21B-0-1

CLUTCH

F5M41, F5M42, W5M42

CONTENTS

1. SPECIFICATIONS. 21B-1-1 GENERAL SPECIFICATIONS. 21B-1-1 SERVICE SPECIFICATIONS. 21B-1-1 TORQUE SPECIFICATIONS. 21B-1-2 LUBRICANTS. 21B-1-2 2. CLUTCH. 21B-2-1 3. CLUTCH RELEASE CYLINDER. 21B-3-1
E Mitsubishi Motors Corporation

Jun. 1998

PWEE9508-E

Revised

21B-0-2

Nov. 1995

PWEE9508-A

CLUTCH - Specifications

21B-1-1

1. SPECIFICATIONS

GENERAL SPECIFICATIONS
Items Clutch operating method Clutch disc type Clutch disc size O.D. x I.D. mm Clutch cover type Clutch cover setting load N Clutch release cylinder I.D. mm Items Clutch operating method Clutch disc type Clutch disc size O.D. x I.D. mm Clutch cover type Clutch cover setting load N Clutch release cylinder I.D. mm Items Clutch operating method Clutch disc type Clutch disc size O.D. x I.D. mm Clutch cover type Clutch cover setting load N Clutch release cylinder I.D. mm F5M41-4G13, 4G15 Hydraulic type Single dry disc type 184 x 127 Diaphragm spring type 3256 20.64 F5M42-4G93, 4G63 Hydraulic type Single dry disc type 215 x 140 Diaphragm spring type 4511 20.64 F5M51 Hydraulic type Single dry disc type 225 x 150 Diaphragm spring type 5864 20.64 F5M41-4G92 Hydraulic type Single dry disc type 200 x 130 Diaphragm spring type 4193 20.64 F5M42-4G64, 6A12, 4D68 Hydraulic type Single dry disc type 225 x 150 Diaphragm spring type 4511 20.64 F5M42-4G92 Hydraulic type Single dry disc type 215 x 140 Diaphragm spring type 4539 20.64 F5M42-6A13 Hydraulic type Single dry disc type 225 x 150 Diaphragm spring type 5198 20.64 F5M42-4G64-GDI, W5M42 Hydraulic type Single dry disc type 230 x 150 Diaphragm spring type 4511 20.64

SERVICE SPECIFICATIONS

Items Clutch disc facing rivet sink mm Diaphragm spring end height difference mm <F5M41, F5M42, W5M42> Release cylinder I.D. to piston O.D. clearance mm Specifications (limit) 0.3 0.5 0.15

21B-1-2

TORQUE SPECIFICATIONS

Specified torque 9.8

Clutch damper mounting bolt Nm <F5M41, F5M42, W5M42> Clutch fluid line bracket Nm Clutch release cylinder air bleeder Nm Clutch release cylinder mounting bolt Nm <F5M41, F5M42, W5M42> Clutch release cylinder union bolt Nm Clutch tube flare nut Nm Clutch release cylinder and clutch damper mounting bolt Nm <F5M51> Fulcrum Nm <F5M41, F5M42, W5M42> Release fork shaft mounting bolt Nm <F5M51>

LUBRICANTS

Items Clutch release bearing inner surface Release fork and fulcrum contact surface <F5M41, F5M42, W5M42> Release fork and release bearing contact surface Release fork and release cylinder push rod contact surface Release fork and release fork shaft contact surface <F5M51> Piston and piston cup outer surface Release cylinder inner surface Brake fluid SAE J1703 (DOT3) Specified lubricants MITSUBISHI genuine grease Part No. 0101011 or equivalent

CLUTCH - Clutch

21B-2-1

2. CLUTCH

REMOVAL AND INSTALLATION <F5M41>

TFM0595

Removal steps 1. Clutch fluid line bracket 2. Insulator 3. Washer 4. Clutch tube 5. Union bolt 6. Union 7. Gasket 8. Clutch release cylinder
9. 10. 11. "BA 12. AA" "AA 13. 14. 15.
Clutch cover Clutch disc Return clip Clutch release bearing Release fork Release fork boot Fulcrum

21B-2-2

REMOVAL AND INSTALLATION <F5M42-4G92-MIVEC, 4G64-GDI, 6A12-MIVEC, 6A13, W5M42>

22 Nm 18 Nm

TFM0900
Removal steps 1. Clutch fluid line bracket 2. Insulator 3. Washer 4. Clutch tube (A) 5. Tube clip 6. Clutch tube 7. Union bolt 8. Union 9. Gasket
10. 11. 12. 13. 14. "BA 15. AA" "AA 16. 17. 18.
Clutch release cylinder Clutch damper Clutch cover Clutch disc Return clip Clutch release bearing Release fork Release fork boot Fulcrum
CLUTCH - Clutch REMOVAL AND INSTALLATION <F5M42-4G93, 4G93-GDI (For SPACE RUNNER), 4G63, 4G64, 4D68>

