Content

Transmission

Chapter I Outline ..................................................... 1 l Check ............................................................ 17

l Structure type and main technique parameters 1 Chapter V Output disintegration and assembly ..... 19
l Transport and storage ...................................... 1 l Disintegration instructions ............................ 20
l Control ............................................................ 1 l Assembly instructions ................................... 21
l Maintenance and service ................................. 2 l Check ............................................................ 23
l Maintenance specifications ............................. 3 Chapter VI Disintegration and assembly of reverse
l Sealant and adhesive ....................................... 3 intermediate gear ................................................... 25
l Grease .............................................................. 4 l Check ............................................................ 25
l Adjusting snap ring and spacer ....................... 4 Chapter VII Disintegration and assembly of control
l Specifications of tightening torque.................. 6 shell ....................................................................... 26
Chapter II General faults and their troubleshooting 7 l Disintegration instructions ............................ 27
l Out-of-gear ...................................................... 7 l Assembly instructions ................................... 27
l Difficulty in shifting ........................................ 7 Chapter VIII Disintegration and assembly of clutch
l Noise in the transmission ................................ 7 housing .................................................................. 28
l Oil leakage ...................................................... 7 l Disintegration instructions ............................ 28
l Bearing abnormally damaged .......................... 7 l Assembly instructions ................................... 29
Chapter III Removal of transmission assembly....... 8 Chapter IX Disintegration and assembly of
l Disintegration instructions: ............................. 9 transmission housing ............................................. 30
l Adjustment prior to assembly ......................... 9 l Assembly instructions ................................... 30
l Assembly instructions ................................... 10 Chapter X Disintegration and assembly of
l Check ............................................................ 12 differential case ..................................................... 32
Chapter IV Disintegration and assembly of input l Disintegration instructions ............................ 32
shaft ....................................................................... 13 l Assembly instructions ................................... 32
l Disintegration instructions ............................ 14 Chapter XI Special tools ....................................... 34
l Assembly instructions ................................... 15
 Outline

Chapter I Outline
l Structure type and main technique parameters
1. Structure type
All synchronized manual shift mechanical transmission features flexible shifting, good hand fell, low
noise, compact in structure, powerful loading capacity, good air tightness performance. Its five forward
gears and one reverse gear are characterized by helical gear constant mesh drive, where the 1st and 2nd
gear are of three-cone synchronizer and others of shifting by the single-cone synchronizer. The shifting
mechanism applies the cable-type remote control.
2. Main technique parameters

Torque capacity 230N.m

Type Manual
Drive mode 2 front wheels drive
Number of gears 5
Clutching control Hydraulic pressure
Weight (kg) 48(oil-free)
Specification of transmission lubricant 75W-90(GL-4)
Fill sidewise the necessary amount into the plug hole.
Fill method of transmission lubricant
Lubricant level: lower plane of plug hole.
Filling volume of transmission lubricant 2.1L

l Transport and storage

1. The transmission shall take the anti-rust measures to protect the transmission from rust during the
normal transport and storage.
2. The transmission should be packed prior to the transport. The packing case shall ensure that no damage
on the transmission occurs under normal transport.
3. The transmission shall be stored in a ventilated and dry warehouse.

l Control
Through the control lever in cab, you can finally control the gear selector and shifting lever to operate
the shifting. Different gear selections and shifting positions are displayed in correspondence with
various directions shown on the handle ball of control lever. Each time when down shifted, the control
lever will return automatically to the N position; The gear selection is only permitted when returned to
the neutral position.
1. While shifting, you should fully step down the clutch pedal to disengage the transmission from the
engine torque, and quickly control the gear shift lever. The slow gear shall be applied at the start time.
2. In uphill, downhill and turning around, slow gear shall be applied, the coast with cut-off clutch is not
allowed.
3. When it is difficult to operate the transmission lever, you should park your vehicle to check the cause of
failure instead of applying the excessive thrust power.

1
 Outline

l Maintenance and service

1. The maintenance of transmission use will be carried out as per the requirements by the use of business
car and maintenance, which are generally divided into the technical maintenances in three levels.
2. Regularly check and replace (or add) the transmission lubricant.

Table of regular inspection and maintenance of transmission

The items are indicated with the distance and time (monthly), the check should be based on whichever comes
first.
○ Position check, tightening or adjustment; ★ Replace the lubricant

Interval of inspection(For the odometer readings and number of months, whichever comes first)
Month － 3 6 12 18 24 30 36 42 48 54
Item
Odometer reading
1 5 10 20 30 40 50 60 70 80 90
×1000kms
Check of internal transmission
Check the level of gear oil inside
○ ○ ○ ○ ○
the transmission
Replace the Common use
★ ★ ★ ★ ★
gear oil conditions
inside the
transmission Severe use
★ ★ ★ ★ ★ ★ ★ ★
. conditions

Other inspections

Note: The “severe use conditions” include the following items:

1. Driving in dusty areas or vehicles are often exposed to the saline air or salt water
2. Driving on uneven and ponding or mountain road.
3. Traveling in the cold regions.
4. In the cold season, the engine has been running idle for a long time or often drives in short-distance.
5. In case, where frequent use of brakes and use of emergency braking are required.
6. Towing of vehicle.
7. Used as a taxi or a rent car
8. The time to slowly drive in urban area with heavy traffic in temperatures over 32℃, is more than 50% of
the total travel time.
9. The time to drive at the high-speed more than120 km/h or more, in temperatures over 30 ℃, is more
than 50% of the total travel time
10. Overload driving.

