User manual MITSUBISHI F5M41 - MANUAL TRANSMISSION

22B-0-1 MANUAL TRANSMISSION F5M41, F5M42, W5M42 CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-1 TRANSMISSION MODEL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-1 GEAR RATIO TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-2f SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-2f SEALANTS AND ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-2g LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-3 SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-4 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-1-9 2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-2-1 3. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-3-1 4. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-4-1 5. INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-5-1 6. INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-6-1 7. OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-7-1 8. OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-8-1 9. REVERSE IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . 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 , FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-15-1 16. CENTER DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-16-1 17. TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-17-1 E Mitsubishi Motors Corporation Mar. 2002 PWEE9508-I Revised 22B-0-2 NOTES MANUAL TRANSMISSION (E - W) - General Information 22B-0-3 GENERAL INFORMATION F5M41 6 2 3 7 8 1 4 5 9 10 15 14 13 12 11 TFM0809 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 8. 9. 10. 11. 12. 13. 14. 15. Clutch housing Release bearing retainer Input shaft Differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear Output shaft E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised 22B-0-4 MANUAL TRANSMISSION (E - W) - General Information F5M41 6 7 8 1 2 3 4 5 9 10 15 14 13 12 11 1. Reverse gear meshing noise prevention device 2. 5th-reverse speed synchronizer hub 3. 5th speed gear 4. 4th speed gear 5. 3rd-4th speed synchronizer hub 6. 3rd speed gear 7. Transmission case 8. 9. 10. 11. 12. 13. 14. 15. Clutch housing Release bearing retainer Input shaft Differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear Output shaft E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised MANUAL TRANSMISSION (E­W) ­ General Information 22B-0-4a F5M41 1 23 4 5 6 7 8 9 14 13 12 11 10 1. 2. 3. 4. 5. 6. 7. 5th-reverse speed synchronizer hub 5th speed gear 4th speed gear 3rd-4th speed synchronizer hub 3rd speed gear Transmission case Clutch housing 8. 9. 10. 11. 12. 13. 14. Release bearing retainer Input shaft Differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear Output shaft E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Added 22B-0-4b MANUAL TRANSMISSION (E­W) ­ General Information Intentionally blank E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Added MANUAL TRANSMISSION (E - W) - General Information 22B-0-5 F5M42 4 1 2 3 5 6 7 8 9 16 15 14 13 12 11 10 1. 2. 3. 4. 5. 6. 7. 8. Reverse idler gear 4th speed gear 3rd-4th speed synchronizer hub 3rd speed gear Transmission case Clutch housing Release bearing retainer Input shaft 9. 10. 11. 12. 13. 14. 