together with the 3rd and
4th gear shift fork in the synchronizer sleeve.
(3) Locate the shaft in the clutch housing.
Fit a new spring pin in the shift fork (it must be fully
inserted in the shift fork).
NOTE
The slit in the spring pin must be in axial alignment with
the shift rail assembly.
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Transmission
22A-3-13
<F5MR1, F5MR2>
<F5MR3>
"PA
MAGNET INSTALLATION
Fit the magnet in the differential housing.
"QA
POPPET BALL/POPPET SPRING/TRANSMISSION
CASE INSTALLATION
(1) Apply liquid gasket cement (Loctite 518) to the mating
face.
NOTE
Do not apply too much gasket cement. Let the gasket
cement dry for at least thirty minutes before filling the
manual transmission with oil.
(2) Locate the transmission case over the shafts.
(3) Locate the balls and poppet springs for the 1st, 2nd,
3rd and 4th gear shift rail assemblies, using two hex
nut drivers.
(4) Now press the transmission case on to the mating face,
insert some of the retaining bolts and secure them
finger-tight.
NOTE
If necessary, push up the 5th gear shift rail assembly
a short distance.
<F5MR1, F5MR2>
RMT0021
<F5MR3>
"RA
POPPET BALL/POPPET SPRING/COVER PLATE
INSTALLATION
(1) Pull the reverse idler gear shaft upwards with a wire hook.
(2) Locate the ball and poppet spring and fit the retainer
plate (with the bulge underneath).
RMT0022
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-3-14
MANUAL TRANSMISSION (E- W) -
(3) Rotate the input shaft and check whether the remote
control arm can move freely.
(4) Check that all the gears can be engaged and disengaged.
Transmission
A
A
C
A
B
A
B
A
A
C
A
B
A
B
A
A
B
C
A
B
<F5MR1,
F5MR2>
B
B
B
B
<F5MR3>
B
C
B
RMT0023
(5) Fit the bolts as shown in the illustration.
NOTE
The bolts have three different lengths:
A = long (45 mm)
B = medium (40 mm)
C = short (35 mm)
B
B
B
"SA
LOCATING PIN INSTALLATION
(1) Apply sealant (Loctite 572) to the locating pin.
(2) Fit and tighten the locating pin.
10
"TA
RETAINING RING/BEARING SLEEVE/5TH SPEED
GEAR/SYNCHRONIZER RING INSTALLATION
(1) Locate the retaining ring 10 on the shaft with the collar
facing towards the bearing.
(2) Locate the bearing sleeve 11 over the input shaft.
(3) Locate the 5th speed gear together with the synchronizer
11
May 1996
E
E
May 1995Mitsubishi Motors Corporation
ring over the shaft.
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Transmission
22A-3-15
1314
135 Nm
12
80 Nm
15
"UA
5TH GEAR WHEEL INSTALLATION
(1) Apply a few drops of sealant (Loctite 242) to the gear
wheel.
(2) Fit the gear wheel on the shaft.
(3) Press the gear wheel with the bolt and shim on to the
output shaft.
(4) Remove the bolt and shim.
"VA
SYNCHRONIZER HUB/SYNCHRONIZER SPRING/
SYNCHRONIZER SLEEVE/5TH SPEED SHIFT FORK
INSTALLATION
(1) Fit the hub in the synchronizer sleeve.
(2) Locate the synchronizer spring 12 at the bottom in the
recess.
(3) Locate the selector fork 13 in the synchronizer hub 14
with the long side facing towards the transmission case.
(4) Fit the hub over the input shaft and at the same time
slide the selector fork over the shift rail assembly.
(5) Press the hub on to the input shaft with the old lock
nut.
(6) Remove the lock nut.
"WA
LOCK NUT/SHIM/BOLT INSTALLATION
(1) Press the synchronizer hub into 5th gear.
(2) Push down the reverse idler gear shaft.
(3) Fit and tighten a new lock nut.
(4) Locate the shim 15.
(5) Apply a few drops of sealant (Loctite 242) to the bolt.
(6) Fit and tighten the bolt.
25 Nm
NOTE
Put the gears in neutral.
"XA
SPRING PIN INSTALLATION
(1) Raise the selector fork.
(2) Fit a new (long) spring pin in the selector fork.
(3) Tap in the spring pin to its full extent.
NOTE
The slit in the spring pin must be in axial alignment with
the reverse idler gear shaft.
(4) Check for correct operation.
"YA
O-RING/REAR COVER/BOLT INSTALLATION
(1) Place a new O-ring on the transmission case.
(2) Locate the rear cover carefully on account of the oil guide.
(3) Fit and tighten the bolts.
25 Nm
E
E
25 Nm
May 1996
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-3-16
MANUAL TRANSMISSION (E- W) -
Transmission
"ZA
BACK-UP LAMP SWITCH INSTALLATION
(1) Apply sealant (Loctite 572) to the back-up lamp switch.
(2) Fit and tighten the back-up lamp switch.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
4. OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2>
Output Shaft
22A-4-1
3
15
14
2
1
11
12
13
10
9
8
6
5
24
7
4
23
21
20
22
19
18
17
16
Disassembly steps
1. Shim
AA""NA
AG"
AG"
AB""KA
AC""IA
2. 4th gear wheel
3. Synchronizer ring
4. 3rd - 4th synchronizer sleeve
5. Synchronizer springs
6. Rollers
7. 3rd - 4th synchronizer hub
8. Snap ring
9. Serrated ring
10. Synchronizer ring
11. 3rd gear wheel
12. Serrated ring
13. Snap ring
AD""FA
AG"
AG"
AE""DA
AF""AA
25
Lubricate all internal
parts with gear oil
during reassembly.
14. Serrated ring
15. 2nd gear wheel
16. Serrated ring
17. Snap ring
18. Synchronizer ring
19. 1st - 2nd synchronizer sleeve
20. Synchronizer springs
21. Rollers
22. 1st - 2nd synchronizer hub
23. Synchronizer ring
24. 1st gear wheel
25. Output shaft
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-4-2
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY AND REASSEMBLY <F5MR3>
Output Shaft
4
13
12
3
11
2
1
8
5
10
7
9
6
5
16
18
19
15
17
16
14
21
Lubricate all internal
parts with gear oil
during reassembly.
Disassembly steps
1. Bearing
2. Shim
AA""OA
AH""MA
AI"
"LA
AH""JA
AH""HA
3. 4th gear wheel
4. Synchronizer ring
5. Bearing bushing
6. 3rd - 4th gear synchronizer sleeve
7. Synchronizer spring
8. Roller
9. 3rd - 4th gear synchronizer hub
10. 3rd gear wheel
11. Bearing bushing
AH""GA
AH""EA
AI""BA
AH""DA
AH""AA
AJ""CA
20
RMT0024
12. Shim
13. 2nd gear wheel
14. Bearing bushing
15. 1st - 2nd gear synchronizer sleeve
16. Synchronizer spring
17. 1st - 2nd gear synchronizer hub
18. Synchronizer ring
19. 1st gear wheel
20. Output shaft
21. Bearing cup
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Output Shaft
22A-4-3
<F5MR1, F5MR2>
<F5MR3>
1
RMT0025
DISASSEMBLY SERVICE POINTS
AA"
(1) Remove the shim 1. <F5MR1, R5MR2>
(2) Remove the bearing and the shim. <F5MR3>
(3) Take the gear wheel and synchronizer ring off the shaft.
AB"
Take the hub together with the synchronizer sleeve off the
shaft.
4TH GEAR WHEEL REMOVAL
3RD - 4TH SYNCHRONIZER HUB REMOVAL
2
3
7
5
6
4
AC"
3RD GEAR WHEEL REMOVAL
(1) Remove the snap ring 2.
(2) Take the blocker ring 3 together with the gear wheel and
synchronizer ring off the shaft.
(3) Remove the serrated ring 4.
AD"
2ND GEAR WHEEL REMOVAL
(1) Remove the snap ring 5.
(2) Take the gear wheel together with the synchronizer ring
and the serrated ring 6 off the shaft.
(3) Remove the serrated ring 7.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-4-4
MANUAL TRANSMISSION (E- W) -
Output Shaft
AE"
1ST - 2ND SYNCHRONIZER HUB REMOVAL
(1) Remove the snap ring 8.
8
(2) Take the hub together with the synchronizer sleeve off
the shaft.
AF"
1ST GEAR WHEEL REMOVAL
Take the gear wheel together with the synchronizer ring off
the shaft.
AG"
9
(1) Press the hub 9 out of the synchronizer sleeve.
(2) Remove the rollers 10 and springs 11.
