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Mitsubishi W5M42 manual

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Table of contents for the manual

  • Page 1

    GENERAL INFORMA TION 22B-0-3 ........................................... 1. SPECIFICA TIONS 22B-1-1 .................................................. TRANSMISSION MODEL T ABLE 22B-1-1 ............................... GEAR RA TIO T ABLE 22B-1-2d .......................................... SER VICE SPECIFICA TIONS 22B-1-2d ............................[...]

  • Page 2

    22B-0-2 NOTES[...]

  • Page 3

    MANUAL TRANSMISSION (E - W) - General Information 22B-0-3 GENERAL INFORMA TION F5M41 <T ypes with single synchronizer ring for 2nd gear> 1 2 3 4 5 67 10 9 8 11 12 14 13 15 TFM0809 1. Reverse gear meshing noise pre- vention device <Models with reverse brake> 2. 5th-reverse speed synchronizer hub 3. 5th speed gear 4. 4th speed gear 5. 3rd[...]

  • Page 4

    MANUAL TRANSMISSION (E - W) - General Information 22B-0-4 F5M41 <T ypes with double synchronizer ring for 2nd gear> 12 34 5 6 7 10 9 8 11 12 14 13 15 1. Reverse gear meshing noise pre- vention 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. T ransmission c[...]

  • Page 5

    MANUAL TRANSMISSION (E - W) - General Information 22B-0-5 F5M42 <T ypes with single synchronizer ring for 1st gear and double synchronizer ring for 2nd gear> 1 2 3 4 5 6 7 10 9 8 11 12 14 13 15 16 1. Reverse idler gear 2. 4th speed gear 3. 3rd-4th speed synchronizer hub 4. 3rd speed gear 5. T ransmission case 6. Clutch housing 7. Release bear[...]

  • Page 6

    MANUAL TRANSMISSION (E - W) - General Information 22B-0-6 F5M42 <T ypes 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> 1 2 3 4 5 6 7 10 9 8 11 12 14 13 15 16 1. Reverse idler gear 2. 4th speed gear 3. 3rd-4th speed synchronizer hub 4. 3rd sp[...]

  • Page 7

    MANUAL TRANSMISSION (E - W) - General Information 22B-0-7 W5M42 1 2 3 4 56 7 10 9 8 11 12 14 13 15 16 17 18 19 1. Reverse idler gear 2. 4th speed gear 3. 3rd-4th speed synchronizer hub 4. 3rd speed gear 5. T ransmission case 6. Clutch housing 7. Release bearing retainer 8. Input shaft 9. Output shaft 10. Viscous coupling 1 1. Front differential 12.[...]

  • Page 8

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-1 1. SPECIFICA TIONS TRANSMISSION MODEL T ABLE - MODEL 1996 T ransmission model Gear ratio Speedometer gear ratio Final gear ratio V ehicle model Engine 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 F5[...]

  • Page 9

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-2 TRANSMISSION MODEL T ABLE - MODEL 1998 T ransmission model Gear ratio Speedometer gear ratio Final gear ratio V ehicle model Engine 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 4[...]

  • Page 10

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-2a TRANSMISSION MODEL T ABLE - MODEL 1999 T ransmission model Gear ratio Speedometer gear ratio Final gear ratio V ehicle model Engine 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 [...]

  • Page 11

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-2b TRANSMISSION MODEL T ABLE - MODEL 2000 T ransmission model Gear ratio Speedometer gear ratio Final gear ratio V ehicle model Engine model EUR F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13 F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92 F5M41-1-B8A2 B 31/36 3.454 CJ4A 4G92-MVV F5M42-1-R7A2 D 30/36 4.058 DA2A 4G93-GD[...]

  • Page 12

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-2c TRANSMISSION MODEL T ABLE - MODEL 2001 T ransmission model Gear ratio Speedometer gear ratio Final gear ratio V ehicle model Engine model EUR F5M41-1-R8A1 A 31/36 4.052 CJ1A 4G13 F5M41-1-F8A5 A 31/36 3.714 CJ4A 4G92 F5M41-1-F8AC B 31/36 3.454 DG5A 4G93 F5M42-2-R7A2 D 30/36 4.058 DA2A 4G93 F5M42-[...]

