Mitsubishi L200. Manual - part 244

22B-1

GROUP 22B

MANUAL 

TRANSMISSION 

OVERHAUL 

<R5MB1>

CONTENTS

GENERAL INFORMATION . . . . . . . .

22B-2

GENERAL SPECIFICATIONS . . . . . .

22B-2

SERVICE SPECIFICATIONS. . . . . . .

22B-2

SNAP RING, SPACER AND THRUST PLATE 
FOR ADJUSTMENT. . . . . . . . . . . . . .

22B-3

TORQUE SPECIFICATIONS . . . . . . .

22B-4

SEALANT(S) AND ADHESIVE(S) . . .

22B-5

LUBRICANTS  . . . . . . . . . . . . . . . . . .

22B-6

SPECIAL TOOLS. . . . . . . . . . . . . . . .

22B-6

TRANSMISSION  . . . . . . . . . . . . . . . .

22B-8

TRANSMISSION DISASSEMBLY AND REASSEMBLY

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22B-8

TRANSMISSION INSPECTION . . . . . . . . . 

22B-27

INPUT SHAFT. . . . . . . . . . . . . . . . . . .

22B-29

INPUT SHAFT DISASSEMBLY AND REASSEMBLY

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22B-29

INPUT SHAFT INSPECTION  . . . . . . . . . . . 

22B-30

OUTPUT SHAFT. . . . . . . . . . . . . . . . .

22B-31

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . 

22B-31

OUTPUT SHAFT INSPECTION  . . . . . . . . . 

22B-35

COUNTERSHAFT. . . . . . . . . . . . . . . .

22B-37

COUNTERSHAFT DISASSEMBLY AND 
REASSEMBLY  . . . . . . . . . . . . . . . . . . . . . . 

22B-37

COUNTERSHAFT INSPECTION  . . . . . . . . 

22B-38

REVERSE IDLER GEAR  . . . . . . . . . .

22B-39

REVERSE IDLER GEAR DISASSEMBLY AND 
REASSEMBLY  . . . . . . . . . . . . . . . . . . . . . . 

22B-39

REVERSE IDLER GEAR INSPECTION . . . 

22B-39

EXTENSION HOUSING  . . . . . . . . . . .

22B-40

EXTENSION HOUSING DISASSEMBLY AND 
REASSEMBLY  . . . . . . . . . . . . . . . . . . . . . . 

22B-40

GENERAL INFORMATION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-2

GENERAL INFORMATION

M1222000101275

MANUAL TRANSMISSION MODELS

Transmission model

Engine model

Vehicle model

R5MB1-J-NC

4D56 DI-D DOHC

KA4T

R5MB1-J-ND1

GENERAL SPECIFICATIONS

M1222000200785

Item

Specifications

Transmission model

R5MB1

Transmission type

5-speed transmission, floor shift

Transmission gear ratio

1st

4.313

2nd

2.330

3rd

1.436

4th

1.000

5th

0.789

Reverse

4.220

SERVICE SPECIFICATIONS

M1222000300492

Item

Standard value

Limit

Transmission
Gear spline piece No.5 end play mm

0 

− 0.1

−

Clearance between the synchronizer ring and the gear mm

0.52 - 1.88

0.52

Counter shaft gear No.5

thrust 
clearance mm

0.10 - 0.35

0.35

radial 
clearance mm

0.015 

− 0.068

0.068

inside diameter 
mm

38.015 

− 38.040

38.040

Input shaft
Input shaft radial ball bearing end play mm

0 

− 0.1

−

clearance between the synchronizer ring and the 4th gear mm

0.70 

− 1.70

0.70

Output shaft
Thrust clearance mm

1st gear

0.20 

− 0.45

0.45

2nd gear

0.10 

− 0.25

0.25

3rd gear

0.10 

− 0.25

0.25

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-3

SNAP RING, SPACER AND THRUST PLATE FOR 

ADJUSTMENT

M1222012000595

Shaft snap ring (For adjustment of gear spline piece No.5 end play)