SYNCHRONIZER SPRINGS/ROLLERS REMOVAL
NOTE
11
Make sure that no parts are lost.
10
RMT0026
AH"
OUTPUT SHAFT FROM/GEAR WHEELS
REMOVAL
(1) Place the output shaft under a press and support the
1st gear wheel.
(2) Press the output shaft completely out of the bearing
bushes of the gear wheels.
NOTE
The bearing bush of the 1st gear wheel cannot be
disassembled.
AI"
SYNCHRONIZER SPRINGS REMOVAL
(1) Press the hub out of the synchronizer sleeve.
(2) Remove the two springs.
NOTE
Make sure that none of the parts are lost.
RMT0027
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Output Shaft
22A-4-5
MD998801
RMT0028
RMT0029
AJ"
BEARING CUP/OUTPUT SHAFT REMOVAL
(1) Place the output shaft on a soft surface.
(2) Tap the bearing cup partway off the output shaft with
a chisel.
(3) Locatethe bearing remover MD998801 behind the bearing
cup.
(4) Press the output shaft out of the bearing cup.
PREPARATION BEFORE REASSEMBLY
<F5MR3>
BEARING BUSHES INSTALLATION
(1) Place the three bearing bushings on a hot plate.
(2) Heat the bearing bushings to 150°C maximum.
AB
RMT0030
MB996013
REASSEMBLY SERVICE POINTS
"AA
Locate the gear wheel together with the synchronizer ring
on the shaft.
"BA
(1) Place the hub on a workbench.
(2) Position the two synchronizer springs so that the wider
(3) Locate the synchronizer sleeve on the hub.
"CA
(1) Place the output shaft under a press and support the
(2) Press the bearing cup on to the output shaft with bearing
1ST GEAR WHEEL INSTALLATION
SYNCHRONIZER SPRINGS INSTALLATION
sections engage the recesses in the hub.
NOTE
Take special note of the engaging sleeve lugs.
OUTPUT SHAFT BEARING CUP INSTALLATION
1st gear wheel.
drift MB996013.
RMT0031
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-4-6
MANUAL TRANSMISSION (E- W) -
Output Shaft
"DA
1ST - 2ND SYNCHRONIZER HUB INSTALLATION
(1) Place the hub on a workbench.
(2) Locate the synchronizer sleeve on the hub with the groove
for the selector fork facing up; see the illustration.
(3) Locate the three synchronizer springs together with the
rollers in the hub.
NOTE
Always use new synchronizer springs.
8
<F5MR1, F5MR2>
(4) Locate the hub together with the synchronizer sleeve
on the shaft.
(5) Fit a new snap ring 8 <F5MR1, F5MR2> or synchronizer
ring <F5MR3>.
NOTE
Make sure that the lugs of the synchronizer ring engage
the recesses in the synchronizer sleeve.
<F5MR3>
7
5
6
RMT0033
RMT0034
"EA
2ND GEAR WHEEL BEARING BUSH
INSTALLATION
(1) Locate the bearing bush so that the oil passages of the
bearing bush and the output shaft are opposed.
(2) Place the heated bearing bush, using a pair of gripping
pliers, over the output shaft on the synchronizer hub.
NOTE
Allow the bearing bush to cool and then lubricate copiously
with transmission fluid.
"FA
2ND GEAR WHEEL INSTALLATION
(1) Locate the serrated ring 7 (thickness: 1.5 mm) with the
bevelled edge facing towards the gear wheel.
(2) Locate the gear wheel together with the synchronizer
ring on the shaft.
(3) Fit the serrated ring 6 (thickness: 2.5 mm) with the bevelled
edge facing towards the gear wheel.
(4) Fit a new snap ring 5.
NOTE
Make sure that the lugs of the synchronizer ring engage
the recesses in the synchronizer sleeve.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Output Shaft
22A-4-7
3
RMT0035
RMT0036
4
"GA
2ND GEAR WHEEL INSTALLATION
(1) Locate the gear wheel on the bearing bush.
(2) Fit the shim.
"HA
3RD GEAR WHEEL BEARING BUSH
INSTALLATION
(1) Locate the bearing bush so that the oil passages of the
bearing bush and the output shaft are opposed.
(2) Place the heated bearing bush, using a pair of gripping
pliers, over the output shaft on the shim.
NOTE
Allow the bearing bush to cool and then lubricate copiously
with transmission fluid.