21B-2-1 21B-2-2a

21B-2-2b
REMOVAL AND INSTALLATION <F5M42-4G93-GDI (For CARISMA)>
Removal steps 1. Clutch tube 2. Union bolt 3. Union 4. Gasket 5. Clutch release cylinder 6. Clutch cover
7. 8. "BA 9. AA" "AA 10. 11. 12.
Clutch disc Return clip Clutch release bearing Release fork Release fork boot Fulcrum

CLUTCH - Clutch REMOVAL AND INSTALLATION <F5M51>

21B-2-1 21B-2-2c

15 Nm 15 Nm

9.8 Nm

Removal steps 1. Clutch fluid line bracket 2. Insulator 3. Washer 4. Clutch tube (A) 5. Clutch tube 6. Union bolt 7. Union 8. Gasket 9. Valve 10. Valve spring 11. Clutch release cylinder 12. Clutch damper

"EA

"DA "CA "BA
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Clutch cover Clutch disc Sealing cap Release fork shaft Support spring (L) Packing Release fork Bushing Clutch release bearing Packing Support spring (R) Release fork boot Maintenance hole cover

21B-2-2d

Intentionally blank
CLUTCH - Clutch REMOVAL SERVICE POINT

21B-2-3

AA" RELEASE FORK REMOVAL Move the release fork in the direction shown to remove the clip from the fulcrum.

Release Fork

INSTALLATION SERVICE POINTS

Apply grease

"AA RELEASE FORK INSTALLATION Apply/pack grease to the illustrated positions of the release fork. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent

Pack grease

<F5M41, F5M42, W5M42>
"BA CLUTCH RELEASE BEARING INSTALLATION Apply grease to the illustrated position of the clutch release bearing. Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent.

TFM0917

21B-2-4

<F5M51>

TFM0918
"CA BUSHING INSTALLATION Press in the bushing into the release fork to the position shown in the illustration.

Bushing

TFM0710
"DA RELEASE FORK INSTALLATION Apply/pack grease to the illustrated positions of the release fork. Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent

TFM0919

"EA SEALING CAP INSTALLATION Press in the sealing cap to the position shown in the illustration. Be sure that it is not installed aslant.

TFM0712

Jan. 1997

PWEE9508-C

CLUTCH - Clutch INSPECTION

21B-2-3 21B-2-4a

CLUTCH COVER Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit. <F5M41, F5M42, W5M42> Limit: 0.5 mm Check the pressure plate surface for wear, cracks and discoloration. Check the rivets of the strap plate for looseness. If loose, replace the clutch cover.

Rivet sink

CLUTCH DISC
Caution Dont clean the clutch disc in a cleaning fluid. Check the facing for loose rivets, uneven contact, evidence of seizure, or deposited oils and greases. If defective, replace the clutch disc. Measure the rivet sink and replace the clutch disc if it is out of specification. Limit: 0.3 mm Check the torsion spring for looseness and damage. If defective, replace the clutch disc. Combine the clutch disc with the input shaft and check for sliding condition and play in the rotating direction. If poor sliding condition is evident, clean, reassemble, and recheck. If excessive looseness is evident, replace the clutch disc and/or input shaft.

CLUTCH RELEASE BEARING

Caution Release bearing is packed with grease. Therefore, do not wash it in a cleaning fluid and the like. Check for seizure, damage, noise or improper rotation. Check for wear on the surface which contacts with the diaphragm spring. <F5M41, F5M42, W5M42> Check for wear on the surface which contacts with release fork. If abnormally worn, replace.
Jun. 1998 PWEE9508-E Revised

21B-2-4b

Check the pull ring for wear and replace the clutch release bearing if necessary. <F5M51>

TFM0920

RELEASE FORK
If the surface which contacts with the bearing is abnormally worn, replace.
RELEASE FORK SHAFT <F5M51>
Check the release fork shaft for bend and wear, and replace if necessary.
CLUTCH - Clutch Release Cylinder

21B-3-1

3. CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY <F5M41, F5M42, W5M42>

TFM0594

Disassembly steps 1. Cap 2. Air bleeder 3. Push rod 4. Boot
AA" "AA 5. AA" "AA 6. 7. 8.
Piston cup Piston Conical spring Release cylinder

Nov. 1998 Jun. 1995

PWEE9508-A PWEE9508-E

Added Revised

21B-3-2
DISASSEMBLY AND REASSEMBLY <F5M51>

TFM0709

DISASSEMBLY SERVICE POINT
AA" PISTON CUP / PISTON REMOVAL Remove the piston from the release cylinder using compressed air. Caution 1. Cover with shop towel to prevent the piston from popping out. 2. Apply compressed air slowly to prevent brake fluid from splashing.
Nov. 1997 Jan. 1995 PWEE9508-A PWEE9508-C Added Revised
CLUTCH - Clutch Release Cylinder REASSEMBLY SERVICE POINT

21B-3-1 21B-3-2a

"AA PISTON / PISTON CUP INSTALLATION After applying brake fluid to the inside wall surface of the release cylinder and all the circumferential surfaces of the piston and piston cup, insert the piston and piston cup into the cylinder. Specified brake fluid: Brake fluid SAE J1703 (DOT3)