  • Page 13

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-2d GEAR RA TIO T ABLE A B C D E F G 1st 3.583 3.727 3.071 3.583 3.583 3.583 3.583 2nd 1.947 1.947 1.947 1.947 1.947 1.947 1.947 3rd 1.343 1.343 1.379 1.379 1.379 1.379 1.266 4th 0.976 0.976 1.030 1.030 1.030 1.030 0.970 5th 0.804 0.804 0.820 0.820 0.733 0.767 0.767 Reverse 3.416 3.416 3.363 3.363 3[...]

  • Page 14

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-2e Items Allowable range Limit Front differential case preload <W5M42> mm 0.05 - 0.1 1 - Center differential case pinion backlash <W5M42> mm 0.025 - 0.150 - Center differential case preload <W5M42> mm 0.05 - 0.1 1 - Synchronizer ring back surface to gear clearance mm - 0.5 NOTE: S[...]

  • Page 15

    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. T o 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. T oo [...]

  • Page 16

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-4 SNAP RINGS, SP ACERS AND THRUST PLA TE ADJUSTMENT Part name Thickness mm Identification symbol Part No. Snap ring 2.24 None MD706537 (For adjustment of input shaft front bearing end play) 2.31 Blue MD706538 2.38 Brown MD706539 Snap ring 2.31 Black (2) MD747149 (For adjustment of input shaft rear [...]

  • Page 17

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-5 Part name Part No. Identification symbol Thickness mm Snap ring: F5M41 2.31 Black (2) MD748800 (For adjustment of output shaft rear bearing end play) 2.35 None MD748801 2.39 Blue MD748802 2.43 Brown MD748803 2.47 Green MD748804 2.51 White MD748805 2.55 Y ellow MD748806 2.59 Black MD748807 2.63 Or[...]

  • Page 18

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-6 Part name Part No. Identification symbol Thickness mm Spacer: F5M41 0.77 77 MD754476 (For adjustment of differential case end play) 0.86 86 MD720938 0.95 95 MD720941 1.04 04 MD720944 1.13 D MD700270 1.22 G MD700271 1.31 E MD706574 1.40 None MD706573 1.49 C MD706572 1.58 B MD706571 1.67 A MD706570[...]

  • Page 19

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-7 Part name Part No. Identification symbol Thickness mm Spacer: F5M42 0.71 71 MD754475 (For adjustment of differential case preload) 0.74 74 MD727660 0.77 77 MD754476 0.80 80 MD727661 0.83 83 MD720937 0.86 86 MD720938 0.89 89 MD720939 0.92 92 MD720940 0.95 95 MD720941 0.98 98 MD720942 1.01 01 MD720[...]

  • Page 20

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-8 Part name Part No. Identification symbol Thickness mm Spacer: W5M42 0.74 74 MD727660 (For adjustment of center differential case preload) 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 0[...]

  • Page 21

    MANUAL TRANSMISSION (E - W) - Specifications 22B-1-9 TORQUE SPECIFICA TIONS 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 Speed[...]

  • Page 22

    MANUAL TRANSMISSION (E - W) - Special T ools 22B-2-1 2. SPECIAL TOOLS TRANSMISSION T ool Number Name Use MB990926 Installer adapter Installation of clutch housing input shaft oil seal MB990927 Installer adapter Installation of sealing cap MB990930 Installer adapter Removal of center differential taper roller bearing <W5M42> MB990934 Installer[...]

  • Page 23

    MANUAL TRANSMISSION (E - W) - Special T ools 22B-2-2 T ool Use Name Number MD998346 Bearing outer race remover Removal of roller bearing outer race MD998772 V alve spring com- pressor Removal of roller bearing outer race MD998801 Bearing remover Installation and removal of gears, bearings and sleeves MD998812 Installer cap Use with Installer and In[...]

  • Page 24

    MANUAL TRANSMISSION (E - W) - Special T ools 22B-2-3 T ool Use Name Number MD998819 Installer adapter (40) Installation of 5th-reverse speed synchronizer hub, dif ferential case bearing, 4th speed gear and 5th speed gear sleeve <F5M42, W5M42> MD998820 Installer adapter (42) Installation of 5th speed gear sleeve, 2nd speed gear sleeve <F5M4[...]