"IA
3RD GEAR WHEEL INSTALLATION
(1) Locate the serrated ring 4 (thickness: 1.5 mm) with the
bevelled edge facing towards the gear wheel.
(2) Locate the gear wheel together with the synchronizer
ring on the shaft.
2
(3) Locate the serrated ring 2 (thickness: 1.5 mm) with the
bevelled edge facing towards the gear wheel.
(4) Fit a new snap ring 3.
NOTE
Make sure that the lugs of the synchronizer ring engage
the recesses in the synchronizer sleeve.
"JA
3RD GEAR WHEEL INSTALLATION
(1) Locate the gear wheel together with the synchronizer
ring on the bearing bush.
RMT0037
"KA
3RD - 4TH SYNCHRONIZER HUB INSTALLATION
(1) Place the hub on a workbench.
(2) Locate the synchronizer sleeve on the hub with the groove
for the selector fork facing up; see the illustration.
(3) Locate the three synchronizer springs together with the
rollers in the hub.
NOTE
Always use new synchronizer springs.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-4-8
MANUAL TRANSMISSION (E- W) -
(4) Locate the hub together with the synchronizer sleeve
on the shaft with the teeth facing towards the gear wheels.
NOTE
Make sure that the lugs of the synchronizer ring engage
the recesses in the synchronizer sleeve.
Output Shaft
RMT0058
RMT0038
"LA
3RD - 4TH GEAR SYNCHRONIZER HUB
INSTALLATION
Locate the hub together with the synchronizer sleeve, with
the groove for the shift fork facing up.
"MA
4TH GEAR WHEEL BEARING BUSH
INSTALLATION
(1) Locate the bearing bush so that the oil passages of the
bearing bush and the output shaft are opposed.
(2) Place the heated bearing bush, using a pair of gripping
pliers, over the output shaft on the synchronizer hub.
NOTE
Allow the bearing bush to cool and then lubricate copiously
with transmission fluid.
(3) Check that the bearing bush is flush with the mating face
of the output shaft and the shim. Bring the bearing bush
to the same height as the mating face.
E
E
MD998812
MD998813
MD998819
May 1996
May 1995Mitsubishi Motors Corporation
RMT0039
RMT0040
(4) Place the output shaft under a press.
(5) Press the bearing bush down with drift installer cap
MD998812, installer - 100 MD998813, installer adapter
MD998819 until the drift abuts the mating face of the
shim.
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Output Shaft
22A-4-9
RMT0041
1
"NA
4TH GEAR WHEEL INSTALLATION
(1) Locate the gear wheel together with the synchronizer
ring on the shaft.
(2) Fit the shim 1.
NOTE
Make sure that the lugs of the synchronizer ring engage
the recesses in the synchronizer sleeve.
"OA
4TH GEAR WHEEL INSTALLATION
(1) Locate the synchronizer ring.
(2) Locate the gear wheel on the bearing bush.
(3) Fit the shim.
NOTE
In the case of old bearings: fit the old shim.
In the case of new bearings: fit a shim with a thickness
of 1.6 mm.
(4) Fit the bearing.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-4-10
NOTES
MANUAL TRANSMISSION (E- W) -
Output Shaft
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
PWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
5. DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2>
Differential
22A-5-1
8
9
14
10
11
12
7
6
16
15
13
5
1
4
Disassembly steps
1. O-ring
AA""HA
AB""GA
AD""EA
AD""EA
AD""EA
2. Oil seal
3. Snap ring
4. Speedometer drive gear
5. Spring ring
6. Guard ring
7. Differential case
8. Snap ring
3
2
AF""CA
AG""BA
AH""AA
Lubricate all internal
parts with gear oil
during reassembly.
9. Shim
10. Side gear
11. Spring pin
12. Bush
13. Shaft
14. Pinion gear
15. Washer
16. Side gear
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-5-2
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY AND REASSEMBLY <F5MR3>
Differential
Lubricate all internal
parts with gear oil
during reassembly.
6
10
13
9
7
8
11
12
15
14
5
1
4
3
Disassembly steps
1. O-ring
AA""HA
AC""FA
AE""DA
2. Oil seal
3. Nut
4. Guard ring
5. Speedometer drive gear
6. Differential case
7. Snap ring
8. Shim
2
RMT0042
AF""CA
AG""BA
AH""AA
9. Side gear
10. Spring pin
11. Bushing
12. Shaft
13. Pinion gear
14. Washer
15. Side gear
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY SERVICE POINTS
AA"
(1) Remove the O-ring.