2
 Outline

l Maintenance specifications
Allowable range Limit value
End play of front axle bearing of input shaft: mm －0.01～0.21 －
End play of rear axle bearing of input shaft: mm －0.01～0.12 －
End play of the 5th gear shaft of input shaft: mm －0.01～0.09 －
End play of front axle bearing of output shaft: mm －0.01～0.12 －
End play of rear axle bearing of output shaft: mm －0.01～0.09 －
rd
End play of the 3 gear shaft of output shaft: mm －0.01～0.09 －
Backlash of differential case pinion: mm 0.025～0.150 －
Preload of differential case: mm 0.05～0.11 －
Clearance between the synchronizer ring back and gear: mm － 0.05

Remark: Standard clearance -0mm

l Sealant and adhesive

Items Specified sealant and adhesive
Matching surface of clutch housing － Mitsubishi genuine sealant
transmission housing Part no.MD997740 or equivalent
Matching surface between the control shell
and transmission housing
Matching surface between the back cover
and transmission housing
Air vent 3M SUPER WEATHERSTRIP NO.8001 or equivalent
Gear bolt of differential drive 3M STUD LOCKING NO.4170 or equivalent

1. Formed in Place Gasket (FIPG)

Formed in Place Gasket (FIPG) is applied in many positions on the transmission. In use of this type of
sealant, to adequately achieve the purpose of air tightness, special attentions has to be paid to the
application amount, application position and spread state. If the sealant applied too little, leakage is
likely to occur, if applied too much, the sealant will spill over and jam the water or oil channel or lessen
the passage. Thus, in order to prevent the joint face from leakage, it is absolutely necessary to smear in
the correct amount and the part not disconnected.
The Room Temperature Vulcanization (RTV) will be hardened after reacted with moisture in the
atmosphere, Thus it is often used on the metal flange parts.

2. Disintegration
A component of sealant assembly can be easily disassembled without using special methods, however,
in some cases, it is necessary to tap the component by use of a mallet or similar tool, to destroy the
sealant on the joint face, or use a smooth and thin sealant scraper to softly penetrate into the joint face,
but, full cares must be given not to damage the joint face.

3
 Outline

3. Cleaning of seal surface

Clean out the impurities on the seal surface by use of a sealant scraper or a wire brush. Confirm that the
seal surface is smooth and flat and no oil stains and foreign matters exist. Don’t forget cleaning out the
oil sealant in the mounting and tapped holes.
4. Essentials to application
Precautions to part assembly with FIPG:
Smear evenly the sealant on the defined diameter, and round up the mounting hole. The sealant not yet
hardened can be wiped out. When the sealant is in wet state(within 15mins), fit the part in the specified
position. At the installation, be careful not to stain the sealant to the place unnecessary. After the part
installed, you should wait until the sealant has been hardened(ca. 1hour). At this time, do not add oil on
or moisten the smeared portion or start the engine.
The smearing steps of FIPG sealant may vary depending on the part shape. Please refer to the smear
method as described in the text.

l Grease

Items Specified grease

Conform to the gear oil SAE 75W/85W for the hypoid gear above the GL-4
Oil seal lip of drive axle
in the API classification
Genuine brand Mitsubishi
Oil seal lip of input shaft
Grease part no.0101011 or equivalent

l Adjusting snap ring and spacer

Identification
Part name Thickness mm Part code
mark
2.24 Non SMD706537
Snap ring
(Designed to adjust input shaft front axle bearing end 2.31 Blue SMD706538
play)
2.38 Brown SMD706539
2.31 Black (2) SMD747149
2.35 Non SMD746561
2.39 Blue SMD746562
2.43 Brown SMD746563
Snap ring
2.47 Green SMD746564
(Designed to adjust the end play of rear axle bearing of
input shaft) 2.51 White SMD746565
(Designed to adjust the end play of rear axle bearing of 2.55 Yellow SMD746566
output shaft)
2.59 Black SMD746567
2.63 Orange SMD746568
2.67 Blue SMD746569
2.71 Brown SMD746570

4
 Outline

Identification
Part name Thickness mm Part code
mark
2.82 － SMD748015

2.86 － SMD748016
2.9 － SMD748017
Thrust plate 2.94 － SMD748018
(Designed to adjust the end play of input axle of the 5th
gear shaft) 2.98 － SMD748019
3.02 － SMD748020
3.06 － SMD748021

3.1 － SMD748022

Snap ring 1.43 Green(2) SMD746708

(Designed to adjust end play of front axle bearing of 1.51 While (2) SMD746709
output shaft) 1.59 Yellow (2) SMD746710
2.81 Green SMD745799
2.85 While SMD745800
2.89 Yellow SMD745801
Snap ring 2.93 Black SMD745802
(Designed to adjust the end play of 3rd gear axle of output
shaft) 2.97 Orange SMD745803
3.01 Red SMD745804
3.05 Peach SMD745805
3.09 Blue SMD745806
0.8 80 SMD727661
0.83 83 SMD720937
0.86 86 SMD720938
0.89 89 SMD720939
0.92 92 SMD720940
0.95 95 SMD720941

Spacer 0.98 98 SMD720942

(Designed to adjust the preload of differential case) 1.01 1 SMD720943
1.04 4 SMD720944
1.07 7 SMD720945
1.1 J SMD710454
1.13 D SMD700270
1.16 K SMD710455
1.19 L SMD710456