15. 16. Output shaft Differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear 5th speed gear 5th-reverse speed synchronizer hub Reverse gear E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised 22B-0-6 MANUAL TRANSMISSION (E - W) - General Information F5M42 4 1 2 3 5 6 7 8 9 16 15 14 13 12 11 10 1. 2. 3. 4. 5. 6. 7. 8. Reverse idler gear 4th speed gear 3rd-4th speed synchronizer hub 3rd speed gear Transmission case Clutch housing Release bearing retainer Input shaft 9. 10. 11. 12. 13. 14. 15. 16. Output shaft Differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear 5th speed gear 5th-reverse speed synchronizer hub Reverse gear E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised MANUAL TRANSMISSION (E - W) - General Information W5M42 1 2 3 4 5 6 22B-0-7 7 8 9 10 19 18 17 16 15 14 13 11 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Reverse idler gear 4th speed gear 3rd-4th speed synchronizer hub 3rd speed gear Transmission case Clutch housing Release bearing retainer Input shaft Output shaft Viscous coupling 11. 12. 13. 14. 15. 16. 17. 18. 19. Front differential Transfer driven gear Center differential 1st speed gear 1st-2nd speed synchronizer hub 2nd speed gear 5th speed gear 5th-reverse speed synchronizer hub Reverse gear E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Added MANUAL TRANSMISSION (E­W) ­ Specifications 22B-1-1 1. SPECIFICATIONS TRANSMISSION MODEL TABLE ­ MODEL 1996 Transmission model EUR F5M41-1-B8A1 F5M41-1-F8A1 F5M41-1-R8A EXP F5M41-1-F8A1 F5M41-1-R8A F5M41-1-R8A F5M42-1-Y8A Gear ratio B A A A A A C Speedometer gear ratio 31/36 31/36 31/36 31/36 31/36 31/36 31/36 Final gear ratio 3.454 3.714 4.052 3.714 4.052 4.052 4.625 Vehicle model CJ4A CJ4A, CK4A CJ1A, CK1A CJ4A, CK4A CJ1A, CK1A CJ2A, CK2A CK4A Engine model 4G92-MVV 4G92-MPI 4G13 4G92-MPI 4G13 4G15 4G92-MIVEC TRANSMISSION MODEL TABLE ­ MODEL 1997 Transmission model EUR F5M42-1-F7N F5M42-2-F6N2 F5M42-2-F6N5 EXP F5M42-1-F6N4 F5M42-1-F7N F5M42-1-R6N2 F5M42-1-R6N3 F5M42-2-F6N2 F5M42-2-V6N Gear ratio D F E D D D D F D Speedometer gear ratio 30/36 29/36 29/36 29/36 30/36 29/36 29/36 29/36 29/36 Final gear ratio 3.722 3.722 3.722 3.722 3.722 4.058 4.058 3.722 4.312 Vehicle model EA2A, EA2W EA5A, EA5W EA6A, EA6W EA2A EA2A EA1A EA2A EA5A EA4A Engine model 4G63 6A13 4D68 4G63-MPI 4G63-MPI 4G93 4G63-CARB 6A13 6A12 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised 22B-1-2 MANUAL TRANSMISSION (E­W) ­ Specifications TRANSMISSION MODEL TABLE ­ MODEL 1998 Transmission model EUR F5M41-1-B8A2 F5M41-1-F8A5 F5M41-1-R8A1 F5M42-2-F7N2 F5M42-1-F8A4 F5M42-2-F6NA F5M42-2-F6N7 EXP F5M41-1-F8A5 F5M41-1-R8A1 F5M41-1-R8A1 F5M42-1-R6N6 F5M42-1­F6N9 F5M42-2-R6N8 Gear ratio B A A D G E F A A A D D E Speedometer gear ratio 31/36 31/36 31/36 30/36 31/36 29/36 29/36 31/36 31/36 31/36 29/36 29/36 29/36 Final gear ratio 3.454 3.714 4.052 3.722 3.722 3.722 3.722 3.714 4.052 4.052 4.058 3.722 4.058 Vehicle model CJ4A CJ4A CK1A, CJ1A EA2A, EA2W DA2A EA6A, EA6W EA5A, EA5W CJ4A, CK4A CJ1A, CK1A CJ2A, CK2A EA1A EA2A EA6A Engine model 4G92 4G92 4G13 4G63 4G93-GDI 4D68 6A13 4G92 4G13 4G15 4G93 4G63 4D68 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised MANUAL TRANSMISSION (E­W) ­ Specifications