(2) Tap the oil seal inwards at one side and remove it at
OIL SEAL REMOVAL
the other side.
Differential
22A-5-3
MB996003
+1mm
MB996005
AB"
SNAP RING REMOVAL
(1) Place the clutch housing under a press and support the
differential gear assembly.
(2) Press the clutch housing downwards (1 mm).
(3) Make sure that the bearing abuts accurately against its
seating.
NOTE
The open side of the bearing must be facing inwards.
(4) Support the clutch housing and press cut the differential
assembly out.
AC"
DIFFERENTIAL GEAR ASSEMBLY REMOVAL
(1) Lock the differential gear assembly with counterhold
MB996005.
(2) Remove the nut with socket wrench MB996003.
(3) Remove the counterhold and take out the differential gear
assembly.
(4) Remove the shim.
(5) Take out the bearing.
RMT0043
AD"
SPEEDOMETER DRIVE GEAR/SPRING RING/
GUARD GEAR REMOVAL
(1) Take the speedometer drive gear off the differential.
(2) Remove the spring ring.
(3) Remove the guard ring.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-5-4
MANUAL TRANSMISSION (E- W) -
Differential
AE"
SPEEDOMETER DRIVE GEAR REMOVAL
Take the speedometer drive gear out of the differential.
RMT0044
3
2
AF"
SIDE GEAR REMOVAL
(1) Remove the snap ring 1.
(2) Remove the shim 2.
(3) Withdraw the side gear 3.
1
1
6
2
MD998019
3
AG"
PINION GEAR REMOVAL
(1) Remove the spring pin with spring pin extractor
MD998019.
5
4
6
5
(2) Take out the shaft 4 together with the bush 5.
(3) Remove the pinion gears 6 together with the thrust
washers.
4
AH"
SIDE GEAR REMOVAL
Take the side gear out of the differential case.
REASSEMBLY SERVICE POINTS
"AA
(1) Smear the side gears with grease.
(2) Locate the side gear in the differential case.
SIDE GEAR INSTALLATION
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Differential
22A-5-5
6
MD998245
"BA
PINION GEARS INSTALLATION
(1) Smear the pinion gears and thrust washers with grease.
(2) Locate the pinion gears 6 together with the thrust washers
5
4
6
3
2
5
4
and fit the shaft 4.
(3) Locate the bush 5 over the shaft.
(4) Locate the pinion gears 6 together with the thrust washers
and press the shaft in further.
(5) Fit the spring pin with the slit at right-angles to the shaft
and tap it in with spring pin installer MD998245.
"CA
SIDE GEAR INSTALLATION
(1) Smear the side gears with grease.
(2) Insert the side gear 3.
(3) Locate the shim 2.
(4) Fit the snap ring 1.
1
1
2
3
"DA
SPEEDOMETER DRIVE GEAR INSTALLATION
(1) Locate the speedometer drive gear with the locking lug
in the recess in the differential.
(2) Place the guard ring on the differential.
(3) Place the spring ring on the differential.
130 Nm
MB996003
RMT0044
MB996005
"EA
SPEEDOMETER DRIVE GEAR/SPRING RING/
GUARD GEAR INSTALLATION
(1) Locate the speedometer drive gear with the locking lug
in the recesses in the differential.
(2) Place the guard ring on the differential.
(3) Place the spring ring on the differential.
"FA
DIFFERENTIAL GEAR ASSEMBLY INSTALLATION
(1) Locate the differential gear assembly in the clutch housing.
(2) Lock the differential gear assembly with counterhold
MB996005.
(3) Fit the shim.
(4) Locate the bearing.
(5) Smear the nut with a locking agent (Loctite 270).
(6) Fit the nut with the opening facing towards the bearing.
RMT0045
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-5-6
MANUAL TRANSMISSION (E- W) -
(7) Press the nut on to the threaded end with socket wrench
MB996003 until it catches the thread and then tighten
the nut to 18 Nm.
(8) Remove the counterhold.
(9) Rotate the differential a few times.
(10)Fit counterhold MB996005.
(11)Tighten the nut to 130 Nm.
(12)Remove the counterhold.
Differential
MB996010
MB996010
MB996010
"GA
SNAP RING INSTALLATION
(1) Locate the differential in the clutch housing.