5
 Outline

Identification
Part name Thickness mm Part code
mark
1.22 G SMD700271
1.25 M SMD710457
0.75～0.82 - SMA180862
0.83～0.92 - SMA180861
Spacer
0.93～1.00 - SMA180860
(Designed to adjust the backlash of differential case)
1.01～1.08 - SMA180875
1.09～1.16 - SMA180876

l Specifications of tightening torque

Items Torque N.m (kgf)
Mounting bolt of back cover 6.9(0.7)
Interlocking board bolt 30(3.1)
Clutch housing－mounting bolt of transmission housing 44(4.5)
Mounting bolt of clutch bearing retainer 9.8(1.0)
Mounting bolt of controller casing 18(1.9)
Mounting bolt of shifting cable tray 18(1.9)
Mounting bolt of speedometer gear 3.9(0.4)
Mounting bolt of check bracket 22(2.3)
Mounting bolt of gear selector 18(1.9)
Mounting nut of gear selector 11(1.2)
Mounting bolt of differential drive gear 132(13.5)
Reversing light switch 32(3.3)
Front bearing mounting bolt 18(1.9)
Lifting spring assembly 32(3.3)
Mounting bolt of reverse intermediate gear shaft 48(4.9)
Mounting bolt of roll limiter bracket 69(7.0)

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 General faults and their troubleshooting

Chapter II General faults and their ④ Insufficient lubricant

troubleshooting Judgment and exclusion method:
l Out-of-gear ① Check the position of causation and
troubleshoot;
Possible reasons:
② Remove, check, clean and replace the damage
① Excessive wear of circular slot of fork shaft,
gear or bearing;
elastic deformation of lock ball spring;
③ Replace or add new oil
② Excessive wear on the fork working face;

③ Excessive wear on the joint face of gear ring or

gear sleeve; l Oil leakage
④ Shaft in axial looseness Possible reasons:
Judgment and exclusion method: ① Excessive oil addition and oil level too high;
① Check whether the shifting rocker arm of ② Excessive wear or damage of oil seal;
transmission has been pushed in place by the
control system or push manually the fork for ③ Uneven sealant smear of or paper gasket
engagement instead of disengage the damage;
transmission and check the mesh-in:
④ Inactive vent plug;
② If not completely coupled, check whether the
fork is distorted or the working face ⑤ The chipped joint face not repaired in time.
excessively worn; Judgment and exclusion method:
③ If the sleeve gear completed meshed in, check ① Remove the oil refilling plug and check the oil
the wears in the sleeve gear and inverted cone level;
area of coupled teeth;
② Replace the oil seal;
④ If excessive clearance is felt by poking, check
whether the fork shaft slot and positioning ③ Remove each joint face part and check the
spring are worn or ineffective. chipped point, repair and smear evenly the
sealant;
④ Replace the vent plug.
l Difficulty in shifting
Possible reasons: The synchronizer ring
seriously worn l Bearing abnormally damaged
Judgment and exclusion method: Replace the Possible reasons:
synchronizer ring
① Lubricant too dirty;

② Insufficient lubrication or lubricant

l Noise in the transmission non-conform to the requirements; too bad
① Regular crash; quality;
③ Use of unqualified bearing.
② Even noise:
Judgment and exclusion method:
Possible reasons:
① Replace the lubricant;
① Due to the breakage of individual gear tooth;
② Check the lubricant level, add or replace the
② Increase of backlash or damage of gear;
lubricant;
③ Wear of bearing;
③ Replace the bearing.

7
 Removal of transmission assembly

Chapter III Removal of transmission assembly

In the assembly, lubricate

with gear oil all internal
components

9. Interlock plate bolt F6N6-SMD744628 18. Transmission housing HM523-1701002

(1pc/set) (1pc/set)
10. Pad F6N6-SMD720603 (2pc/set) 19. Outer race of cone bearing (2pc/set)
11. Controller shell V4B1-SMR534360 (1pc/set) 20. Adjusting spacer F6N6-SMD727670 (1pc/set)
12. N position return spring component 21 Magnetic plug seat F6N6-SMD748126
F6N6-SMD770438 (1pc/set) (1pc/set)
13. Back cover F6N6-SMD747923 (1pc/set) 22. Magnet 015301109AA (2pc/set)
14. Reverse idle bolt F6N6-SMD749478 (1pc/set) 23. Flange bolts MF140266 (16pc/set)
15. Pad F6N6-SMD720603 (2pc/set) 24. Flange bolts MF140227 (4pc/set)
16. Reverse idle gear F6N6-SMD747924 (1pc/set) 25. Flange bolts F6N6-SMD097012 (6pc/set)
17. Plug cover A F6N6-SMD746157 (1pc/set)

8
 Removal of transmission assembly

l Disintegration instructions:
5th and 4th
1. Removal of seal cover shift forks
3rd and 4th
Pry up the seal cover by use of a straight shift forks
screwdriver
2. Removal of transmission housing

Seal cover

4. Removal of input shaft/output

At the meantime, remove the input and output
shafts.