INSPECTION

RELEASE CYLINDER Check the inside wall surface of the release cylinder for rust and damage. Using a cylinder gauge, measure the inside diameter of the release cylinder at about three positions (the deepest, middle and brim positions). If the clearance from the outside diameter of the piston exceeds the limit, replace the release cylinder as an assembly. Limit: 0.15 mm

Nov. 1997 Jan. 1995

PWEE9508-A PWEE9508-C

22B-0-1

F5M41, F5M42, W5M42

CONTENTS

GENERAL INFORMATION. 22B-0-3 1. SPECIFICATIONS. 22B-1-1 TRANSMISSION MODEL TABLE. 22B-1-1 GEAR RATIO TABLE. 22B-1-2d SERVICE SPECIFICATIONS. 22B-1-2d SEALANTS AND ADHESIVES. 22B-1-2e LUBRICANTS. 22B-1-3 SNAP RINGS, SPACERS AND THRUST PLATE ADJUSTMENT. 22B-1-4 TORQUE SPECIFICATIONS. 22B-1-9 2. SPECIAL TOOLS. 22B-2-1 3. TRANSMISSION <F5M41>. 22B-3-1 4. TRANSMISSION <F5M42, W5M42>. 22B-4-1 5. INPUT SHAFT <F5M41>. 22B-5-1 6. INPUT SHAFT <F5M42, W5M42>. 22B-6-1 7. OUTPUT SHAFT <F5M41>. 22B-7-1 8. OUTPUT SHAFT <F5M42, W5M42>. 22B-8-1 9. REVERSE IDLER GEAR <F5M42, W5M42>. 22B-9-1 10. SPEEDOMETER GEAR. 22B-10-1 11. SELECT LEVER. 22B-11-1 12. CONTROL HOUSING. 22B-12-1 13. CLUTCH HOUSING. 22B-13-1 14. TRANSMISSION CASE. 22B-14-1 15. DIFFERENTIAL <F5M41, F5M42>, FRONT DIFFERENTIAL <W5M42>. 22B-15-1 16. CENTER DIFFERENTIAL <W5M42>. 22B-16-1 17. TRANSFER <W5M42>. 22B-17-1

MANUAL TRANSMISSION

E Mitsubishi Motors Corporation

Jun. 2000

PWEE9508-G

Revised

22B-0-2
MANUAL TRANSMISSION (E - W) - General Information

22B-0-3

GENERAL INFORMATION
F5M41 <Types with single synchronizer ring for 2nd gear>

TFM0809

1. Reverse gear meshing noise prevention device <Models with reverse brake> 2. 5th-reverse speed synchronizer hub 3. 5th speed gear 4. 4th speed gear 5. 3rd-4th speed synchronizer hub 6. 3rd speed gear 7. Transmission case
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

July 1999

PWEE9508-F

22B-0-4

F5M41 <Types with double synchronizer ring for 2nd gear>
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

22B-0-5

F5M42 <Types with single synchronizer ring for 1st gear and double synchronizer ring for 2nd gear>

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

22B-0-6

F5M42 <Types with double synchronizer ring for both 1st and 2nd gears, types with double synchronizer ring for 1st gear and triple synchronizer ring for 2nd gear>
MANUAL TRANSMISSION (E - W) - General Information W5M42

22B-0-7

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

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

22B-1-2b

TRANSMISSION MODEL TABLE - MODEL 2000
Gear ratio A A B D 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
F5M41-1-R8A1 F5M41-1-F8A5 F5M41-1-B8A2 F5M42-1-R7A2 F5M42-1-V5A4 F5M42-2-R5A3 W5M42-1-V5A1
F5M41-1-R8A1 F5M41-1-F8A5 F5M42-1-R6N6 F5M42-1-R6N7 F5M42-1-F6N9 F5M42-2-F6N7 F5M42-2-R5A2

F5M42-2-R5A2

MANUAL TRANSMISSION (E - W) - Specifications TRANSMISSION MODEL TABLE - MODEL 2001
Transmission model EUR F5M41-1-R8A1 F5M41-1-F8A5 F5M41-1-F8AC F5M42-2-R7A2 F5M42-2-F7N2 F5M42-2-F6NC F5M42-2-F6N7 F5M42-2-V5A F5M42-2-R5A3 EXP F5M41-1-R8A1 F5M41-1-F8A5 F5M42-1-F6N9 F5M42-1-F7N1 F5M42-1-R6N6 F5M42-1-F6N7 F5M42-1-R6N7 F5M42-1-F6N9 F5M42-1-F6N7 F5M42-2-R6N8 F5M42-2-R5A2 MMAL F5M41-1-F8A5 F5M42-1-F8A7 F5M42-2-R5A2 Gear ratio A A B D D G F D G A A D D D F 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 31/36 29/36 30/36 29/36 29/36 29/36 29/36 29/36 29/36 28/36 31/36 31/36 31/36 Final gear ratio 4.052 3.714 3.454 4.058 3.722 3.722 3.722 4.352 4.058 4.052 3.714 3.722 3.722 4.058 3.722 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 CJ4A EA2W EA2W EA1A EA1A EA2A EA2A EA5A EA6A N84W CJ2A CJ5A N84W