TRANSMISSION MODEL TABLE ­ MODEL 1999 Transmission model EUR F5M42-1-V5A4 F5M42-2-R5A3 W5M42-1-V5A1 F5M42-1-F8A4 F5M42-2-F7N2 F5M42-2-F6NC F5M42-2-F6N7 F5M42-2-F6NA EXP F5M42-1-R6N6 F5M42-1-R6N7 F5M42-1-F6N9 F5M42-1-F7N1 F5M42-2-V6N1 F5M42-2-F6N7 F5M42-2-R6N8 F5M42-2-R5A2 MMAL F5M41-1-F8A5 F5M42-1-F8A7 F5M42-2-R5A2 Gear ratio D G H G D G F E D D D D D F E D A F D Speedometer gear ratio 28/36 28/36 28/36 31/36 30/36 29/36 29/36 29/36 29/36 29/36 29/36 30/36 29/36 29/36 29/36 28/36 31/36 31/36 28/36 Final gear ratio 4.312 4.058 4.352 3.722 3.722 3.722 3.722 3.722 4.058 4.058 3.722 3.722 4.312 3.722 4.058 4.058 3.714 3.722 4.058 Vehicle model N61W N84W N94W DA2A EA2A, EA2W EA3A, EA3W EA5A, EA5W EA6A, EA6W EA1A EA2A EA2A EA2A EA4A EA5A EA6A N84W CJ2A, CK2A CJ5A, CK5A N84W 22B-1-2a Engine model 4G93-GDI 4G64-GDI 4G64-GDI 4G93-GDI 4G93 4G64-GDI 6A13 4D65 4G93 4G63 4G63 4G63 6A12-MIVEC 6A13 4D56 4G64 4G15 4G93 4G64 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised 22B-1-2b MANUAL TRANSMISSION (E­W) ­ Specifications TRANSMISSION MODEL TABLE ­ MODEL 2000 Transmission model EUR F5M41-1-R8A1 F5M41-1-F8A5 F5M41-1-B8A2 F5M42-1-R7A2 F5M42-1-V5A4 F5M42-2-R5A3 W5M42-1-V5A1 EXP F5M41-1-R8A1 F5M41-1-F8A5 F5M42-1-R6N6 F5M42-1-R6N7 F5M42-1-F6N9 F5M42-2-F6N7 F5M42-2-R5A2 MMAL F5M42-2-R5A2 Gear ratio A A B G D G H A A D D D F D D Speedometer gear ratio 31/36 31/36 31/36 30/36 28/36 28/36 28/36 31/36 31/36 29/36 29/36 29/36 29/36 28/36 28/36 Final gear ratio 4.052 3.714 3.454 4.058 4.312 4.058 4.352 4.052 3.714 4.058 4.058 3.722 3.722 4.058 4.058 Vehicle model CJ1A CJ4A CJ4A DA2A N61W N64W, N84W N94W CJ1A, CK1A CJ4A, CK4A EA1A EA2A EA2A, EA2W EA5A N84W N84W Engine model 4G13 4G92 4G92-MVV 4G93-GDI 4G93-GDI 4G64-GDI 4G64-GDI 4G13 4G92 4G93 4G63 4G63 6A13 4G64 4G64 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised MANUAL TRANSMISSION (E­W) ­ Specifications TRANSMISSION MODEL TABLE ­ MODEL 2001 Transmission model EUR F5M41-1-R8A1 F5M41-1-F8A5 F5M42-1-F8AC F5M42-1-R7A2 F5M42-2-F7N2 F5M42-2-F6NC F5M42-2-F6N7 F5M42-2-V5A F5M42-2-R5A3 EXP F5M41-1-R8A1 F5M41-1-R7B F5M41-1-R8B F5M41-1-F8A5 F5M42-1-F6N9 F5M42-1-F7N1 F5M42-1-R6N6 F5M42-2-R6N7 F5M42-1-F6N9 F5M42-2-F6N7 F5M42-2-R6N8 F5M42-2-R5A2 MMAL F5M41-1-F8A5 F5M42-1-F8A7 F5M42-2-R5A2 Gear ratio A A I G D G F D G A A A A D D D D D F E D A F D Speedometer gear ratio 31/36 31/36 31/36 30/36 30/36 29/36 29/36 28/36 28/36 31/36 30/36 31/36 31/36 29/36 30/36 29/36 29/36 29/36 29/36 29/36 28/36 31/36 31/36 28/36 Final gear ratio 4.052 3.714 3.722 4.058 3.722 3.722 3.722 4.312 4.058 4.052 4.052 4.052 3.714 3.722 3.722 4.058 4.058 3.722 3.722 4.058 4.058 3.714 3.722 4.058 Vehicle model CJ1A CJ4A DG5A DA2A EA2A, W EA3A, W EA5A, W N63W N64W CJ1A, CJ2A CS1A, CS3A CS1A, CS3A CJ4A EA2W EA2W EA1A EA2A EA2A EA5A EA6A N84W CJ2A, CK2A CJ5A, CK5A N84W 22B-1-2c Engine model 4G13 4G92 4G93 4G93 4G63 4G64 6A13 4G63 4G64 4G13, 4G15 4G13, 4G18 4G13, 4G18 4G92 4G63 4G63 4G93 4G63 4G63 6A13 4D68 4G64 4G15 4G93 4G64 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised 22B-1-2d MANUAL TRANSMISSION (E­W) ­ Specifications TRANSMISSION MODEL TABLE ­ MODEL 2002 Transmission model EUR F5M41-1-R8A1 F5M41-1-F8A5 F5M41-1-R8B F5M42-1-F8AC F5M42-1-R7A2 F5M42-2-V5A