Input shaft
Output shaft

Expand the snap ring of spring and remove this

snap ring from the groove of roller bearing.
Remark:
Once the snap ring of spring extended, the
snap ring of spring will come off in reliance of
its self weight
3. Removal of the 3rd-4th gear shift slide/3rd-4th
shift fork/5th-reverse shift slide/5th-reverse
shift fork. l Adjustment prior to assembly
th th
1) Move the 3rd -4 shift fork and 5 -reverse Choose the washer thickness to adjust the preload of
shift fork in the direction as shown in Fig. differential.
1) Place the solder film (length: 10mm and
rd th
3 -4 shift
diameter:1.6mm L/R) on the place of
forks transmission housing as shown in figure, and
then fit up the bearing outer racer and
differential
2) Install the clutch housing, tighten the bolt to
5th-4th shift the specified torque.
forks
3) If the soldering tin is not flattened, replace it
by a thicker solder film and repeat the steps (1)
Shift fork
and (2).
4) Use the micrometer calipers to measure the
2) Slide the 3rd-4th shift forks and 5th-reverse flattened thickness(T) of solder film, choose
shift forks in the direction as shown in Fig., the thickness of washer to be installed
and remove it with the shift fork. according to the following equation:

Thickness of washer: (T+0.05mm) ～

(T+0.11mm)

9
 Removal of transmission assembly

2) Install the 3rd -4th gear shift slides and forks

Washer and 5th -reverse shift slides and forks.

5th and reverse

shift guide rails
3rd and 4th shift
guide rails

3) Install every shift fork in the sleeve while

moving the shift slide rails in the direction as
shown in Fig.

3rd -4th shift guide rails

3rd -4th shift forks

5th -reverse
shift forks 5th-reverse shift guide rails

l Assembly instructions
1. Installation of input /output shafts
3. Installation of spring pin
Install the input shaft and output at the
meantime.

Input
Output shaft shaft

2. Installation of the 5th- reverse shift forks 4. Installation of washer

/5th -reverse shift slides/3rd - 4th gear shift Install the washer chosen from the
forks/3rd - 4th gear shift slides “Adjustment Prior to Assembly”.
1) Move the synchronizer sleeves of 3rd - 4th
gears and the synchronizer sleeves of 5th Washer
–reverse gears in the direction as shown in Fig.

3rd and 4th

shift forks

5th and 4th

shift forks

10
 Removal of transmission assembly

5. Installation of housing ring 3) Tighten the bolt of transmission housing to the

specified torque.
Remark:
Turn over the transmission, enabling the
weight output by the snap ring of spring to
embed automatically into the slot.

7. Installation of seal cover

Press the seal cover to the bottom as shown in
Fig.

Seal cover
6. Installation of transmission housing
1) Extrude the sealant in diameter of 1.5mm at
the place of transmission housing as shown in
the figure.
Specified sealant:
Mitsubishi genuine sealant
Part no. MD997740 or equivalent (Loctite
5699).
Attention:
The extruded sealant shall be in an even and
continuous line without interruption or
excessive smearing.

8. Installation of back cover

Extrude the sealant in diameter of 1.5mm at
the place of transmission housing as shown in
2) Install the transmission housing and then
the figure.
expand the snap ring of spring.
Specified sealant:
Mitsubishi genuine sealant
Part no.MD997740 or equivalent (Loctite
5699).
Attention:
The extruded sealant shall be in an even and
continuous line without interruption or
excessive smearing.

11
 Removal of transmission assembly

Control shaft

Selector
lever

l Check
9. Installation of controller casing body Reverse light switch

Extrude the sealant in diameter of 1.5mm at Check whether there are any short-circuits
the place of transmission housing as shown in between the terminals.
the figure.
State of switch Circuit
Specified sealant:
Pressed Disconnected
Mitsubishi genuine sealant
Released Put through
Part no.MD997740 or equivalent(Loctite5699).
Attention:
The extruded sealant shall be in an even and
continuous line without interruption or
excessive smearing.

10. Installation of selector lever

Smear the grease on the control axis sliding
surface of selector lever support pad.
Specified grease:
Mitsubishi genuine grease
Part no.0101011 or equivalent.

12
 Decomposition and assembly of Input shaft

Chapter IV Disintegration and assembly of input shaft

In assembly, use the gear

grease to lubricate all
internal parts

1. Snap ring F6N6-SMD746711 (2pcs/set) 11. Synchronizer sleeve (3rd-4th gears)

F6N6-SMR581381 (1pc/set)
2. Radial ball bearing F6N6-SMD717670 (1pc/set)
12. Synchronizer hub (3rd -4th gears)
3. Thrust plate stopper F6N6-SMD748128 F6N6-SMD747004 (1pc/set)
(1pc/set)
13. Synchronizer ring (3rd gear) F6N6-SMR581382
4. Thrust plate F6N6-SMD748024 (2pcs/set) (1pc/set)
5. 5th input gear F6N9-SMR534544 (1pc/set) 14. Synchronizer spring F6N6-SMR581383
6. th
4 gear component V4B2-S2528A056 (1pc/set) (4pcs/set)

7. Needle roller bearing F6N6-SMD744537 15. 3rd gear component V4B2-S2528A054 (1pc/set)
(2pcs/set) 16. Needle roller bearing F6N6-SMD744538
8. th
4 gear sleeve F6N6-SMR477080 (2pcs/set) (3pcs/set)

9. Synchronizer ring (4,5 gear) F6N6-SMN168937 17. Snap ring F6N6-SMD733454 (1pc/set)
(2pcs/set) 18. Front bearing F6N6-S2526A001 (1pc/set)
10. Synchronizer spring F6N6-SMR518383 19. Oil seal F6N6-SMD746516 (1pc/set)
(4pcs/set)
20. Input shaft HM523-1701007 (1pc/set)

13
 Decomposition and assembly of Input shaft

l Disintegration instructions
1. Removal of roller bearing 2. Removal of the 5th gear

14
 Decomposition and assembly of Input shaft

3. Removal of the 4th gear sleeve

Fit up the special tool on the 3rd gear to remove
the 4th gear sleeve.