22B-1-2c

Engine model 4G13 4G92 4G93 4G93 4G63 4G64 6A13 4G63 4G64 4G13 4G92 4G63 4G63 4G93 4G93 4G63 4G63 6A13 4D68 4G64 4G15 4G93 4G64

22B-1-2d

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 0.820 3.363 D 3.583 1.947 1.379 1.030 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 <F5M41> mm Input shaft rear bearing end play <F5M42, W5M42> mm Input shaft 5th speed gear end play <F5M42, W5M42> 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 <F5M41> mm Differential case pinion backlash <F5M41, F5M42> mm Front differential case backlash <W5M42> mm Differential case preload <F5M42> mm Allowable range - 0.01 - 0.12 - 0.01 - 0.09 - 0.01 - 0.12 - 0.01 - 0.09 - 0.01 - 0.12 - 0.01 - 0.09 - 0.01 - 0.09 0.05 - 0.17 0.025 - 0.150 0.025 - 0.150 0.05 - 0.11 Limit -

Spacer: F5M41 (For adjustment of differential case end play)
Part name Spacer: F5M42 (For adjustment of differential case preload) 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 1.28 1.31 Identification symbol 07 J D K L G M N E Part No. MD754475 MD727660 MD754476 MD727661 MD720937 MD720938 MD720939 MD720940 MD720941 MD720942 MD720943 MD720944 MD720945 MD710454 MD700270 MD710455 MD710456 MD700271 MD710457 MD710458 MD706574

22B-1-7

22B-1-8
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 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 MA180876 MD744236 MD744235 MD744234 MD744233 MD744232
Spacer: W5M42 (For adjustment of center differential case preload)
Spacer: F5M41, F5M42 (For adjustment of differential case backlash)
0.75 - 0.82 0.83 - 0.92 0.93 - 1.00 1.01 - 1.08 1.09 - 1.16
Spacer: W5M42 (For adjustment of center differential case pinion backlash)
MANUAL TRANSMISSION (E - W) - Specifications TORQUE SPECIFICATIONS
Items Under cover mounting bolt <F5M42, W5M42> Interlock plate bolt Clutch housing- transmission 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 Front differential drive gear mounting bolt <W5M42> Center differential flange mounting screw <W5M42> Center differential drive gear mounting bolt <W5M42> Differential drive gear mounting bolt <F5M41, F5M42> Back-up lamp switch Front bearing retainer mounting bolt Poppet spring Restrict ball <F5M41> Reverse idler gear shaft mounting bolt Reverse shift lever mounting bolt <F5M41> Roll stopper bracket mounting bolt Oil temperature sensor <For GDI engine only> Connector bracket mounting bolt <For GDI engine except DA2A> Clutch fluid line bracket mounting bolt <DA2A only> Nm 6.44 9.18 3.132 3.19

22B-1-9

Items Transfer cover mounting bolt Transmission - transfer mounting bolt Nm 23 69
MANUAL TRANSMISSION (E - W) - Special Tools

22B-2-1

2. SPECIAL TOOLS
Tool Number MB990926 Name Installer adapter Use Installation of clutch housing input shaft oil seal

MB990927

Installer adapter
Installation of sealing cap

MB990930

Removal of center differential taper roller bearing <W5M42>

MB990934

Installation of roller bearing outer race

MB990935

Installation of differential case taper roller bearing outer race

MB990937

Installation of center differential taper roller bearing <W5M42>

MB990938

Handle
Use with Installer adapter

MD998325

Differential oil seal installer
Installation of differential oil seal <F5M41, F5M42>

22B-2-2

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

MD998816

Installer (30)

adapter

Installation of input shaft front bearing <F5M42, W5M42>

MD998817

Installer (34)
Installation of input shaft front bearing <F5M41>, output shaft rear bearing <F5M42, W5M42>

MD998818

Installer (38)
Installation of input shaft rear bearing, roller bearing inner race, reverse gear, needle roller bearing, reverse gear bearing sleeve <F5M42, W5M42> and reverse bearing sleeve <F5M41>
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 <F5M42, W5M42>

MD998820

Installer (42)
Installation of 5th speed gear sleeve, 2nd speed gear sleeve <F5M41>

(2) Install the transmission case and expand the snap ring. (3) Tighten 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 shafts own weight.
"GA SEALING CAP INSTALLATION Press-fit the sealing cap all the way up to the illustrated position.
"HA UNDER COVER INSTALLATION Apply a 1.5 mm bead of sealant to the illustrated position of the transmission case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied. "IA CONTROL HOUSING INSTALLATION Apply a 1.5 mm bead of sealant to the illustrated position of the transmission case. Specified sealant: MITSUBISHI genuine sealant part No. MD997740 or equivalent Caution Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied.
22B-4-8 MANUAL TRANSMISSION (E - W) O-ring
"JA SPEEDOMETER GEAR INSTALLATION Apply transmission oil to the O-ring of the speedometer gear. Transmission oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher
"KA SELECT LEVER INSTALLATION Apply grease to the control shaft sliding portion of the select lever shoe. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent
BACK-UP LAMP SWITCH (1) Check for continuity between terminals.
(2) If the above requirements are not met, replace the back-up lamp switch with a new one. OIL TEMPERATURE SENSOR <For GDI engine only> (1) Check for continuity between terminals.
Temperature (C) Standard value (kW) 2.31 - 2.59 0.1451 - 0.1491
(2) If the standard value is not met, replace the oil temperature sensor with a new one.

