Disassembly and Assembly
TRANSAXLE DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - SPRING PIN REMOVAL
Remove the spring pin.
B - LOCK NUTS REMOVAL
1. Unstake lock nuts of the input shaft and intermediate gear.
2. Shift the transmission in reverse using the control lever and select lever.
3. Install the special tool onto the input shaft.
4. Screw a bolt 10 mm (0.39 in.) into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
5. Remove the lock nut, while using the bolt as a spinner handle stopper.
C - SPRING PINS REMOVAL
Remove the spring pins for 1st-2nd and 3rd-4th speed shift forks.
D - SHIFT RAIL ASSEMBLY REMOVAL
1. Shift the 1st-2nd speed shift fork to the 2nd speed.
2. Shift the 3rd-4th speed shift fork to the 4th speed.
3. Rotate the shift controls in the direction of the arrow in numerical order. Remove the shift lugs from the control finger and interlock plate.
4. Raise each of the shift rails upward and remove them from the clutch housing.
5. Remove all the shift rails and forks.
E - INTERMEDIATE GEAR ASSEMBLY REMOVAL
Lift up the input shaft assembly and remove the intermediate gear assembly.
INSPECTION
BACKUP LIGHT SWITCH
Operate the backup light switch to check continuity with an ohmmeter. If no continuity, replace the switch.
REASSEMBLY SERVICE POINTS
A - OIL SEAL INSTALLATION
Install the drive shaft oil seal using the special tool.
B - OIL SEAL INSTALLATION
Install the input shaft front oil seal using the special tool.
C - INTERMEDIATE GEAR ASSEMBLY/INPUT SHAFT ASSEMBLY INSTALLATION
Lifting up the input shaft assembly, install it simultaneously with the intermediate gear assembly.
SEALANT TO SCREW APPLICATION
Apply specified sealant, MOPAR Part No.4318031 or No.4318032 or equivalent, to the bolt threads.
CAUTION: Do not apply to the bolt head.
E - SHIFT RAIL ASSEMBLY INSTALLATION
1. Set the 1st-2nd speed synchronizer sleeve at 2nd speed.
2. Set the 3rd-4th speed synchronizer sleeve at 4th speed.
3. Fit the shift forks of shift rail assembly to groove of sleeves.
4. Insert the shift rails into the shift rail holes of clutch housing.
5. Turn the shift rails in the directions indicated by the arrows in the order shown in the illustration, and engage the shift lugs to control finger and interlock plate.
F - SPRING PINS INSTALLATION
Install the spring pins using the special tool or a pin punch. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.
CAUTION: Do not reuse the spring pins.
G - SPACERS SELECTION
1. Place two pieces of solder measuring about 10 mm (0.39 in.) in length and 1.6 mm (0.063 in.) in diameter as illustrated and install the outer races.
2. Install the transaxle case and tighten the bolts to specified torque.
3. Remove the transaxle case.
4. Remove the outer races and take out the crushed solder.
5. If the solder is not broken, carry out the work in steps 1 and 4 with large diameter solder.
6. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives specified value.
Standard value:
Intermediate gear preload 0.05-0.10 mm (0.0020-0.0039 in.)
Output shaft preload 0.05-0.10 mm (0.0020-0.0039 in.)
Differential case preload 0.05-0.10 mm (0.0020-0.0039 in.)
7. Install the selected spacers, and then install bearing outer races into holes of case.
H - OIL SEAL INSTALLATION
Install the drive shaft oil seal using the special tool.
I - OIL GUIDE INSTALLATION
Install the oil guide to the transaxle case as illustrated.
J - TRANSAXLE CASE INSTALLATION
1. Set so that the threaded hole in the head of the reverse idler gear shaft is in the direction shown in the illustration.
NOTE: If there is a significant deviation of the direction of the threaded hole, it will become impossible to align the threaded hole and the hole in the case after the transaxle case is installed.
2. Apply specified sealant, MITSUBISHI Genuine Part No. MD997740 or equivalent, to gasket surface side of the transaxle case.
3. Install the transaxle case onto the clutch housing.
4. As shown in the illustration, insert a Phillips-head screwdriver [with an 8 mm (0.31 in.) shaft diameter] from the bolt hole in the case, and use it to align the threaded hole in the reverse idler gear shaft and the bolt hole in the case.
5. Install the reverse idler gear shaft bolt and tighten the bolt by fingers.
6. Tighten the all transaxle case tightening bolts to specified torque.
7. Tighten the reverse idler gear shaft bolt to specified torque.
K - LOCK NUTS INSTALLATION
1. Install the special tool to the splined end of input shaft.
2. Screw a bolt 10 mm (0.39 in.) into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
3. Shift the transaxle in reverse using control lever and select lever.
4. Tighten the lock nut to specified torque, while using the bolt attached in the above step as a spinner handle stopper.
5. Loosen the lock nuts.
6. Retighten the lock nuts to specified torque.
7. Stake the lock nut.
L - SPRING PIN INSTALLATION
1. Install the spring pin using the special tool or a pin punch.
CAUTION: Do not reuse the spring pins.
2. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.
M - ADHESIVE TO AIR BREATHER APPLICATION
Apply specified adhesive, MOPAR Part No.4318025 or equivalent, to air breather mounting portion and install to the clutch housing.
N - SEALANT TO SCREW BOLTS APPLICATION
Apply specified sealant, MOPAR Part No.4318031 or MOPAR Part No.4318032 or equivalent, to screw bolts mounting portion.
O - SEALANT TO REAR COVER APPLICATION
Apply specified sealant, MITSUBISHI Genuine Part No.MD997740 or equivalent, to the rear cover.
CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuity.