Mitsubishi L200. Manual - part 251

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-29

INPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1222001600526

AK500516

Apply gear oil to
all moving parts
before installation.

AB

1

2

5

3

4

Disassembly steps 

>>

B

<<

1.

Shaft snap ring

<<

A

>>

>>

A

<<

2.

Radial ball bearing

3.

Synchronizer ring No.2

4.

Needle roller bearing

5.

Input shaft sub-assembly

DISASSEMBLY SERVICE POINT

<<A>> RADIAL BALL BEARING REMOVAL

AK403995

AC

MD998801

Using special tool Bearing remover (MD998801), 
support the radial ball bearing and remove it.

REASSEMBLY SERVICE POINTS

>>A<< RADIAL BALL BEARING INSTALLATION

AK500606AB

Installation
direction

1. Check the installation direction of the radial ball 

bearing, and put it on the input shaft.

CAUTION

Never push on the sealing area when installing.

AK403996

MD998812

AB

MD998823

MD998814

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-30

2. Using special tools to install the radial ball 

bearing.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (48) (MD998823)

>>B<< SNAP RING INSTALLATION

AK403997

1. Select a snap ring to secure the standard 

clearance between the radial ball bearing and the 
input shaft sub-assembly.

Standard value: 0 

− 0.1 mm

2. Install the selected snap ring.

INSPECTION

M1222001700222

INPUT SHAFT SUB-ASSEMBLY

AK500677AB

1. Check the helical gear teeth and clutch gear teeth 

of each input shaft sub-assembly for damage and 
excessive wear.

2. Check the synchronizer cone surface of each 

input shaft sub-assembly for roughness, damage, 
and excessive wear.

3. Check the inside surface and front and back sides 

of each input shaft sub-assembly for damage and 
excessive wear.

SYNCHRONIZER RING No.2

AK500676AB

1. Check the clutch gear on the synchronizer ring for 

damaged and missing teeth.

2. Check the synchronizer ring inner cone surface 

for damage or wear. Also check that the inside 
ridges are intact.

AK403998

3. After applying oil to the taper portion on gear, 

press and fit the synchronizer ring by hand. 
Confirm the synchronizer ring cannot be rotated.

AK403999

4. Using the thickness gauge, check the clearance 

between the synchronizer ring and the 4th gear.

Standard value: 0.70 

− 1.70 mm

Minimum limit: 0.70 mm

NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input 

shaft, and check that it rotates smoothly without 
noise or play.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-31

2. Check the needle roller bearing cage for 

deformation.

OUTPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1222002100160

AK500517

Apply gear oil to
all moving parts
before installation.

AB

1

2

3

4

5

8

7

6

9

10

11

14

12

15

16

17

13

26

25

24

18

19

21

22

20

23

Disassembly steps 

>>

G

<< 1.

Shaft snap ring

<<

A

>>

>>

F

<<

2.

5th gear

<<

B

>>

>>

E

<<

3.

Radial ball bearing

<<

B

>>

>>

E

<<

4.

1st gear sub-assembly

5.

1st gear thrust washer

6.

Straight pin

7.

Needle roller bearing

8.

D spacer

9.

Synchronizer ring set No.1

>>

D

<<

10. Shaft snap ring

<<

C

>>

>>

C

<<

11. Reverse gear

<<

C

>>

>>

C

<<

12. Synchronizer shifting key No.1

<<

C

>>

>>

C

<<

13. Compression spring

<<

C

>>

>>

C

<<

14. Transmission clutch No.1 hub

<<

C

>>

>>

C

<<

15. Synchronizer ring set No.1

<<

C

>>

>>

C

<<

16. 2nd gear sub-assembly
17. Needle roller bearing

>>

B

<<

18. Shaft snap ring

<<

D

>>

>>

A

<<

19. Transmission hub sleeve No.2

<<

D

>>

>>

A

<<

20. Synchronizer shifting key No.2

<<

D

>>

>>

A

<<

21. Compression spring

<<

D

>>

>>

A

<<

22. Transmission clutch No.2 hub

<<

D

>>

>>

A

<<

23. Synchronizer ring set No.2

<<

D

>>

>>

A

<<

24. 3rd gear sub-assembly

Disassembly steps (Continued)

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-32

INSPECTION BEFORE DISASSEMBLY

THRUST CLEARANCE FOR EACH GEAR

AK404000

AB

2nd

3rd

1st

Inspect the thrust clearance of each gear.

Gear

Standard value mm

Limit mm

1st

0.20 

− 0.45

0.45

2nd

0.10 

− 0.25

0.25

3rd

0.10 

− 0.25

0.25

RADIAL CLEARANCE FOR EACH GEAR

AK404001

AB

1. Fix the output shaft by a vice.
2. Inspect the radial clearance of each gear.

Gear

Standard value mm

Limit mm

1st

0.020 

− 0.073

0.073

2nd

0.015 

− 0.068

0.068

3rd

0.015 

− 0.068

0.068

DISASSEMBLY SERVICE POINTS

<<A>> 5TH GEAR REMOVAL

AK404004

MD998801

AB

Using special tool Bearing remover (MD998801), 
support the 5th gear and remove it.

<<B>> RADIAL BALL BEARING / 1ST GEAR SUB-
ASSEMBLY REMOVAL

AK404006

MD998801

AB

Using special tool Bearing remover (MD998801), 
support the 1st gear sub-assembly and remove the 
radial ball bearing and the 1st gear sub-assembly.

<<C>> REVERSE GEAR / SYNCHRONIZER 
SHIFTING KEY No.1 / COMPRESSION SPRING / 
TRANSMISSION CLUTCH No.1 HUB /    
SYNCHRONIZER RING SET No.1 / 2ND GEAR 
SUB-ASSEMBLY REMOVAL

AK404014

MD998801

AB

Using special tool Bearing remover (MD998801), 
support the 2nd gear sub-assembly and remove the 
reverse gear, synchronizer shifting key No.1, com-
pression spring, the transmission clutch No.1 hub, 
synchronizer ring set No.1 and the 2nd gear sub-

assembly.

25. Needle roller bearing
26. Output shaft

Disassembly steps (Continued)