Transmission oil

MANUAL TRANSMISSION (E - W) - Input Shaft <F5M41>

22B-5-1

5. INPUT SHAFT <F5M41>
DISASSEMBLY AND REASSEMBLY <Models with reverse brake>
Disassembly steps "MA 1. Snap ring AA" "LA 2. Ball bearing AB" "KA 3. Reverse brake sleeve 4. Needle roller bearing 5. Reverse brake cone 6. Reverse brake ring "DA 7. Synchronizer spring "JA 8. Synchronizer sleeve AC" "IA 9. 5th-reverse speed synchronizer hub 10. Synchronizer ring "DA 11. Synchronizer spring 12. 5th speed gear 13. Needle roller bearing AD" "HA 14. 5th speed gear sleeve

TFM0834

AE" "GA "DA "FA "EA "DA "CA AF" "BA "AA
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
4th speed gear Needle roller bearing 4th speed gear sleeve Synchronizer ring Synchronizer spring Synchronizer sleeve 3rd-4th speed synchronizer hub Synchronizer ring Synchronizer spring 3rd speed gear Needle roller bearing Snap ring Ball bearing Oil seal Input shaft

SYNCHRONIZER SPRING Check to ensure that the spring is not sagging, deformed or broken.
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 are not damaged and worn.

Nov. 2000 Jun. 1995

PWEE9508-A PWEE9508-G

Added Revised

MANUAL TRANSMISSION (E - W) - Input Shaft <F5M42, W5M42>

22B-6-1

6. INPUT SHAFT <F5M42, W5M42>

TFM0591

"LA AA" "KA "JA "IA AB" "HA
Disassembly steps 1. Snap ring 2. Ball bearing 3. Thrust plate stopper 4. Thrust plate 5. 5th speed gear 6. 4th speed gear 7. Needle roller bearing AC" "GA 8. 4th speed gear sleeve 9. Synchronizer ring "DA 10. Synchronizer spring
"FA 11. Synchronizer sleeve "EA 12. 3rd-4th speed synchronizer hub 13. Synchronizer ring "DA 14. Synchronizer spring 15. 3rd speed gear 16. Needle roller bearing "CA 17. Snap ring AD" "BA 18. Ball bearing "AA 19. Oil seal 20. Input shaft
22B-6-2 MANUAL TRANSMISSION (E - W) MD998801
Input Shaft <F5M42, W5M42>
AA" BALL BEARING REMOVAL Use the special tool to remove the ball bearing.
AB" 5TH SPEED GEAR REMOVAL Use the special tool to remove the 5th speed gear.
AC" 4TH SPEED GEAR SLEEVE REMOVAL Mount a special tool on the 3rd gear and remove the 4th speed gear sleeve.
AD" BALL BEARING REMOVAL Use the special tool to remove the ball bearing.
MD998812 MD998813 MD998801 MD998816

22B-6-3

"BA BALL BEARING INSTALLATION Use the special tools to install the ball bearing.

Synchronizer spring

Rear of transmission Identification mark
MD998812 MD998813 MD998801 MD998825
22B-6-4 MANUAL TRANSMISSION (E - W) Identification groove
"GA 4TH SPEED GEAR SLEEVE INSTALLATION Use the special tools to install the 4th speed gear sleeve.

Inner ring

22B-7-7
MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-1
8. OUTPUT SHAFT <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY <Types with single synchronizer ring for 1st gear and double synchronizer ring for 2nd gear>
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 2nd speed gear Needle roller bearing 2nd speed gear sleeve Inner synchronizer ring Synchronizer cone Outer synchronizer ring Synchronizer spring Synchronizer sleeve 1st-2nd speed synchronizer hub Synchronizer ring Synchronizer spring 1st speed gear Needle roller bearing 1st speed gear sleeve Snap ring Roller bearing inner race Output shaft

AA" AB"

AC"

AD"

Disassembly steps "PA 1. Snap ring "OA 2. Ball bearing "NA 3. Reverse gear bearing sleeve "NA 4. Needle roller bearing "NA 5. Reverse gear 6. Synchronizer ring "DA 7. Synchronizer spring "FA 8. Synchronizer sleeve "MA 9. 5th-reverse speed synchronizer hub 10. Synchronizer ring "DA 11. Synchronizer spring 12. 5th speed gear 13. Needle roller bearing "LA 14. 5th speed gear sleeve "KA 15. 4th speed gear "JA 16. Snap ring "IA 17. 3rd speed gear