F5M42-2-R5A3 W5M42-1-V5A1 EXP F5M41-1-F8A5 F5M41-1-R8A1 F5M42-2-F6N7 F5M42-1-R6N6 F5M42-1-R6N7 F5M42-1-F6N9 F5M42-2-R6N8 F5M41-1-R7B F5M41-1-R8B F5M41-1-V7B F5M41-1-V8B1 F5M42-1-R7A2 F5M42-2-R5A2 MMAL F5M42-2-R5A2 F5M41-1-F8A5 F4M42-1-F8A7 Gear ratio A A A I G D G H A A F D D D E A A A A G D D A F Speedometer gear ratio 31/36 31/36 31/36 31/36 30/36 28/36 28/36 28/36 31/36 31/36 29/36 29/36 29/36 29/36 29/36 30/36 31/36 30/36 31/36 30/36 28/36 28/36 31/36 31/36 Final gear ratio 4.052 3.714 4.052 3.722 4.058 4.312 4.058 4.352 3.714 4.052 3.722 4.058 4.058 3.722 4.058 4.052 4.052 4.333 4.333 4.058 4.058 4.058 3.714 3.722 Vehicle model CJ1A CJ4A CS3A DG5A DA2A N83W N84W N94W CJ4A CJ1A, CJ2A EA5A EA1A EA2A EA2A, W EA6A CS1A, CS3A CS1A, CS3A CS1A CS1A DA3A N84W N84W CJ2A CJ5A, CK5A Engine model 4G13 4G92 4G18 4G93 4G93 4G63 4G64 4G64 4G92 4G13, 4G15 6A13 4G93 4G63 4G63 4D68 4G13, 4G18 4G13, 4G18 4G13 4G13 4G93 4G64 4G64 4G15 4G93 E Mitsubishi Motors Corporation Mar. 2002 PWEE9508-I Revised MANUAL TRANSMISSION (E­W) ­ Specifications TRANSMISSION MODEL TABLE ­ MODEL 2003 Transmission model EUR F5M41-1-F8A5 F5M41-1-R8A1 F5M42-2-V5A F5M42-2-R5A3 W5M42-1-V5A1 F5M42-1-R7A2 EXP F5M41-1-F8A5 F5M41-1-R8A1 F5M42-2-R5A2 F5M41-1-R7B1 F5M41-1-R8B1 MMAL F5M41-1-F8A5 F5M42-1-F8A7 F5M42-2-R5A2 F5M42-1-F8B2 Gear ratio A A D G H G A A D A A A F D F Speedometer gear ratio 31/36 31/36 28/36 28/36 28/36 30/36 31/36 31/36 28/36 30/36 31/36 31/36 31/36 28/36 31/36 Final gear ratio 3.714 4.052 4.312 4.058 4.325 4.058 3.714 4.052 4.058 4.052 4.052 3.714 3.722 4.058 3.722 Vehicle model CJ4A CJ1A N83W N84W N94W DA2A CJ4A CJ1A, CJ2A N84W CS1A, CS3A CS1A, CS3A CJ2A CJ5A, CK5A N84W CS6A 22B-1-2e Engine model 4G92 4G13 4G64 4G64 4G64 4G93 4G92 4G13, 4G15 4G64 4G13, 4G18 4G13, 4G18 4G15 4G93 4G64 4G93 E Mitsubishi Motors Corporation Mar. 2002 PWEE9508-I Revised 22B-1-2f MANUAL TRANSMISSION (E­W) ­ Specifications GEAR RATIO TABLE A 1st 2nd 3rd 4th 5th Reverse 3.583 1.947 1.343 0.976 0.804 3.416 H 1st 2nd 3rd 4th 5th Reverse Transfer 3.583 1.947 1.266 0.970 0.767 3.363 0.3018 B 3.727 1.947 1.343 0.976 0.804 3.416 C 3.071 1.947 1.379 1.030 0.767 3.363 D 3.583 1.947 1.379 1.030 0.820 3.363 I 3.583 1.947 1.266 0.970 0.820 3.363 ­ E 3.583 1.947 1.379 1.030 0.733 3.363 F 3.583 1.947 1.379 1.030 0.767 3.363 G 3.583 1.947 1.266 0.970 0.767 3.363 SERVICE SPECIFICATIONS Items Input shaft front bearing end play mm Input shaft rear bearing end play mm Input shaft rear bearing end play mm Input shaft 5th speed gear end play mm Output shaft front bearing end play mm Output shaft rear bearing end play mm Output shaft 3rd speed gear end play mm Differential case end play mm Differential case pinion backlash mm Differential case preload mm Allowable range ­0.01­0.12 ­0.01­0.09 ­0.01­0.12 ­0.01­0.09 ­0.01­0.12 ­0.01­0.09 ­0.01­0.09 0.05­0.17 0­0.150 0.05­0.11 Limit ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ NOTE: Standard play = 0 mm E Mitsubishi Motors Corporation Mar. 2002 PWEE9508-I Revised MANUAL TRANSMISSION (E­W) ­ Specifications Items Center differential case pinion backlash mm Center differential case preload mm Synchronizer ring back surface to gear clearance mm Allowable range 0.025­0.150 0.05­0.11 ­ Limit ­ ­ 0.5 22B-1-2g NOTE: Standard play = 0 mm SEALANTS AND ADHESIVES TRANSMISSION Items Clutch housing­transmission case mating surface Control housing­transmission case mating surface Under cover­transmission case mating surface Air breather Differential drive gear bolt Center differential drive gear bolt Front bearing retainer bolt (countersink head bolt) 3M SUPER WEATHERSTRIP No. 8001 or equivalent 3M STUD Locking No. 4170 or equivalent Specified sealants and adhesives MITSUBISHI genuine sealant part No. MD997740 or equivalent TRANSFER Item Air breather Specified sealant 3M SUPER WEATHERSTRIP No. 8001 or equivalent E Mitsubishi Motors Corporation Mar. 2002 PWEE9508-I Added 22B-1-2h MANUAL TRANSMISSION (E­W) ­ Specifications Intentionally blank E Mitsubishi Motors Corporation Mar. 2002 PWEE9508-I Added MANUAL TRANSMISSION (E - W) - Specifications 22B-1-3 FORM-IN-PLACE GASKET The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size. Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. DISASSEMBLY The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remaining in the bolt holes. FORM-IN-PLACE GASKET APPLICATION When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG. LUBRICANTS TRANSMISSION Items Drive shaft oil seal lip area Control shaft oil seal lip area Input shaft oil seal lip area Select lever shoe Specified lubricants Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher MITSUBISHI genuine grease part No. 0101011 or equivalent TRANSFER Items Drive shaft oil seal lip area Front differential oil seal lip area Each O-ring Specified lubricants Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised 22B-1-4 MANUAL TRANSMISSION (E­W) ­ Specifications SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT Part name Snap ring (For adjustment o input sha t front bearing end of shaft ront play) Thickness mm 2.24 2.31 2.38 Snap ring (For adjustment o input sha t rear bearing end of shaft play ....F5M41) (For adjustment of output shaft rear bearing end play ....F5M42, W5M42) 2.31 2.35 2.39 2.43 2.47 2.51 2.55 2.59 2.63 2.67 2.71 Thrust plate: F5M42, W5M42 (For adjustment o input sha t 5th speed gear of shaft end play) 2.82 2.86 2.90 2.94 2.98 3.02 3.06 3.10 Snap ring (For adjustment o output sha t front bearing end of shaft ront play) (For adjustment o input sha t rear bearing end of shaft play ....F5M42, W5M42) 1.43 1.51 1.59 Identification symbol None Blue Brown Black (2) None Blue Brown Green White Yellow Black Orange Blue Brown 0 2 3 5 6 7 8 9 Green (2) White (2) Yellow (2) Part No. MD706537 MD706538 MD706539 MD747149 MD746561 MD746562 MD746563 MD746564 MD746565 MD746566 MD746567 MD746568 MD746569 MD746570 MD748015 MD748016 MD748017 MD748018 MD748019 MD748020 MD748021 MD748022 MD746708 MD746709 MD746710 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised MANUAL TRANSMISSION (E - W) - Specifications Part name Snap ring: F5M41 (For adjustment of output shaft rear bearing end play) Thickness mm 2.31 2.35 2.39 2.43 2.47 2.51 2.55 2.59 2.63 2.67 2.71 Snap ring: F5M41 (For adjustment of output shaft 3rd speed gear end play) 2.81 2.85 2.89 2.93 2.97 3.01 3.05 3.09 Snap ring: F5M42, W5M42 (For adjustment of output shaft 3rd speed gear end play) 2.81 2.85 2.89 2.93 