3. Installation of spring snap ring

Select the thickness of spring snap ring,
enabling the end play of front axle bearing of
4. Removal of roller bearing input shaft to meet the standard
Standard value: -0.01～0.12mm

Spring of snap ring

4. Installation of synchronizer spring

l Assembly instructions
Fit up the synchronizer spring on the place of
1. Installation of oil seal synchronizer ring as shown in Fig.
Press-in the oil seal until the size shown in Fig
has been achieved.

Oil seal

Synchronizer spring

5. Installation of synchronizer hubs of 3rd -

4th gears
2. Installation of roller bearing
Fit up the synchronizer hubs of 3rd - 4th gears
in the direction as shown in Fig.

15
 Decomposition and assembly of Input shaft

7. Installation of 4th gear sleeve

Rear part of
transmission

Sign of identification

8. Installation of 5th gear

Attention:
In the installation of synchronizer hub,
confirm whether the synchronizer ring is
locked or not. 9. Installation of transmission housing

6. Installation of synchronizer sleeve Select the thickness of thrust plate, enabling

the end play of the 5th gear axle of input shaft
1) Install the synchronizer sleeve in the direction to meet the standard
as shown in Fig.
Standard value: -0.01～0.09mm
Rear part of
transmission

Sign of
identification

2) In the installation of synchronizer sleeve,

confirm that two deep slots of synchronizer 10. Installation of thrust plate limiter
hub meet correctly two high rack. In the installation of thrust plate, confirm that
the thrust plate doesn’t tilt.
Synchronizer sleeve
Thrust plate limiter

Synchronizer
hub Thrust plate

16
 Decomposition and assembly of Input shaft

11. Installation of roller bearing

12. Installation of spring snap ring 3. Synchronizer ring

Select the thickness of spring snap ring, 1) Check whether there is any injury or damage
enabling the end play of rear axle bearing of on the dental surface of clutch gear.
input shaft to meet the standard.
2) Check whether there is any damage or wear on
Installation of spring snap ring the cone part, any crush on the threads.

Standard value: 0.01～0.12mm

Spring snap
ring

3) Check the clearance “A” by pressing

downward the synchronizer ring toward. If
l Check “A” is less than the limit value, replace it.
1. Input shaft Limit value: 0.5mm
1) Check whether there are any damages on the
outer diameter surface of mounting position
abnormal wear or blockage etc.,
2) Check the spline part for any damage or wear.
2. Needle roller bearing
Check whether the input shaft and gear have
been correctly assembled, smoothly rotated, Synchronizer Gear
there are any looseness or noise etc., ring

4. Synchronizer sleeve and hub

1) Assemble the synchronizer sleeve and hub to
check its smooth sliding and blockage.
2) Check whether there are any damages on the
front/rear ends of the inner sleeve surface.

17
 Decomposition and assembly of Input shaft

Attention:
When necessary to replace the synchronizer
sleeve and hub, the replacement in full set
shall be made.

5. Synchronizer spring
Check whether the spring is sagged, distorted
or broken
6. Speed gear
1) Check whether there is any damage or wear on
the gear faces of helical gearing and clutch
gear
2) Check whether the synchronizer conical
surface is thickened, damaged or worn.
3) Check whether there is any damage or wear on
the gear I/D and front/rear head faces.

18
 Output disintegration and assembly

Chapter V Output disintegration and assembly

In assembly, use gear
grease to lubricant all
internal parts

1. Snap ring F6N6-SMD746197 (1pc/set) 19. Needle roller bearing F6N6-SMD744537 (2pcs/set)
2. Ball bearings F6N6-SMD747740 (1pc/set) 20. 2nd gear sleeve F6N6-SMD747318 (1pc/set)
3. Reverse gear sleeveF6N6-SMD747124 (1pc/set) 21. Synchronizer inner ring V4B1-SMN168459 (2pcs/set)
4. Needle roller bearing F6N6-SMD744538 (3pcS/set) 22. Synchronizer cone F6N6-SMN168258 (2pcs/set)
5. Reverse gear F6N6-SMR486153 (1pc/set) 23. Synchronizer outer ring V4B1-S2551A012 (2pcs/set)
6. Synchronizer ring (reverse) F6N6-SMN168936 (1pc/set) 24. Synchronizer spring F6N6-SMD744602 (2pcs/set)
7. Synchronizer spring F6N6-SMR581383 (4pcS/set) 25. Synchronizer sleeve (1/2 gear) R5A4-SMD770154
th
(1pc/set)
8. Synchronizer sleeve (5 and reverse gears)
F6N6-SMN168857 (1pc/set) 26. Synchronizer hub (1/2 gear) V4B1-SMN132495 (1pc/set)

9. Synchronizer hub (5th and reverse gear) 27. Synchronizer ring group V4B1-S2551A011 (2pcs/set)
F6N6-SMD747005 (1pc/set)
28. Synchronizer spring F6N6-SMD744602 (2pcs/set)
10. Synchronizer ring (4th and 5th gears) F6N6-SMN168937
(2pcs/set) 29. 1st gear component V4B2-SMN168179 (1pc/set)