  • Page 25

    MANUAL TRANSMISSION (E - W) - Special T ools 22B-2-4 TRANSFER T ool Number Name Use MB990887 Arm bush remover and installer ring Installation of transfer oil seal MB990891 Arm bush remover and installer base Installation of transfer oil seal MB990933 Installer adapter Installation of transfer cover oil seal MD998304 Oil seal installer Installation [...]

  • Page 26

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-1 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 3. TRANSMISSION <F5M41> DISASSEMBL Y AND REASSEMBL Y 1 2 3 4 5 6 7 10 9 8 11 12 32 Nm 18 Nm 69 Nm 3.9 Nm 69 Nm 1 TFM0718 Disassembly steps 1. Roll stopper bracket 2. Insulator washer 3. Shift cable bracket 4. Insulator[...]

  • Page 27

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-2 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 14 13 15 Lubricate all internal parts with gear oil dur- ing reassembly . 16 17 18 19 20 22 23 24 25 26 27 28 18 Nm 44 Nm 30 Nm 18 Nm 48 Nm TFM0719 21 Disassembly steps 13. Interlock plate bolt 14. Gasket " K A 15. Cont[...]

  • Page 28

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-3 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added Lubricate all internal parts with gear oil dur- ing reassembly . 18 Nm 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 TFM0720 Disassembly steps " D A 29. Spring pin 30. 1st-2nd speed shift rail 31. 1st-2nd speed [...]

  • Page 29

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-4 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added DISASSEMBL Y SERVICE POINTS A A " SEALING CAP REMOV AL A B " TRANSMISSION CASE REMOV AL Expand the snap ring to remove it from the snap ring groove of the ball bearing. NOTE Expansion of the snap ring causes the sn[...]

  • Page 30

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-5 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added A E " INPUT SHAFT / OUTPUT SHAFT REMOV AL Remove the input and output shafts together . ADJUSTMENT BEFORE REASSEMBL Y SP ACER SELECTION FOR DIFFERENTIAL CASE END PLA Y ADJUSTMENT (1) Put solders (about 10 mm long, 1.6 m[...]

  • Page 31

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-6 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " C A REVERSE INTERLOCK RAIL / STEEL BALL / 5TH SPEED SHIFT RAIL / REVERSE SHIFT LUG / SNAP RING / 5TH SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT RAIL INST ALLA TION (1) Install th e 3rd-4th shift[...]

  • Page 32

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-7 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " E A SP ACER INST ALLA TION Install th e spacer selected in t he section “ADJUSTMENT BEFORE REASSEMBL Y”. " F A OIL GUIDE INST ALLA TION " G A REVERSE IDLER GEAR SHAFT INST ALLA TION (1) Shift the 3rd-4th[...]

  • Page 33

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-8 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added (2) Install the transmission case and expand the snap ring. (3) T ighten the transmission case mounting bolts to the specified torque. NOTE Place the transmission upside down and let the snap ring fit in the groove by taking[...]

  • Page 34

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M41> 22B-3-9 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " L A SPEEDOMETER GEAR INST ALLA TION Apply transmission oil to t he O-ring of th e speedometer gear . T ransmission oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher " M A SELECT LEV[...]

  • Page 35

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-1 4. TRANSMISSION <F5M42, W5M42> DISASSEMBL Y AND REASSEMBL Y 11 2 3 4 5 7 9 8 10 32 Nm 18 Nm 69 Nm 3.9 Nm 69 Nm 1 3 12 13 14 15 32 Nm 19 Nm 69 Nm 6 Apply gear oil to all moving parts before installation. Disassembly steps 1. T ransfer <W5M42> 2. O-ring <W5M42>[...]

  • Page 36

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-2 19 18 20 21 22 23 24 25 26 27 28 29 16 17 18 Nm 44 Nm 30 Nm 6.9 Nm 48 Nm TFM0597 Apply gear oil to all moving parts before installation. Disassembly steps 16. Interlock plate bolt 17. Gasket " I A 18. Control housing 19. Neutral return spring " H A 20. Under cover 21[...]

  • Page 37

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-3 18 Nm 34 35 36 37 38 39 40 41 42 43 30 31 32 33 TFM0598 Apply gear oil to all moving parts before installation. Disassembly steps " C A 30. Spring pin 31. 1st-2nd speed shift rail 32. 1st-2nd speed shift fork " C A 33. Spring pin " C A 34. Spring pin A C "&[...]