2.97 3.01 3.05 3.09 Identification symbol Black (2) None Blue Brown Green White Yellow Black Orange Blue Brown Green White Yellow Black Orange Red Pink Blue Green White Yellow Black Orange Red Pink Blue Part No. MD748800 MD748801 MD748802 MD748803 MD748804 MD748805 MD748806 MD748807 MD748808 MD748809 MD748810 MD748782 MD748783 MD748784 MD748785 MD748786 MD748787 MD748788 MD748789 MD745799 MD745800 MD745801 MD745802 MD745803 MD745804 MD745805 MD745806 22B-1-5 E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised 22B-1-6 Part name MANUAL TRANSMISSION (E - W) - Specifications Thickness mm 0.77 0.86 0.95 1.04 1.13 1.22 1.31 1.40 1.49 1.58 1.67 1.76 Identification symbol 77 86 95 04 D G E None C B A F Part No. MD754476 MD720938 MD720941 MD720944 MD700270 MD700271 MD706574 MD706573 MD706572 MD706571 MD706570 MD706575 Spacer: F5M41 (For adjustment of differential case end play) E Mitsubishi Motors Corporation July 1999 PWEE9508-F Revised MANUAL TRANSMISSION (E­W) ­ Specifications Part name Spacer: F5M42 (For adjustment o differential case preload) of di erential Thickness mm 0.71 0.74 0.77 0.80 0.83 0.86 0.89 0.92 0.95 0.98 1.01 1.04 1.07 1.10 1.13 1.16 1.19 1.22 1.25 Identification symbol 71 74 77 80 83 86 89 92 95 98 01 04 07 J D K L G M Part No. MD754475 MD727660 MD754476 MD727661 MD720937 MD720938 MD720939 MD720940 MD720941 MD720942 MD720943 MD720944 MD720945 MD710454 MD700270 MD710455 MD710456 MD700271 MD710457 22B-1-7 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised 22B-1-8 Part name MANUAL TRANSMISSION (E­W) ­ Specifications Thickness mm 0.74 0.77 0.80 0.83 0.86 0.89 0.92 0.95 0.98 1.01 1.04 1.07 1.10 1.13 1.16 1.19 1.22 1.25 1.28 1.31 Identification symbol 74 77 80 83 86 89 92 95 98 01 04 07 J D K L G M N E ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ Part No. MD727660 MD745476 MD727661 MD720937 MD720938 MD720939 MD720940 MD720941 MD720942 MD720943 MD720944 MD720945 MD710454 MD700270 MD710455 MD710456 MD700271 MD710457 MD710458 MD706574 MA180862 MA180861 MA180860 MA180875 MR581570 MA180876 MR581571 MD744236 MD744235 MD744234 MD744233 MD744232 Revised Spacer: W5M42 (For adjustment o center di erential case of differential preload) Spacer: F5M41, F5M42 (For adjustment o differential case backlash) of di erential 0.72 ­ 0.79 0.85 ­ 0.90 0.94 ­ 0.98 1.02 ­ 1.06 1.06 ­ 1.10 1.12 ­ 1.16 1.16 ­ 1.20 Spacer: W5M42 (For adjustment o center di erential case pinion of differential backlash) 0.48 ­ 0.55 0.56 ­ 0.65 0.66 ­ 0.73 0.74 ­ 0.81 0.82 ­ 0.89 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H MANUAL TRANSMISSION (E­W) ­ Specifications TORQUE SPECIFICATIONS TRANSMISSION Items Under cover mounting bolt Interlock plate bolt Clutch housing­transmission case mounting bolt Clutch release bearing retainer mounting bolt Control housing mounting bolt Shift cable bracket mounting bolt Speedometer gear mounting bolt Stopper bracket mounting bolt Select lever mounting bolt Select lever mounting nut Center differential flange mounting screw Center differential drive gear mounting bolt Differential drive gear mounting bolt Back-up lamp switch Front bearing retainer mounting bolt Poppet spring Restrict ball Reverse idler gear shaft mounting bolt Reverse shift