(2) Place the clutch housing under a press and support the
differential.
(3) Using special tool MB996010, press the housing
downwards until it abuts against the stop.
(4) Now press the housing downwards, against the spring
pressure, until it is possible to fit the snap ring.
(5) Fit the snap ring.
"HA
OIL SEAL INSTALLATION
(1) Pack the lip of the new oil seal with grease.
(2) Place the guide on the shaft and locate the oil.
(3) Fit the oil seal with drift MB996010.
(4) Fit a new O-ring.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Clutch Housing
6. CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2>
22A-6-1
6
5
8
AA""GA
AC""EA
AE""DA
AF""CA
AG""AA
Lubricate all internal
parts with gear oil
during reassembly.
Disassembly steps
1. Input shaft bearing
2. Output shaft bearing
3. Oil baffle
4. Large bearing
5. Speedometer drive gear
6. Shaft
7. Snap ring
8. Small bearing
7
3
1
2
4
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-6-2
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY AND REASSEMBLY <F5MR3>
Lubricate all internal
parts with gear oil
during reassembly.
Clutch Housing
6
5
7
Disassembly steps
AB""HA
AD""FA
AC""BA
AF""CA
AH""BA
1. Input shaft bearing cup
2. Output shaft bearing
3. Oil baffle
4. Large bearing cup
5. Speedometer drive gear
6. Shaft
7. Small bearing cup
1
32
4
RMT0046
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
DISASSEMBLY SERVICE POINTS
MB990938
MB990927
AA"
Tap the bearing out of the housing with handle MB990938
and bearing installer set MB990927.
INPUT SHAFT BEARING REMOVAL
Clutch Housing
22A-6-3
1
RMT0047
MB996001
MB996006
MB996001
AB"
INPUT SHAFT BEARING CUP REMOVAL
Tap the bearing cup out of the housing with a drift.
NOTE
Take care not to damage any of the parts.
AC"
OUTPUT SHAFT BEARING REMOVAL
(1) Tap back the upset (staked) edges of the lock washer
with a punch.
(2) Locate puller MB996001 in the bearing and position
bracket MB996006 between the jaws.
(3) Pull the bearing out of the housing.
(4) Remove the oil baffle 1.
NOTE
Remove all traces of the staking with emery cloth.
AD"
OUTPUT SHAFT BEARING REMOVAL
(1) Locate bearing puller MB996001 in the bearing and
position the bracket MB996006 between the jaws.
(2) Pull the bearing out of the housing.
(3) Remove the oil baffle.
MB996006
E
E
May 1996
May 1995Mitsubishi Motors Corporation
RMT0048
AE"
LARGE BEARING REMOVAL
Tap the bearing cup out of the housing with a long punch.
NOTE
Take care not to damage any parts.
PWEE9508
RevisedPWEE9508-BMitsubishi Motors Corporation
22A-6-4
MANUAL TRANSMISSION (E- W) -
Clutch Housing
MB990938
MB990930
MB990938
AF"
SPEEDOMETER DRIVE GEAR REMOVAL
(1) Pull the shaft out of the speedometer drive gear with
a pair of needle nose pliers.
NOTE
Break the shaft if it cannot be released.
(2) Take the speedometer drive gear out of the differential
housing.
AG"
SMALL BEARING REMOVAL
(1) Remove the snap ring with a pair of pliers.
(2) Remove the bearing with handle MB990938 and installer
MB990930.
(3) In the case of a new clutch housing, transfer the following
parts:
Studs
Fitted sleeves
AH"
SMALL BEARING CUP REMOVAL
(1) Remove the bearing cup with handle MB990938 and
installer MB990932.
(2) In the case of a new clutch housing, transfer the following
parts:
- threaded ends;
- fitted dowels.
MB990938
MB990934
MB990932
RMT0049
MB996008
MB996004
REASSEMBLY SERVICE POINTS
"AA
(1) Coat the mating face with the specified sealant.
(2) Press in the bearing with handle MB990938 and installer
(3) Fit the snap ring with a pair of pliers and secure in the
"BA
(1) Coat the mating faces with the specified sealant.
(2) Press in the bearing cups with spindle MB996000 and
SMALL BEARING INSTALLATION
MB990934.
groove.
LARGE AND SMALL BEARING CUP
INSTALLATION
installers MB996004 and MB996008.