  • Page 38

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-4 DISASSEMBL Y SERVICE POINTS A A " SEALING CAP REMOV AL Drive a screwdriver into the sealing cap at the center , then pry off the sealing cap with t he screwdriver . A B " TRANSMISSION CASE REMOV AL Expand the snap ring to remove it from the snap ring groove of the ba[...]

  • Page 39

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-5 ADJUSTMENT BEFORE REASSEMBL Y SP ACER SELECTION FOR DIFFERENTIAL CASE PRELOAD ADJUSTMENT (1) Put solders (about 10 mm long, 1.6 mm in diameter) in the illustrated positions of th e transmission case an d install the bearing outer race a nd differential. (2) Install the clutch [...]

  • Page 40

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-6 (3) While fitting each shift fork in the sleeve, slide the shift rails in the direction shown and install. " C A SPRING PIN INST ALLA TION Install the spring pin such that its slit may face in the axial direction of the shift rail. " D A SP ACER INST ALLA TION Instal[...]

  • Page 41

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-7 (2) Install the transmission case and expand the snap ring. (3) T ighten the transmission case to the specified torque. NOTE Place the transmission upside down and let the snap ring fit in the groove by taking advantage of the output shaft’s own weight. " G A SEALING CA[...]

  • Page 42

    MANUAL TRANSMISSION (E - W) - T ransmission <F5M42, W5M42> 22B-4-8 " J A SPEEDOMETER GEAR INST ALLA TION Apply transmission oil to t he O-ring of th e speedometer gear . T ransmission oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher " K A SELECT LEVER INST ALLA TION Apply grease to the control shaft s[...]

  • Page 43

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-1 5. INPUT SHAFT <F5M41> DISASSEMBL Y AND REASSEMBL Y <Models with reverse brake> Apply gear oil to all moving parts before installation. TFM0834 18 19 20 21 22 23 25 11 24 10 12 13 9 8 7 6 5 4 3 2 1 26 27 25 13 14 15 16 17 29 28 Disassembly steps " M A 1. Snap ring A A [...]

  • Page 44

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-2 DISASSEMBL Y AND REASSEMBL Y <Except models with reverse brake> 18 19 20 21 23 25 11 10 12 13 9 8 7 6 5 4 3 2 1 22 14 15 16 17 24 21 9 Apply gear oil to all moving parts before installation. Disassembly steps " M A 1. Snap ring A A "" L A 2. Ball bearing 3. Collar [...]

  • Page 45

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-2a DISASSEMBL Y SERVICE POINTS A A " BALL BEARING REMOV AL A B " REVERSE BRAKE SLEEVE REMOV AL Mount a special tool on the 5th speed gear an d remove the reverse brake sleeve. A C " 5TH-REVERSE SPEED SYNCHRONIZER HUB REMOV AL Mount a special tool on the 5th speed gear an d[...]

  • Page 46

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-2b Intentionally blank PWEE9508-F E July 1999 Mitsubishi Motors Corporation Added[...]

  • Page 47

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-3 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added A F " BALL BEARING REMOV AL REASSEMBL Y SERVICE POINTS " A A OIL SEAL INST ALLA TION Drive in the oil seal all the way up to the illustrated dimension. " B A BALL BEARING INST ALLA TION " C A SNAP RING INST[...]

  • Page 48

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-4 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " E A 3RD-4TH SPEED SYNCHRONIZER HUB INST ALLA TION Install the 3rd-4th speed synchronizer h ub in such a way that it will be oriented in the direction shown. Caution When the hub is installed, make sure that the synchron[...]

  • Page 49

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-5 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " H A 5TH SPEED GEAR SLEEVE INST ALLA TION " I A 5TH-REVERSE SPEED SYNCHRONIZER HUB INST ALLA TION Install the 5th-reverse speed synchronizer h ub in such a way that it will be oriented in the direction shown. Cautio[...]

  • Page 50

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-6 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " K A REVERSE BRAKE SLEEVE INST ALLA TION " L A BALL BEARING INST ALLA TION " M A SNAP RING INST ALLA TION Select and install a snap ring so that the input shaft rear bearing en d play will have the standard val[...]

  • Page 51

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41> 22B-5-7 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added SYNCHRONIZER RING (1) Check to ensure that the clutch gear tooth surfaces are not damaged and broken. (2) Check to ensure that the cone inside diameter is not damaged or worn and that the threads are not crushed. (3) Press the[...]