Thickness mm

Identification symbol Thickness mm

Identification symbol

2.80 

− 2.85

A

3.00 

− 3.05

E

2.85 

− 2.90

B

3.05 

− 3.10

F

2.90 

− 2.95

C

3.10 

− 3.15

G

2.95 

− 3.00

D

Radial clearance mm

1st gear 

0.020 

− 0.073

0.073

2nd gear

0.015 

− 0.068

0.068

3rd gear

0.015 

− 0.068

0.068

Transmission clutch hub No.1 end play mm

0 

− 0.1

−

Transmission clutch hub No.2 end play mm

0 

− 0.1

−

5th gear end play mm

0 

− 0.1

−

Clearance between the synchronizer ring and the 
each gear mm

1st gear

0.65 

− 1.75

0.65

2nd gear

0.65 

− 1.75

0.65

3rd gear

0.65 

− 1.75

0.65

Clearance between the each sleeve and the shift 
fork mm

sleeve No.1

0.15 

− 0.41

0.41

sleeve No.2

0.15 

− 0.35

0.35

sleeve No.3

0.26 

− 0.84

0.84

Output shaft outer shape of the needle roller 
bearing race mm

A

37.984 

− 38.000

37.984

B

46.984 

− 47.000

46.984

C

38.979 

− 38.995

38.979

Output shaft flange thickness mm

−

4.800

Output shaft runout mm

−

0.015

Each gear inside diameter mm

1st gear

46.015 

− 46.040

46.040

2nd gear

53.015 

− 53.040

53.040

3rd gear

44.015 

− 44.040

44.040

Counter shaft
Counter gear shaft cylindrical roller bearing end play mm

0 

− 0.1

−

Counter shaft outer shape of the needle roller 
bearing race mm

D

34.000 

− 34.105

34.000

E

29.984 

− 30.000

29.984

Reverse idler gear
Reverse idler gear radial clearance mm

0.040 

− 0.082

0.082

Item

Standard value

Limit

TORQUE SPECIFICATIONS

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-4

Shaft snap ring (For adjustment of input shaft radial ball bearing end play)

Thickness mm

Identification symbol Thickness mm

Identification symbol

2.10 

− 2.15

A

2.30 

− 2.35

E

2.15 

− 2.20

B

2.35 

− 2.40

F

2.20 

− 2.25

C

2.40 

− 2.45

G

2.25 

− 2.30

D

Shaft snap ring (For adjustment of transmission clutch hub No.2 end play)

Thickness mm

Identification symbol Thickness mm

Identification symbol

1.80 

− 1.85

A

2.00 

− 2.05

E

1.85 

− 1.90

B

2.05 

− 2.10

F

1.90 

− 1.95

C

2.10 

− 2.15

G

1.95 

− 2.00

D

Shaft snap ring (For adjustment of transmission clutch hub No.1 end play)

Thickness mm

Identification symbol Thickness mm

Identification symbol

2.30 

− 2.35

A

2.50 

− 2.55

E

2.35 

− 2.40

B

2.55 

− 2.60

F

2.40 

− 2.45

C

2.60 

− 2.65

G

2.45 

− 2.50

D

Shaft snap ring (For adjustment of 5th gear end play)

Thickness mm

Identification symbol Thickness mm

Identification symbol

2.75 

− 2.80

C

3.05 

− 3.10

J

2.80 

− 2.85

D

3.10 

− 3.15

K

2.85 

− 2.90

E

3.15 

− 3.20

L

2.90 

− 2.95

F

3.20 

− 3.25

M

2.95 

− 3.00

G

3.25 

− 3.30

N

3.00 

− 3.05

H

3.30 

− 3.35

P

Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)

Thickness mm

Identification symbol Thickness mm

Identification symbol

2.05 

− 2.10

A

2.20 

− 2.25

D

2.10 

− 2.15

B

2.25 

− 2.30

E

2.15 

− 2.20

C

2.30 

− 2.35

F

TORQUE SPECIFICATIONS

M1222013900494

Item

N

⋅m

Intermediate plate 

− reverse shift arm bracket mounting bolt

18 

± 5

Transmission case 

− clutch housing mounting bolt

36 

± 7

Transmission case 

− clutch housing mounting bolt (with seal)

34 

± 6 

Transmission case 

− front bearing retainer sub-assembly mounting bolt

16.5 

± 5.0