E
E
MB996000
May 1996
May 1995Mitsubishi Motors Corporation
RMT0050
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Clutch Housing
22A-6-5
"CA
SPEEDOMETER DRIVE GEAR INSTALLATION
(1) Introduce the shaft together with the speedometer drive
gear in the clutch housing and note the position of the
speedometer drive gear relative to the shaft.
(2) Press the shaft firmly into place (snap connection).
(3) Smear liberal amounts of grease on the gears.
"DA
LARGE BEARING INSTALLATION
(1) Coat the mating face with the specified sealant.
(2) Fit the bearing by tapping it in with a plastic-hammer.
(3) Make sure that the bearing abuts accurately against its
seating.
NOTE
The open side of the bearing must be facing inwards.
1
"EA
OUTPUT SHAFT BEARING INSTALLATION
(1) Fit the oil baffle 1.
MB990938
(2) Coat the mating face with the specified sealant.
(3) Tap in the bearing with handle MB990938 and installer
MB990931.
(4) Stake the lock washers (upset: about 1 mm) with a centre
punch.
MD998717
MB990931
MB990938
MB990931
RMT0051
NOTE
The bearing must be flush with the housing.
"FA
OUTPUT SHAFT BEARING INSTALLATION
(1) Fit the oil baffle.
(2) Coat the mating face with the specified sealant.
(3) Tap in the bearing with handle MB990938 and installer
MB990931.
NOTE
The bearing must be flush with the housing.
"GA
INPUT SHAFT BEARING INSTALLATION
(1) Coat the mating face with the specified sealant.
(2) Locate the bearing so that the oil passages of the bearing
and the housing are opposed.
(3) Press in the bearing with installer MD998717.
NOTE
The bearing must be flush with the housing.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-6-6
MANUAL TRANSMISSION (E- W) -
Clutch Housing
MB996011
RMT0052
"HA
INPUT SHAFT BEARING CUP INSTALLATION
(1) Coat the mating face with the specified sealant.
(2) Press the bearing cup against the stop with installer
MB996011.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
MANUAL TRANSMISSION (E- W) -
Control Lever
22A-7-1
7. CONTROL LEVER
DISASSEMBLY AND REASSEMBLY
14
6
4
5
13
7
8
3
11
10
2
12
1
22200790010
9
Lubricate all internal
parts with gear oil
during reassembly.
Disassembly steps
1. Compression spring
2. Snap ring
AA""CA
AA""CA
"BA
3. Remote control arm
4. Spring pin
5. Spring pin
6. Selector dog
7. Selector shaft oil seal
AA""CA
AB""AA
AB""AA
8. Rubber seal
9. Bearing bushes
10. Shift lever
11. Rubber seal
12. Rubber seal
13. Outer bearing bush
14. Inner bearing bush
E
May 1995Mitsubishi Motors Corporation
PWEE9508
22A-7-2
MANUAL TRANSMISSION (E- W) -
Control Lever
MD998019
5
DISASSEMBLY SERVICE POINTS
342
AA"
(1) Remove the compression spring 2 on the outside.
(2) Remove the snap ring 3 and take out the bearing bushes.
(3) Remove the two spring pins with spring pin extractor
(4) Remove the remote control arm 4.
(5) Withdraw the shift rail assembly together with the selector
8
76
(6) Remove the rubber seal.
(7) Remove the bearing bushes 6 from the shift lever 7.
(8) Remove the rubber seal 8 from the shift lever.
AB"
Tap out the two bearing bushes with 14 mm Hex socket.
GEAR SHIFT MECHANISM REMOVAL
MD998019.
dog 5.
BEARING BUSHES REMOVAL
MB996007
MB996007
REASSEMBLY SERVICE POINTS
"AA
(1) Coat the mating faces of the housing with the specified
(2) Locate the inner bearing bush and installer MB996007.
(3) Fit the remote control arm in the housing and insert a
(4) Tap in the bearing bush until it abuts against its seating.
(5) Remove the punch, remote control arm and drift
(6) Locate the outer bearing bush and installer MB996007.
(7) Fit the remote control arm in the housing.
(8) Tap in the bearing bush until it abuts against its seating.
(9) Remove the remote control arm and installer MB996007.
BEARING BUSHES INSTALLATION
sealant.
7.5 mm diam. punch in the spring pin hole.
MB996007.