  • Page 52

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-1 6. INPUT SHAFT <F5M42, W5M42> DISASSEMBL Y AND REASSEMBL Y 14 15 16 17 18 19 20 11 10 12 13 9 8 7 6 5 4 3 2 1 16 TFM0591 Apply gear oil to all moving parts before installation. Disassembly steps " L A 1. Snap ring A A "" K A 2. Ball bearing " J A 3. Thr[...]

  • Page 53

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-2 DISASSEMBL Y SERVICE POINTS A A " BALL BEARING REMOV AL Use the special tool to remove th e ball bearing. A B " 5TH SPEED GEAR REMOV AL Use the special tool to remove the 5th speed gear . A C " 4TH SPEED GEAR SLEEVE REMOV AL Mount a special tool on th e 3rd gear a[...]

  • Page 54

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-3 " B A BALL BEARING INST ALLA TION Use the special tools to install th e ball bearing. " C A SNAP RING INST ALLA TION Select and install a snap ring so that the input shaft front bearing en d play will have the standard value. Standard value: - 0.01 - 0.12 mm " D A[...]

  • Page 55

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-4 " F A SYNCHRONIZER SLEEVE INST ALLA TION (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown. (2) When the synchronizer sleeve is installed, make sure that the deep groove portion of the synchronizer hub is aligned with the proj[...]

  • Page 56

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-5 " J A THRUST PLA TE ST OPPER INST ALLA TION When the thrust plate is installed, make sure that it is not tilted. " K A BALL BEARING INST ALLA TION Use the special tools to install th e ball bearing. " L A SNAP RING INST ALLA TION Select and install a snap ring so [...]

  • Page 57

    MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42> 22B-6-6 SYNCHRONIZER RING (1) Check to ensure that the clutch gear tooth surfaces are not damaged and broken. (2) Check to ensure that the cone inside diameter is not damaged or worn and that the threads are not crushed. (3) Press the synchronizer ring against the gear and check clearan[...]

  • Page 58

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-1 7. OUTPUT SHAFT <F5M41> DISASSEMBL Y AND REASSEMBL Y <T ypes with single synchronizer ring for 2nd gear> 14 15 16 17 18 19 20 11 10 12 13 9 8 7 6 5 4 3 2 1 21 9 22 TFM0715 Apply gear oil to all moving parts before installation. Disassembly steps " J A 1. Snap ring A A[...]

  • Page 59

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-2 DISASSEMBL Y AND REASSEMBL Y <T ypes with double synchronizer ring for 2nd gear> 23 16 17 18 19 22 11 10 13 15 9 8 7 6 5 4 3 2 1 21 9 24 Apply gear oil to all moving parts before installation. 12 14 20 Disassembly steps " J A 1. Snap ring A A "" I A 2. Ball bearin[...]

  • Page 60

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-2a DISASSEMBL Y SERVICE POINTS A A " BALL BEARING REMOV AL A B " 2ND SPEED GEAR SLEEVE REMOV AL Mount a special tool on the synchronizer sleeve and remove the 2nd speed gear sleeve. A C " 1ST SPEED GEAR SLEEVE REMOV AL A D " ROLLER BEARING INNER RACE REMOV AL REASSEM[...]

  • Page 61

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-2b Intentionally blank PWEE9508-F E July 1999 Mitsubishi Motors Corporation Added[...]

  • Page 62

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-3 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " B A SNAP RING INST ALLA TION Select and install a snap ring so that the output shaft front bearing en d play will have the standard value. Standard value: - 0.01 - 0.12 mm " C A 1ST SPEED GEAR SLEEVE INST ALLA TIO[...]

  • Page 63

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-4 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " F A SYNCHRONIZER SLEEVE INST ALLA TION (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown. (2) When the synchronizer sleeve is installed, make sure that the deep groove po[...]

  • Page 64

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-5 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " J A SNAP RING INST ALLA TION Select and install a snap ring so that the output shaft rear bearing en d play will have the standard value. Standard value: - 0.01 - 0.09 mm " K A SYNCHRONIZER SPRING INST ALLA TION I[...]