11. Synchronizer spring F6N6-SMR581383 (4pcs/set) 30. Needle roller bearing F6N6-SMD744536 (1pc/set)

12. 5th gear component F6N9-SMD747114 (1pc/set) 31. 1st gear sleeve V4B1-SMR980942 (1pc/set)

13. Needle roller bearing F6N6-SMD744538 (3pcs/set) 32. Snap ring F6N6-SMD746711 (2pcs/set)

14. 5th gear sleeve F6N6-SMD749896 (1pc/set) 33. Roller bearing inner ring F6N6-SMD747707 (1pc/set)

15. 4th gear V4B2-SMN132284 (1pc/set) 34. Output shaft V4B1-S2522A032 (1pc/set)

16. Snap ring F6N6-SMD745798 (1pc/set)

17. 3rd output gear V4B2-SMN132283 (1pc/set)
18. 2nd gear component V4B2-S2528A025 (1pc/set)

19
 Output disintegration and assembly

l Disintegration instructions
1. Removal of roller bearing
3rd gear

Ball bearing

5. Removal of 2nd gear sleeve

Fit up the special tool on the 3rd gear and then
remove the 4th gear sleeve.
2. Removal of reverse gear bearing sleeve
Fit up the special tool on the reverse gear and
then remove the reverse gear bearing sleeve.

Sleeve
Sleeve

6. Removal of 1st gear sleeve

3. Removal of synchronizer hubs of

5th-reverse gears
Fit up the special tool on the 2nd gear and then
remove the 3rd gear Sleeve

Synchronizer
hub

7. Removal of the housing washer in the

cylindrical bearing

Inner housing
washer

4. Removal of 3rd gear

Fit up the special tool on the 2nd gear and then
remove the 3rd gear.

20
 Output disintegration and assembly

l Assembly instructions
1. Installation of inner housing washer of
roller bearing

Synchronizer spring
Inner housing
washer
5. Installation of 1st and 2nd synchronizer hubs
Install the 1st and 2nd synchronizer hubs in the
positions as shown in Fig.

2. Installation of spring snap ring

Select and install the spring snap ring, enabling
the front bearing end play of output shaft to Rear part of
transmission
meet the standard.
Sign of identification
Standard value: -0.01～0.12mm

Synchronizer hub

Spring snap
ring

Attention:
In the installation of synchronizer hub,
3. Installation of 1st gear sleeve confirm that the synchronizer ring is not
blocked up.
6. Installation of synchronizer sleeve

Identification
groove

Rear part of
transmission
4. Installation of synchronizer spring
Install correctly the synchronizer spring in the
place of synchronizer ring as shown in Fig.
1) Install the synchronizer sleeve in the position
as shown in Fig;
2) In the installation of synchronizer hub, confirm
that two deep dental slots of synchronizer hub
are correctly aligned with two high rack of
sleeve.

21
 Output disintegration and assembly

Synchronizer sleeve

Synchronizer hub
Spring snap ring

7. Installation of synchronizer spring

11. Installation of 4th gear

4th gear
Synchronizer
spring

8. Installation of 2nd gear sleeve

12. Installation of 5th gear sleeve

Sleeve thrust
plate
Sleeve

9. Installation of 3rd gear

13. Installation of 5th -reverse synchronizer

hubs
Install the 5th-reverse synchronizer hubs in the
positions as shown in Fig.
3rd gear

Rear part of
10. Installation of spring snap ring transmission

Select and fit up the spring snap ring, enabling

the 3rd gear end play of output shaft to meet the Sign of identification
standard value.

Standard value :-0.01～0.09mm

22
 Output disintegration and assembly

Attention:
In the installation of 5th -reverse gear
synchronizer hubs, confirm that the
synchronizer ring is not locked.
1. Installation of reverse gear/needle roller
bearing /reverse gear bearing sleeve.

Rear gear
Sleeve

2. Needle roller bearing

1) Assembly the bearing sleeve with the gear, and
check whether they can smoothly rotate, there
are any looseness or noise etc.,
2) Synchronizer ring
15. Installation of ball bearing
3. Speed gear
1) Check whether there is any dental injury or
damage on the clutch gear
Ball bearing
2) Check whether there is any damage or wear on
the conical surface and crush on the threads.

16. Installation of spring snap ring

Select and fit up the spring snap ring, enabling
the rear bearing end play of output shaft to
meet the standard value.

Standard value:-0.01～0.09mm

3) Press down the synchronizer ring toward 向

gear. In such state, measure the clearance “A”.
If “A” is less than the limit value, replace it.
Limit value: 0.5mm

l Check
1. Output Synchronizer Synchronizer fork
ring
Check the spline part for any damage or wear.

23
 Output disintegration and assembly

4. Outer synchronizer ring /inter synchronizer

ring /synchronizer cone ring
1) Check the dental face of clutch gear and
conical surface for any injury or damage.

6. Synchronizer spring
Check whether the spring is sagged, distorted
or worn.
7. Transmission gear
2) Fit up the outer ring and inner side, and then
press they down toward the gear to measure 1) Check whether there is any damage or wear on
the clearance “A”. If “A” is less than the limit the dental faces of helical gearing and clutch
value, replace it. gear.