AE" "HA

"GA "FA "EA "DA AF" "CA "BA AG" "AA

22B-8-2

MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42>
DISASSEMBLY AND REASSEMBLY <Types with double synchronizer ring for both 1st and 2nd gears, types with double synchronizer ring for 1st gear and triple synchronizer ring for 2nd gear>
"PA AA" "OA AB" "NA "NA "NA
Disassembly steps 1. Snap ring 2. Ball bearing 3. Reverse gear bearing sleeve 4. Needle roller bearing 5. Reverse gear 6. Synchronizer ring "DA 7. Synchronizer spring "FA 8. Synchronizer sleeve AC" "MA 9. 5th-reverse speed synchronizer hub 10. Synchronizer ring "DA 11. Synchronizer spring 12. 5th speed gear 13. Needle roller bearing "LA 14. 5th speed gear sleeve "KA 15. 4th speed gear "JA 16. Snap ring AD" "IA 17. 3rd speed gear
"GA "FA "EA
"GA AF" "CA "BA AG" "AA

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
2nd speed gear Needle roller bearing 2nd speed gear sleeve Inner synchronizer ring Synchronizer cone Outer synchronizer ring Synchronizer spring Synchronizer sleeve 1st-2nd speed synchronizer hub Inner synchronizer ring Synchronizer cone Outer synchronizer ring Synchronizer spring 1st speed gear Needle roller bearing 1st speed gear sleeve Snap ring Roller bearing inner race Output shaft
MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-3

MD998917 Ball bearing

Sleeve
AB" REVERSE GEAR BEARING SLEEVE REMOVAL Mount a special tool on the reverse gear and remove the reverse gear bearing sleeve.
Synchronizer hub MD998801
AC" 5TH-REVERSE SPEED SYNCHRONIZER HUB REMOVAL Mount a special tool on the 4th speed gear and remove the 5th-reverse speed synchronizer hub.

3rd speed gear MD998917

AD" 3RD SPEED GEAR REMOVAL Mount a special tool on the 2nd speed gear and remove the 3rd speed gear.
AE" 2ND SPEED GEAR SLEEVE REMOVAL Mount a special tool on the 1st speed gear and remove the 2nd speed gear sleeve.

MD998917 Sleeve

22B-8-4
AF" 1ST SPEED GEAR SLEEVE REMOVAL Use the special tool to remove the 1st speed gear sleeve.
AG" ROLLER BEARING INNER RACE REMOVAL Use the special tool to remove the roller bearing inner race.
"AA ROLLER BEARING INNER RACE INSTALLATION Use the special tools to install the roller bearing inner race.
"CA 1ST SPEED GEAR SLEEVE INSTALLATION Use the special tools to install the 1st speed gear sleeve.
MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-5
MD998814 Synchronizer hub MD998825

22B-8-6

"GA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring securely up to the illustrated position of the synchronizer ring.
"HA 2ND SPEED GEAR SLEEVE INSTALLATION Use the special tools to install the 2nd speed gear sleeve.

MD998814 Sleeve MD998822

"IA 3RD SPEED GEAR INSTALLATION Use the special tools to install the 3rd speed gear.
MD998814 3rd speed gear MD998822
"JA SNAP RING INSTALLATION Select and install a snap ring so that the output shaft 3rd speed gear end play will have the standard value. Standard value: - 0.01 - 0.09 mm
MD998812 MD998813 MD998819 4th speed gear
"KA 4TH SPEED GEAR INSTALLATION Use the special tools to install the 4th speed gear.
MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-7
MD998812 MD998813 MD998819 Sleeve
"LA 5TH SPEED GEAR SLEEVE INSTALLATION Use the special tools to install the 5th speed gear sleeve.

"MA5TH-REVERSE SPEED SYNCHRONIZER HUB INSTALLATION Install the 5th-reverse speed synchronizer hub in such a way that it will be oriented in the direction shown.
MD998812 MD998813 Synchronizer hub MD998819
MD998812 MD998818 Reverse gear Sleeve
"NA REVERSE GEAR / NEEDLE ROLLER BEARING / REVERSE GEAR BEARING SLEEVE INSTALLATION Use the special tools to install the reverse gear, needle roller bearing and reverse gear bearing sleeve.
MD998812 MD998818 Ball bearing
"OA BALL BEARING INSTALLATION Use the special tools to install the ball bearing.