  • Page 65

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-6 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added (3) Press the synchronizer ring against the gear and check clearance “A”. If “A” is less than the limit, replace. Limit: 0.5 mm OUTER SYNCHRONIZER RING / INNER SYNCHRONIZER RING / SYNCHRONIZER CONE (1) Check to ensure[...]

  • Page 66

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M41> 22B-7-7 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added SPEED GEARS (1) Check to ensure that the helical and clutch gear tooth surfaces are not damaged or worn. (2) Check to ensure that the synchronizer cone surfaces are not roughened, damaged or worn. (3) Check to ensure that the[...]

  • Page 67

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-1 8. OUTPUT SHAFT <F5M42, W5M42> DISASSEMBL Y AND REASSEMBL Y <T ypes with single synchronizer ring for 1st gear and double synchronizer ring for 2nd gear> 14 15 16 17 18 19 20 11 10 12 13 9 8 7 6 5 4 3 2 1 21 22 23 24 25 26 27 28 29 30 31 32 33 34 13 4 Apply gear oil[...]

  • Page 68

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-2 DISASSEMBL Y AND REASSEMBL Y <T ypes 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> 14 15 16 17 18 19 20 10 11 12 13 9 8 7 6 5 4 3 2 1 21 22 23 24 25 26 27 28 29 30 31 3[...]

  • Page 69

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-3 DISASSEMBL Y SERVICE POINTS A A " BALL BEARING REMOV AL Use the special tool to remove th e ball bearing. A B " REVERSE GEAR BEARING SLEEVE REMOV AL Mount a special tool on the reverse gear and remove the reverse gear bearing sleeve. A C " 5TH-REVERSE SPEED SYNCH[...]

  • Page 70

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-4 A F " 1ST SPEED GEAR SLEEVE REMOV AL Use the special tool to remove the 1st speed gear sleeve. A G " ROLLER BEARING INNER RACE REMOV AL Use th e special tool to remove t he roller bearing inner race. REASSEMBL Y SERVICE POINTS " A A ROLLER BEARING INNER RACE INST[...]

  • Page 71

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-5 " D A SYNCHRONIZER SPRING INST ALLA TION Install the synchronizer spring securely up to the illustrated position of th e synchronizer ring. " E A 1ST -2ND SPEED SYNCHRONIZER HUB INST ALLA TION Install the 1st-2nd speed synchronizer h ub in such a way that it will be o[...]

  • Page 72

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-6 " G A SYNCHRONIZER SPRING INST ALLA TION Install the synchronizer spring securely up to the illustrated position of th e synchronizer ring. " H A 2ND SPEED GEAR SLEEVE INST ALLA TION Use the special tools to install the 2 nd speed gear sleeve. " I A 3RD SPEED GEA[...]

  • Page 73

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-7 " L A 5TH SPEED GEAR SLEEVE INST ALLA TION Use the special tools to install the 5th speed gear sleeve. " M A 5TH-REVERSE SPEED SYNCHRONIZER HUB INST ALLA TION Install the 5th-reverse speed synchronizer h ub in such a way that it will be oriented in the direction shown[...]

  • Page 74

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-8 " P A SNAP RING INST ALLA TION Select and install a snap ring so that the output shaft rear bearing en d play will have the standard value. Standard value: - 0.01 - 0.09 mm INSPECTION OUTPUT SHAFT Check the splines for damage a nd wear . NEEDLE ROLLER BEARING (1) Check to [...]

  • Page 75

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-9 OUTER SYNCHRONIZER RING / INNER SYNCHRONIZER RING / SYNCHRONIZER CONE (1) Check to ensure that the clutch gear tooth surfaces and cone surfaces are not damaged and broken. (2) Install the outer ring, inner ring and cone, press them against the gear , and check clearance “A”[...]

  • Page 76

    MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-10 SPEED GEARS (1) Check to ensure that the helical and clutch gear tooth surfaces are not damaged or worn. (2) Check to ensure that the synchronizer cone surfaces are not roughened, damaged or worn. (3) Check to ensure that the gear inside diameter and front and rear surfaces ar[...]

  • Page 77

    MANUAL TRANSMISSION (E - W) - Reverse Idler Gear <F5M42, W5M42> 22B-9-1 9. REVERSE IDLER GEAR <F5M42, W5M42> DISASSEMBL Y AND REASSEMBL Y 5 4 3 2 1 TFM0590 Apply gear oil to all moving parts before installation. Disassembly steps 1. Snap ring 2. Thrust washer 3. Reverse idler gear 4. Needle roller bearing 5. Reverse idler gear shaft INS[...]