Limit value: 0.5mm 2) Check whether the conical surface of

synchronizer is thickened, damage or worn.
Attention: If necessary to replace the outer
ring, inside ring or conical ring, the outer 3) Check whether there is any damage or wear
ring, inside ring and conical ring shall be gear on the inner and front/rear head faces
replaced in set.

Gear

Outer ring

Conical
ring

Inside ring

5. Synchronizer sleeve or hub

(1) Assemble the synchronizer sleeve and hub and
check whether they can smoothly slide.
(2) Check whether there is any damage on the
front/rear ends of the inside sleeve.
Attention: If necessary to replace the
synchronizer sleeve, the synchronizer sleeve
and hub shall be replaced in set.

24
 Disintegration and assembly of reverse intermediate gear

Chapter VI Disintegration and assembly of reverse intermediate gear

In assembly, use gear grease to
lubricant all internal

1. Snap ring F6N6-MF522013 (1pc/set)

2. Thrust washer F6N6-SMD747635 (1pc/set)
3. Reverse idle gear F6N6-SMD747924 (1pc/set)
4. Needle roller bearing V4B2-SMA845085 (1pc/set)
5. Reverse idle shaft V4B2-SMR953879 (1pc/set)

l Check
1. Needle roller bearing
1) Assembly the shaft and gear and check whether they can smoothly slide, there are any looseness or
noise.
2) Check whether the bearing holder is deformed or not.

25
 Disintegration and assembly of control shell

Chapter VII Disintegration and assembly of control shell

1. Bolt F6N6-SMD717883 (2pcs/set) 12. N gear return spring seat

2. Spring washer MF450405 (2pcs/set) 13. Control shell V4B1-SMR534360 (1pc/set)
3. Pin (1pc/set) 14. Needle roller bearing F6N6-SMD712913 (2pcs/set)
4. Return spring (1pc/set) 15. Oil seal F6N6-SMD747660 (1pc/set)
5. Stopper plate (1pc/set) 16. Control shaft cover F6N6-SMD718557 (1pc/set)
6. Retainer bracket component V4B1-SMR470009 17. Control shaft component V4B1-SMR410806 (1pc/set)
(including 3, 4, 5, and 6) (1pc/set)
18. Vent tube F6N6-SMD733296 (1pc/set)
7. Interlock plate F6N6-SMD747918 (1pc/set)
19. Control level R5A4-SMD771766 (1pc/set)
8. Lock pin F6N6-SMD705490 (2pcs/set)
20. Control shaft V4B1-SMR581997 (1pc/set)
9. Control claw F6N6-SMD771047 (1pc/set)
21. Lock pin F6N6-SMD705490 (2pcs/set)
10. Retainer body V4B1-SMR410807 (1pc/set)
22. Spring pin MF472572 (1pc/set)
11. N gear return spring R5A4-SMD771413 (including 12)
(1pc/set)

26
 Disintegration and assembly of control shell

l Disintegration instructions Specified sealant:

1. Removal of lock pin 3M SUPER WEATHERSTRIP No.8001 or

equivalent (Loctite480)
Punch out the lock pin in the direction as
shown in Fig.

Lock pin

Control
indication
2) Confirm the protrusion faces the arrow-
oriented direction

l Assembly instructions
1. Installation of needle roller bearing
Press down the needle roller bearing to the size
as shown in Fig. Now, the side with the type
print shall be located at the side of controller
casing.

4. Installation of spring pin

Controller
shell Control shaft Positioned
Needle roller
bearing
Side with the
type printing Mounting direction

Crack
Spring pin
2. Installation of oil seal
Smear the transmission oil on the oil seal lip. Spring pin
Transmission oil:
Conform to the gear oil SAE 75W/85W of
hypoid gear above GL- 4 in the API
classification

5. Installation of lock pin

Lock pin

3. Installation of air vent Control

indication
1) Smear the sealant on the surface of insertion.

27
 Disintegration and assembly of clutch housing

Chapter VIII Disintegration and assembly of clutch housing

1. Clutch release bearing carrier HM523-1701008 6. Housing washer

(1pc/set)
7. Sleeve F6N6-SMD746159 (6pcs/set)
2. Oil seal F6N6-SMD741818 (1pc/set)
8. Clutch shell HM523-1701001 (1pc/set)
3. Oil seal F6N6-SMD755526 (2pcs/set)
9. Flange bolt MF140203 (4pcd/set)
4. Outer ring of tapered roller bearing
F6N6-SMD710663 (2pcs/set) 10. Positioning pin MF472405 (2pcs/set)

5. Roller bearing F6N6-SMD747707 (1pc/set)

l Disintegration instructions
1. Removal of housing washer

28
 Disintegration and assembly of clutch housing

l Assembly instructions 3. Installation of oil seal

1. Installation of bushing Smear the transmission oil on the oil seal lip.

Press down the bushing in the position as Specified oil:

shown in Fig, so to make the bushing cutter
Confirm to the gear oil SAE 75/85W of
end different from the exhaust groove.
quasi-hyperbolic above the GL-4 in the API
classification.
Exhaust Cutter end
groove

2. Installation of outer housing washer

Fit up the housing washer, enabling the face
with the type printing to locate in the position 4. Installation of oil seal
as shown in Fig.
Fill up the oil seal lip with grease.
Specified grease.

Side with the

type printing

Mitsubishi grease Part no.0101011 or

equivalent (Omega 85).