22B-8-8

"PA SNAP RING INSTALLATION Select and install a snap ring so that the output shaft rear bearing end play will have the standard value. Standard value: - 0.01 - 0.09 mm
Synchronizer ring E Mitsubishi Motors Corporation
MANUAL TRANSMISSION (E - W) - Output Shaft <F5M42, W5M42> 22B-8-9

F5M42-2-R5A3 only

<Double synchronizer ring> Gear

A Outer ring Cone

(2) Install the outer ring, inner ring and cone, press them against the gear, and check clearance A. If A is less than the limit, replace. Limit: 0.5 mm <Double synchronizer ring> 0.3 mm <Triple synchronizer ring> Caution When the outer ring, inner ring or cone has to be replaced, make sure that the outer ring, inner ring and cone are replaced as a set.
Inner ring <Triple synchronizer ring> Gear

22B-8-10

MANUAL TRANSMISSION (E - W) - Reverse Idler Gear <F5M42, W5M42>

22B-9-1

9. REVERSE IDLER GEAR <F5M42, W5M42>

TFM0590

Disassembly steps 1. Snap ring 2. Thrust washer 3. Reverse idler gear 4. Needle roller bearing 5. Reverse idler gear shaft
NEEDLE ROLLER BEARING (1) Check to ensure that when the shaft and gear are combined and made to rotate, they rotate smoothly without looseness and noise. (2) Check to ensure that the cage is not deformed.
MANUAL TRANSMISSION (E - W) - Speedometer Gear

22B-10-1

10. SPEEDOMETER GEAR

TFM0593

Disassembly steps 1. e-clip 2. Speedometer driven gear 3. O-ring 4. Sleeve
MANUAL TRANSMISSION (E - W) - Select Lever

22B-11-1

11. SELECT LEVER

TFM0589

Disassembly steps "AA 1. Dust cover 2. Nut 3. Spring washer 4. Washer 5. Select lever bushing

6. 7. 8. "AA 9. 10.

Select lever shoe Select lever Select lever bushing Dust cover Select lever shaft

Dust cover

REASSEMBLY SERVICE POINT
"AA DUST COVER INSTALLATION
MANUAL TRANSMISSION (E - W) - Control Housing

22B-12-1

12. CONTROL HOUSING

22 Nm TFM0916

Disassembly steps AA" "FA 1. Lock pin 2. Interlock plate 3. Control finger 4. Pin 5. Return spring 6. Stopper plate "EA 7. Spring pin "DA 8. Spring pin 9. Stopper body 10. Neutral return spring 11. Spacer
12. Control shaft (Except up to MODEL 1998 of F5M42-1-F6N4, F7N, R6N3, F5M42-2-F6N2, F6N5 and MODEL 1999) 13. Control shaft (Up to MODEL 1998 of F5M42-1-F6N4, F7N, R6N3, F5M42-2-F6N2, F6N5 and MODEL 1999) "CA 14. Air breather 15. Control shaft boot "BA 16. Oil seal "AA 17. Needle bearing 18. Spring washer 19. Stopper bracket 20. Control housing

Nov. 1998 Jun. 1995

PWEE9508-A PWEE9508-E

22B-12-2

Lock pin
MANUAL TRANSMISSION (E - W) - Control Housing DISASSEMBLY SERVICE POINT
AA" LOCK PIN REMOVAL Drive the lock pin out of position from the direction shown.

Control finger

Control housing
Model number stamped side 2 mm

Needle bearing

"AA NEEDLE BEARING INSTALLATION Press fit the needle bearing up the illustrated dimension, while making sure that the model number stamped side is oriented in the direction shown.
"BA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area. Transmission oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher

TFM0859

"CA AIR BREATHER INSTALLATION (1) Apply a sealant to the outside circumference of the inserting portion. Specified sealant: 3M SUPER WEATHERSTRIP No. 8001 or equivalent
(2) Make sure that the projecting portion is oriented in the direction shown.

Nov. 1997 Jan. 1995

PWEE9508-A PWEE9508-C

Control shaft Stopper body

22B-12-1 22B-12-2a

Installation direction Slit Spring pin TFM0860

Spring pin

"EA SPRING PIN INSTALLATION

TFM0861

"FA LOCK PIN INSTALLATION Drive in the lock pin in the direction shown in the illustration.
MANUAL TRANSMISSION (E - W) - Clutch Housing

22B-13-1

13. CLUTCH HOUSING

4 7* 8

9.8 Nm

TFM0759

Disassembly steps 1. Clutch release bearing retainer "EA 2. Oil seal "DA 3. Oil seal <F5M41, F5M42> AA" "CA 4. Outer race <F5M42, W5M42>
AB" "BA 5. 6. "AA 7. 8.
Outer race Oil guide <F5M41> Bushing* Clutch housing
NOTE: Referring to INSTALLATION SERVICE POINTS is required only when the clutch housing is replaced.
AA" OUTER RACE REMOVAL <F5M42, W5M42> Use the special tool to remove the outer race.
Outer race E Mitsubishi Motors Corporation
Nov. 1998 Jun. 1995 PWEE9508-A PWEE9508-E Added Revised

22B-13-2

MD998346
AB" OUTER RACE REMOVAL Use the special tools to remove the outer race.
Split ends Air purge groove
"AA BUSHING INSTALLATION 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.
"BA OUTER RACE INSTALLATION (1) Install the outer race so that the model number stamped side will be oriented in the direction shown.
Model number stamped side
(2) Use the special tools to install the outer race.

