Mitsubishi L200. Manual - part 245

 

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Mitsubishi L200. Manual - part 245

 

 

SEALANTS

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-5

SEALANTS

M1222000501132

Item

Specified sealant and adhesive 

Between transmission case sub-assembly and 
intermediate plate

Mitsubishi Part No.MD974421 or equivalent

Between front bearing retainer and transmission 
case
Between intermediate plate and extension housing 
sub-assembly
Straight screw plug with head
Front bearing retainer mounting bolt
Clutch housing mounting bolt

FORM-IN-PLACE GASKET (FIPG)
This transmission has several areas where the form-
in-place gasket (FIPG) is used for sealing. To ensure 
that the FIPG fully serves its purpose, it is necessary 
to observe some precautions when applying it. Bead 
size, continuity and location are of paramount impor-
tance. 
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 fluid passages. To 
prevent leaks or blocking of passages, therefore, it is 
absolutely necessary to apply the FIPG evenly with-
out a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the 
atmospheric air, and it is usually used for sealing 
metallic flange areas.

CAUTION

When re-applying liquid gasket (FIPG), be sure 
that:

1. Residues of FIPG are cleared from all the ins 

and outs of parts;

2. Use Mitsubishi genuine parts cleaner 

(MZ100387) or equivalent to well degrease the 
FIPG-applied surface.

3. FIPG is correctly applied in accordance with 

FIPG Application.

Disassembly
Parts sealed with a FIPG can be easily removed 
without need for the use of a special method. In 
some cases, however, the FIPG in joints may have to 
be broken by tapping parts with a mallet or similar 
tool. 

Transmission case 

− back-up lamp switch assembly

44 

± 9

Transmission case 

− shift position switch assembly <R5MB1-J-NC>

34 

± 5

Transmission case 

− vehicle speed sensor mounting bolt

11 

± 1

Extension housing 

− straight screw plug with head

18.5 

± 5.5

Transmission case 

− extension housing sub-assembly, and intermediate plate 

mounting bolt

37 

± 11

Intermediate plate 

− straight screw plug with head 

18.5 

± 5.5

Gear shift fork No.1 mounting bolt

19.5 

± 3.9

Gear shift fork No.2 mounting bolt

19.5 

± 3.9

Intermediate plate 

− rear bearing output retainer mounting bolt

18 

± 5

Oil receiver pipe mounting bolt

11 

± 4

Shift lever housing mounting bolt

33 

± 3

Item

N

m

LUBRICANTS

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-6

Surface Preparation 
Thoroughly remove all substances deposited on the 
FIPG application surface, using a gasket scraper. 
Make sure that the FIPG application surfaces is flat 
and smooth. Also make sure that the surface is free 
from oils, greases and foreign substances. Do not fail 
to remove old FIPG that may remain in the fastener 
fitting holes.

FIPG Application
Applied FIPG bead should be of the specified size 
and free of any break. FIPG can be wiped away 
unless it has completely hardened. Install the mating 
parts in position while the FIPG is still wet. Do not 
allow FIPG to spread beyond the sealing areas dur-
ing installation. Avoid operating the transmission or 
letting oils or water come in contact with the sealed 
area before a time sufficient for FIPG to harden 
(approximately one hour) has passed. 
FIPG application method may vary from location to 
location. Follow the instruction for each particular 
case described later in this manual.

LUBRICANTS

M1222000400994

Item

Specified lubricant

Transmission oil

Gear oil API classification GL-3 SAE 75W-85

SPECIAL TOOLS

M1222000600534

Tool

Tool number

Name

Use

MB990803

MB990803

Steering wheel puller

Removal of gear spline 
piece No.5

MB990811

MB990811

Side bearing puller cup

Use with Steering wheel 
puller

MD998812

Installer cap

Use with installer and 
adapter

MD998813

Installer-100

Use with installer cap and 
adapter

SPECIAL TOOLS

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-7

MD998827

Installer adapter (56)

Use with installer cap and 
adapter

MD998801

Remover

Removal of roller bearing 
and ball bearing, input gear 
corn ring, transmission 
clutch hub No.1 and 
transmission clutch hub 
No.2

MD998814

Installer-200

Use with installer cap and 
adapter

MD998823

Installer adapter (48)

Installation of ball bearing, 
5th gear, transmission 
clutch hub No.1 and 
transmission hub No.2

MD998817

Installer adapter (34)

Use with installer cap and 
adapter

MB990699

Differential oil seal 
installer

Installation of oil seal

MB990929

Installer adapter

Installation of oil seal

MB990938

Installer bar

Use with installer adaoter

Tool

Tool number

Name

Use

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-8

TRANSMISSION

DISASSEMBLY AND REASSEMBLY

M1222001001765

AK701068AD

3

36 ± 7 N·m

8

6

7

10

37 ± 11 N·m

12

11

13

16.5 ± 5.0 N·m

19

18

15

1

44 ± 9 N·m

14

4

5

9

18.5 ± 5.5 N·m

7

34 ± 6 N·m

16

17

11 ± 1 N·m

2

34 ± 5 N·m

<R5MB1-J-NC>

Disassembly steps 

1.

Back-up lamp switch assembly

2.

Shift position switch assembly 
<R5MB1-J-NC>

3.

Clutch housing

4.

Vehicle speed sensor

5.

O-ring

6.

Wiring harness clamp bracket

7.

Wiring harness clamp bracket

8.

Extension housing sub-assembly

9.

Oil receiver pipe

10. Straight screw plug with head
11. Slotted spring pin

12. Reverse restrict pin assembly
13. Front bearing retainer
14. Oil seal
15. Shaft snap ring
16. Shaft snap ring
17. Transmission case sub-assembly
18. Intermediate plate with shaft sub-

assembly

19. Transmission magnet

Disassembly steps (Continued)

 

 

 

 

 

 

 

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