  • Page 78

    MANUAL TRANSMISSION (E - W) - Speedometer Gear 22B-10-1 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 10. SPEEDOMETER GEAR DISASSEMBL Y AND REASSEMBL Y Lubricate all internal parts with gear oil dur- ing reassembly . 4 3 2 1 TFM0593 Disassembly steps 1. e-clip 2. Speedometer driven gear 3. O-ring 4. Sleeve[...]

  • Page 79

    MANUAL TRANSMISSION (E - W) - Select Lever 22B-1 1-1 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 1 1. SELECT LEVER DISASSEMBL Y AND REASSEMBL Y 5 4 3 2 1 6 7 8 9 10 11 N m TFM0589 Disassembly steps " A A 1. Dust cover 2. Nut 3. Spring washer 4. W asher 5. Select lever bushing 6. Select lever shoe 7. Select lever 8. Select lever[...]

  • Page 80

    MANUAL TRANSMISSION (E - W) - Control Housing 22B-12-1 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 12. CONTROL HOUSING DISASSEMBL Y AND REASSEMBL Y 5 4 3 2 1 22 Nm 6 9 7 8 10 11 12 13 14 15 16 17 18 19 20 TFM0916 Disassembly steps A A "" F A 1. Lock pin 2. Interlock plate 3. Control finger 4. Pin 5. Return spring 6. Stoppe[...]

  • Page 81

    MANUAL TRANSMISSION (E - W) - Control Housing 22B-12-2 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added DISASSEMBL Y SERVICE POINT A A " LOCK PIN REMOV AL Drive the lock pin out of position from the direction shown. REASSEMBL Y SERVICE POINTS " A A NEEDLE BEARING INST ALLA TION Press fit the needle bearing up the illustrated di[...]

  • Page 82

    MANUAL TRANSMISSION (E - W) - Control Housing 22B-12-1 22B-12-2a PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " D A SPRING PIN INST ALLA TION " E A SPRING PIN INST ALLA TION " F A LOCK PIN INST ALLA TION Drive in the lock pin in th e direction shown in the illustration. PWEE9508-C E Jan. 1997 Mitsubishi Motors Corporat[...]

  • Page 83

    MANUAL TRANSMISSION (E - W) - Clutch Housing 22B-13-1 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 13. CLUTCH HOUSING DISASSEMBL Y AND REASSEMBL Y 5 3 2 1 9.8 Nm 4 6 7* 8 TFM0759 Disassembly steps 1. Clutch release bearing retainer " E A 2. Oil seal " D A 3. Oil seal <F5M41, F5M42> A A "" C A 4. Outer race &[...]

  • Page 84

    MANUAL TRANSMISSION (E - W) - Clutch Housing 22B-13-2 A B " OUTER RACE REMOV AL Use the special tools to remove th e outer race. REASSEMBL Y SERVICE POINTS " A A BUSHING INST ALLA TION Press fit the bushing up to the illustrated position, while making sure that the split ends of the bushing do not coincide with the air purge groove. "[...]

  • Page 85

    MANUAL TRANSMISSION (E - W) - Clutch Housing 22B-13-3 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " C A OUTER RACE INST ALLA TION " D A OIL SEAL INST ALLA TION Apply transmission oil to th e oil seal lip area. Specified oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher " E A OIL SEAL INS[...]

  • Page 86

    MANUAL TRANSMISSION (E - W) - T ransmission Case 22B-14-1 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added 14. TRANSMISSION CASE DISASSEMBL Y AND REASSEMBL Y 5 4 3 2 1 6 TFM0600 Disassembly steps " C A 1. Oil seal " B A 2. Needle bearing 3. Oil guide 4. Snap ring " A A 5. Bushing 6. T ransmission case REASSEMBL Y SERVICE P[...]

  • Page 87

    MANUAL TRANSMISSION (E - W) - T ransmission Case 22B-14-2 PWEE9508-A E Nov . 1995 Mitsubishi Motors Corporation Added " B A NEEDLE BEARING INST ALLA TION Press fit the needle bearing until it is flush with the case, while making sure that the model number stamped side is oriented in the direction shown. " C A OIL SEAL INST ALLA TION Apply[...]