MB990938 MB990934

22B-13-3
"CA OUTER RACE INSTALLATION
"DA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area. Specified oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher
"EA OIL SEAL INSTALLATION Pack grease in the oil seal lip area. Specified grease: MITSUBISHI genuine grease part No. 0101011 or equivalent
MB990926 E Mitsubishi Motors Corporation
MANUAL TRANSMISSION (E - W) - Transmission Case

22B-14-1

14. TRANSMISSION CASE

TFM0600

Disassembly steps "CA 1. Oil seal "BA 2. Needle bearing 3. Oil guide 4. Snap ring "AA 5. Bushing 6. Transmission case

Split ends

Air purge groove E Mitsubishi Motors Corporation

22B-14-2

"BA NEEDLE BEARING INSTALLATION 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.
"CA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area. Specified oil: Hypoid gear oil SAE 75W-85W conforming to API classification GL-4 or higher
MANUAL TRANSMISSION (E - W) -
Differential <F5M41, F5M42>, Front Differential <W5M42>

22B-15-1

15. DIFFERENTIAL <F5M41, F5M42>, FRONT DIFFERENTIAL <W5M42>

132 Nm

TFM0760
"EA AA" "DA AB" "CA "BA "AA "AA "AA "AA "AA
Disassembly steps 1. Differential drive gear 2. Ball bearing <F5M41> 3. Taper roller bearing <F5M42, W5M42> 4. Lock pin 5. Pinion shaft 6. Pinion 7. Washer 8. Side gear 9. Spacer 10. Differential case

22B-15-2

AA" BALL BEARING REMOVAL <F5M41> Use the special tool to remove the ball bearing.
AB" TAPER ROLLER BEARING REMOVAL <F5M42> Use the special tool to remove the taper roller bearing.
"AA SPACER / SIDE GEAR / WASHER / PINION / PINION SHAFT INSTALLATION (1) After a spacer has been mounted on the back surface of the side gear, install the side gear in the differential case. NOTE When a new side gear is to be installed, mount a medium thickness spacer (0.93 - 1.00 mm). (2) Set the washer on the back of each pinion, and put both pinions simultaneously in mesh with the side gears. While rotating them, install them in position.
(3) Insert the pinion shaft.

22B-15-3

(4) Measure the backlash between the side gear and pinion. Standard value: 0.025 - 0.150 mm (5) If the backlash is out of specification, select a spacer and re-measure the backlash. NOTE Adjust until the backlashes on both sides are equal.
"BA LOCK PIN INSTALLATION Install the lock pin in such a way that it will be oriented in the direction shown.
MD998812 Taper roller bearing MD998819
"CA TAPER ROLLER BEARING INSTALLATION <F5M42> Use the special tools to install the taper roller bearing.
MD998812 MD998819 Ball bearing
"DA BALL BEARING INSTALLATION <F5M41> Use the special tools to install the ball bearing.
"EA DIFFERENTIAL DRIVE GEAR INSTALLATION (1) Apply a sealant to the entire threaded portion of the bolt. Specified sealant: 3M STUD Locking No. 4170 or equivalent

22B-15-4

MANUAL TRANSMISSION (E - W) 1 8
(2) Tighten to the specified torque in the illustrated sequence.
MANUAL TRANSMISSION (E - W) - Center Differential <W5M42>

22B-16-1

16. CENTER DIFFERENTIAL <W5M42>
"DA "CA AA" "BA "CA "CA "CA "CA "CA "CA
Disassembly steps 1. Center differential drive gear 2. Center differential flange 3. Taper roller bearing 4. Snap ring 5. Front output shaft 6. Spacer 7. Side gear 8. Lock pin 9. Pinion shaft
"CA "CA "CA "CA "CA AB" "AA
10. 11. 12. 13. 14. 15. 16. 17.
Pinion shaft holder Pinion Washer Side gear Spacer Taper roller bearing Speedometer drive gear Differential case
AA" TAPER ROLLER BEARING REMOVAL Use the special tool to remove the taper roller bearing.

22B-16-2

AB" TAPER ROLLER BEARING REMOVAL Use the special tools to remove the taper roller bearing.

MD990930

"AA TAPER ROLLER BEARING INSTALLATION Use the special tool to install the taper roller bearing.
"BA TAPER ROLLER BEARING INSTALLATION Use the special tools to install the taper roller bearing.
"CA SPACER/SIDE GEAR/WASHER/PINION/PINION HOLDER/PINION SHAFT/LOCK PIN/FRONT OUTPUT SHAFT/SNAP RING/CENTER DIFFERENTIAL FLANGE INSTALLATION (1) Install the side gear in the center differential case with the spacer attached. NOTE: If a new side gear is to be installed, select a spacer with medium thickness (0.93 - 1.00 mm). (2) Fit the washer on the back of each pinion. Engage the 4 pinions simultaneously in the side gear. Rotate the gears to place them in position, then install the pinion shaft holder. (3) Insert the pinion shafts. (4) Install the lock pins in the illustrated direction.
Differential case Lock pin Pinion shaft

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 mm).