29
 Disintegration and assembly of transmission housing

Chapter IX Disintegration and assembly of transmission housing

1. Oil sealF6N6-SMD755526 (2pcs/set)

2. Needle roller bearing F6N6-SMD712913 (2pcs/set)
3. Oil guide F6N6-SMD748139 (1pc/set)
4. Snap ring F6N6-SMD747313 (1pc/set)
5. Bushing F6N6-SMD746159 (6pcs/set) (here, three moving axle holes have bushing)
6. Transmission housing HM523-1701002 (1pc/set)
7. Oil tank cover F6N6-SMD746156 (1pc/set)
8. Positioning pin MF472402 (2pcs/set)

l Assembly instructions
1. Installation of bushing
Press down the bushing into the position as shown in Fig, so to make the bushing cutter end different
from the exhaust groove.

30
 Disintegration and assembly of transmission housing

2. Installation of needle roller bearing

Press-in the needle roller bearing as far as to
flush with the shell surface am confirm the
face with the type printing in the position as
shown in Fig.

Type printing

3. Installation of oil seal

Smear the transmission oil on the oil seal lip.
Specified oil:
Confirm to the gear oil SAE 75/85W of
quasi-hyperbolic above the GL-4 in the API
classification.

31
 Disintegration and assembly of differential case

Chapter X Disintegration and assembly of differential case

● In assembly, use gear grease to

lubricant all internal

1. Differential drive gear HM523-1701006 6. Washer F6N6-SMT203629 (2pc/set)

(1pc/set)
7. Differential side gear V4B1-SMD759515
2. Tapered roller bearing F6N6-SMD710663 (2pcs/set)
(2pcs/set)
8. Differential gear thrust washer
3. Locking pin F6N6-SMD762419 (1pc/set) F6N6-SMA180860 (2pcs/set)
4. Gear shaft F6N6-SMD722632 (1pc/set) 9. Differential case F6N6-SMD746800 (1pc/set)
5. Differential gear V4B1-SMD762411 (2pcs/set) 10. Flywheel bolt F6N6-SMD040557 (8pcs/set)

l Disintegration instructions l Assembly instructions

1. Removal of tapered roller bearing 1. Installation of spacing ring/side gear/
washer/ pinion/pinion shaft
1) Assemble first the spacing ring on the backside
of gear and then install the side gear into the
differential.
Remark:
In assembly of a new side gear, a spacing
ring in medium thickness (0.93~1.00mm)
shall be fitted.
2) After placed the washer on the back of each
pinion, make two pinions mesh in with the side
gear at the same time. Turn the gear while
fitting it in the correct position.

32
 Disintegration and assembly of differential case

Differential
Lock pin
case
Pinion
shaft

3) Install by inserting the pinion shaft.

3. Installation of tapered roller bearing

Tapered roller
bearing

4) Measure the backlash between the gear and

pinion. 4. Differential drive gear Installation of
Standard value: 0.025~0.150mm 1) Smear the sealant on whole threads of bolt.
5) If the measured backlash non-conform the Specified sealant:
standard, then select and fit up the spacing ring
and then measure again the backlash. 3MSTUDLOCKING No.4170 or equivalent

Remark: Adjust the backlash until it is

equal at both sides.

2) Tighten the bolt to the specified torque in the

order as shown in Fig.
2. Installation of lock pin
Fit up the lock pin in the position as shown in
Fig.

33
 Special tools

Chapter XI Special tools Tool Code Name Purpose

Tool Code Name Purpose To install the

Installer
MD998817 rear bearing of
joint (34)
To install the output shaft
Installer input shaft oil
MB990926 To install the
joint seal of clutch
housing ball bearing of
input shaft,
housing
Installer To install the washer of
MB990927
joint seal cover Installer roller bearing,
MD998818
joint (38) reverse gear,
needle roller
To install the
bearing and
housing
Installer bearing sleeve
MB990934 washer of
joint of reverse
cylindrical
gear
bearing
To install the
To install the
5th-reverse
conical roller
gear
bearing
Installer synchronizer
MB990935 housing Installer
joint MD998819 sleeves,
washer of joint (40)
differential
differential
bearing, 4th
case
and 5th gear
To be used sleeves
MB990938 Handle with the
To install the
installer joint
Installer 1st and 2nd
MD998822
Differential To install the joint (46) gear sleeves
MD998325 oil seal differential oil and 3rd gear
installer seal
To install the
Bearing To remove the housing
housing housing washer of
MD998346
washer washer of Installer differential
MD998823
puller roller bearing joint (48) tapered roller
Remove the bearing and
Valve differential
housing
MD998772 spring bearing.
washer of
compressor
roller bearing
To install the
Installer
To install/ MD998824 4th gear sleeve
joint (50)
Bearing remove the and 5th gear
MD998801
puller gear. Bearing
and sleeve To install the
1st-2nd
To be used
synchronizer
Installer with the
MD998812 shaft sleeve,
cover installer and Installer
MD998825 3rd -4th
installer joint. joint (52)
synchronizer
To be used shaft sleeves
with the and 1st gear
Installer
MD998813 installer cover sleeve
(100)
and installer
To install and
joint
remove the
Bearing
To be used MD998917 gears,
puller
with the bearings and
Installer
MD998814 installer cover sleeves
joint (200)
and installer
To remove the
joint.
housing
To install he washer of
Installer MD999566 Hooks
MD998816 front bearing differential
joint (30)
of input shaft tapered roller
bearing

34