E
May 1995Mitsubishi Motors Corporation
PWEE9508
MANUAL TRANSMISSION (E- W) -
Control Lever
22A-7-3
2.5 mm
5
MB990938
"BA
SELECTOR SHAFT OIL SEAL INSTALLATION
(1) Pack the lip of the oil seal with grease.
MB990926
(2) Fit the new oil seal with handle MB990938 and installer
MB990926 so it is located about 2.5 mm ahead of the
mating face.
342
"CA
(1) Coat the shift lever (ball and socket joints) and shift rail
GEAR SHIFT MECHANISM INSTALLATION
assembly shaft with grease.
(2) Fit the rubber seal 8 on the shift lever.
(3) Fit the rubber seal on the shift rail assembly.
(4) Locate the selector dog 5 and insert the remote control
arm 4 in the transmission case.
(5) Fit the two spring pins opposite each other at 180_and
at right-angles to the shaft.
8
76
(6) Locate the two bearing bushes 6 and fit the shift lever
7.
(7) Fit the snap ring 3.
(8) Fit the rubber seal over the oil seal.
(9) Check for correct operation.
(10)Fit the compression spring 2 on the outside.
E
May 1995Mitsubishi Motors Corporation
PWEE9508
MANUAL TRANSMISSION (E- W) -
8. INPUT SHAFT <F5MR3>
DISASSEMBLY AND REASSEMBLY
Lubricate all internal
parts with gear oil
during reassembly.
1
Disassembly steps
AA""BA
AB""AA
1. Bearing
2. Shim
3. Bearing
Input Shaft <F5MR3>
3
2
22A-8-1
RMT0053
MD998801
RMT0054
DISASSEMBLY SERVICE POINTS
AA"
Remove the bearing and the shim.
AB"
(1) Place the input shaft on a soft surface.
(2) Tap the bearing partway off the input shaft with a chisel.
(3) Locate the bearing remover MD998801 behind the
(4) Press the bearing of the input shaft.
INPUT SHAFT BEARINGS/TRANSMISSION CASE
END REMOVAL
INPUT SHAFT BEARING/CLUTCH HOUSING END
REMOVAL
bearing.
RMT0055
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
22A-8-2
MANUAL TRANSMISSION (E- W) -
REASSEMBLY SERVICE POINTS
"AA
INPUT SHAFT BEARING/CLUTCH HOUSING END
INSTALLATION
(1) Locate the bearing on the input shaft.
(2) Tap the bearing with a drift until it abuts against the stop
on the input shaft.
RMT0056
Input Shaft <F5MR3>
RMT0057
"BA
INPUT SHAFT BEARING/TRANSMISSION CASE
END INSTALLATION
(1) Fit the shim.
NOTE
In the case of old bearings: Fit the old shim.
In the case of new bearings: fit a shim with a thickness
of 1.6 mm.
(2) Fit the bearing.
May 1996
E
E
May 1995Mitsubishi Motors Corporation
PWEE9508
AddedPWEE9508-BMitsubishi Motors Corporation
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9508
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
...........................................
..................................................
...............................
..........................................
..................................
................................
...................................................
...................................................
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........................................
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........................................
................................................
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............................................
........................................
............................
..........................
.........................................
E
Jun. 2000Mitsubishi Motors Corporation Revised
PWEE9508-G
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
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
1214 13
11
TFM0809
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
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
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
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
1214 13
11
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
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
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
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
111214 131516
10
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
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
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
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
14
13
1112
10
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
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
W5M42
MANUAL TRANSMISSION (E-W) -
General Information
22B-0-7
1
2
3
4
56
7
8
9
16
171819
15
14
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
9. Output shaft
10. Viscous coupling
13
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) -
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE - MODEL 1996
Specifications
22B-1-1
Transmission model
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
Gear ratio Speedometer
gear ratio
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 D 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 D 29/36 3.722 EA5A 6A13
F5M42-2-V6N D 29/36 4.312 EA4A 6A12
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
22B-1-2
MANUAL TRANSMISSION (E-W) -
TRANSMISSION MODEL TABLE - MODEL 1998
Specifications
Transmission model
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
Gear ratio Speedometer
gear ratio
Final gear ratio Vehicle model Engine model
E
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
MANUAL TRANSMISSION (E-W) -
TRANSMISSION MODEL TABLE - MODEL 1999
Specifications
22B-1-2a
Transmission model
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
Gear ratio Speedometer
gear ratio
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 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
July 1999Mitsubishi Motors Corporation Revised
PWEE9508-F
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