lever mounting bolt Roll stopper bracket mounting bolt Oil temperature sensor Connector bracket mounting bolt Clutch fluid line bracket mounting bolt Nm 6.9 30 44 9.8 18 18 3.9 19 18 11 3.9 132 132 32 18 32 32 48 18 70 22 18 18 22B-1-9 TRANSFER Items Transfer cover mounting bolt Transmission ­ transfer mounting bolt Nm 23 69 E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised MANUAL TRANSMISSION (E - W) - Special Tools 22B-2-1 2. SPECIAL TOOLS TRANSMISSION Tool Number MB990926 Name Installer adapter Use 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 MB990934 Installer adapter Installation of roller bearing outer race MB990935 Installer adapter Installation of differential case taper roller bearing outer race MB990937 Installer adapter Installation of center differential taper roller bearing MB990938 Handle Use with Installer adapter MD998325 Differential oil seal installer Installation of differential oil seal E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised 22B-2-2 Tool MANUAL TRANSMISSION (E - W) - Special Tools Number MD998346 Name Bearing outer race remover Use Removal of roller bearing outer race MD998772 Valve spring compressor Removal of roller bearing outer race MD998801 Bearing remover Installation and removal of gears, bearings and sleeves MD998812 Installer cap Use with Installer and Installer adapter MD998813 Installer-100 Use with Installer cap and Installer adapter MD998814 Installer-200 Use with Installer cap and Installer adapter MD998816 Installer (30) adapter Installation of input shaft front bearing MD998817 Installer (34) adapter Installation of input shaft front bearing , output shaft rear bearing MD998818 Installer (38) adapter Installation of input shaft rear bearing, roller bearing inner race, reverse gear, needle roller bearing, reverse gear bearing sleeve and reverse bearing sleeve E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised MANUAL TRANSMISSION (E - W) - Special Tools Tool Number MD998819 Name Installer (40) adapter Use 22B-2-3 Installation of 5th-reverse speed synchronizer hub, differential case bearing, 4th speed gear and 5th speed gear sleeve MD998820 Installer (42) adapter Installation of 5th speed gear sleeve, 2nd speed gear sleeve MD998822 Installer (46) adapter Installation of 1st speed gear sleeve,1st-2nd speed synchronizer hub , 2nd speed gear sleeve and 3rd speed gear MD998823 Installer (48) adapter Installation of differential case taper roller bearing inner race MD998824 Installer (50) adapter Installation of 4th speed gear sleeve and 5th speed gear MD998825 Installer (52) adapter Installation of 1st-2nd speed synchronizer hub, 3rd-4th speed synchronizer hub and 1st speed gear sleeve MD998826 Installer (54) adapter Installation of 3rd-4th speed synchronizer hub MD998917 Bearing remover Installation and removal of gears, bearings and sleeves MD999566 Claw Removal of differential case taper roller bearing outer race E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised 22B-2-4 TRANSFER Tool MANUAL TRANSMISSION (E - W) - Special Tools Number MB990887 Name Arm bush remover and installer ring Use 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 of transfer extension housing oil seal MD998800