  • Page 88

    MANUAL TRANSMISSION (E - W) - Differential <F5M41, F5M42>, Front Differential <W5M42> 22B-15-1 15. DIFFERENTIAL <F5M41, F5M42>, FRONT DIFFERENTIAL <W5M42> DISASSEMBL Y AND REASSEMBL Y 10 9 8 7 6 5 4 3 2 1 132 Nm 2 9 6 7 3 TFM0760 Apply gear oil to all moving parts before installation. Disassembly steps " E A 1. Dif fere[...]

  • Page 89

    MANUAL TRANSMISSION (E - W) - Differential <F5M41, F5M42>, Front Differential <W5M42> 22B-15-2 DISASSEMBL Y SERVICE POINTS A A " BALL BEARING REMOV AL <F5M41> Use the special tool to remove th e ball bearing. A B " T APER ROLLER BEARING REMOV AL <F5M42> Use the special tool to remove the taper roller bearing. REASS[...]

  • Page 90

    MANUAL TRANSMISSION (E - W) - Differential <F5M41, F5M42>, Front Differential <W5M42> 22B-15-3 (4) Measure the backlash between the side gear an d pinion. Standard value: 0.025 - 0.150 mm (5) If the backlash is o ut of specification, select a spacer and re-measure the backlash. NOTE Adjust until the backlashes on both sides are equal. &[...]

  • Page 91

    MANUAL TRANSMISSION (E - W) - Differential <F5M41, F5M42>, Front Differential <W5M42> 22B-15-4 (2) T ighten to the specified torque in the illustrated sequence. PWEE9508-E E Jun. 1998 Mitsubishi Motors Corporation Revised 1 8 6 4 2 7 5 3[...]

  • Page 92

    MANUAL TRANSMISSION (E - W) - Center Differential <W5M42> 22B-16-1 16. CENTER DIFFERENTIAL <W5M42> DISASSEMBL Y AND REASSEMBL Y 5 4 3 2 1 6 15 16 17 7 8 9 10 11 12 13 14 12 11 12 9 12 132 Nm Apply gear oil to all moving parts before installation. Disassembly steps " D A 1. Center differential drive gear " C A 2. Center differe[...]

  • Page 93

    MANUAL TRANSMISSION (E - W) - Center Differential <W5M42> 22B-16-2 A B " T APER ROLLER BEARING REMOV AL Use the special tools to remove the taper roller bearing. REASSEMBL Y SERVICE POINTS " A A T APER ROLLER BEARING INST ALLA TION Use the special tool to install t he taper roller bearing. " B A T APER ROLLER BEARING INST ALLA [...]

  • Page 94

    MANUAL TRANSMISSION (E - W) - Center Differential <W5M42> 22B-16-3 (5) Install the front output shaft to the side gear and fit the snap ring. (6) Attach the spacer on the other side gear , then install the side gear in the center differential case. NOTE: If a new side gear is to be installed, select a spacer with medium thickness (0.93 - 1.00[...]

  • Page 95

    MANUAL TRANSMISSION (E - W) - T ransfer <W5M42> 22B-17-1 17. TRANSFER <W5M42> DISASSEMBL Y AND REASSEMBL Y 10 2 11 4 8 7 9 23 Nm 5 3 1 6 Apply gear oil to all moving parts before installation. Disassembly steps " F A 1. Air breather 2. Dust seal guard " E A 3. Oil seal " D A 4. Oil seal " A A 5. O-ring " A A 6. [...]

  • Page 96

    MANUAL TRANSMISSION (E - W) - T ransfer <W5M42> 22B-17-2 REASSEMBL Y SERVICE POINTS " A A O-RING INST ALLA TION Apply transmission oil to th e O-ring. T ransmission oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher . " B A OIL SEAL INST ALLA TION (1) Apply transmission oil to the oil seal lip area. T r[...]

  • Page 97

    MANUAL TRANSMISSION (E - W) - T ransfer <W5M42> 22B-17-3 " F A AIR BREA THER INST ALLA TION Apply sealant to t he air breather . Specified sealant: 3M SUPER WEA THERSTRIP No. 8001 or equivalent. PWEE9508-E E Jun. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 98

    NOTES[...]