Mitsubishi L200. Manual - part 252

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-33

<<D>> TRANSMISSION CLUTCH HUB No.2 /
SYNCHRONIZER SHIFTING KEY No.2 /
COMPRESSION SPRING / TRANSMISSION HUB
SLEEVE No.2 / SYNCHRONIZER RING SET No.2 /
3RD GEAR SUB-ASSEMBLY REMOVAL

AK404020

MD998801

Using special tool Bearing remover (MD998801),
support the 3rd gear sub-assembly and remove the
transmission clutch hub No.2, synchronizer shifting
key No.2, compression spring, the transmission hub
sleeve No.2, synchronizer ring set and the 3rd gear
sub-assembly.

REASSEMBLY SERVICE POINTS

>>A<< TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 / COM-
PRESSION SPRING / TRANSMISSION HUB
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY INSTALLATION

AK500607

Installation
direction

1. Check the installation direction of the transmission

clutch hub No. 2, and put it on the output shaft.

AK404029

MD998812

MD998823

MD998813

2. Using special tools to install the transmission

clutch hub No. 2, synchronizer shifting key No. 2,
compression spring, the transmission hub sleeve
No. 2, synchronizer ring set No. 2 and the 3rd
gear sub-assembly.

• Installer cap (MD998812)

• Installer-100 (MD998813)

•

AK500508

Installer adapter (48) (MD998823)

3. Confirm the thrust clearance of the 3rd gear sub-

assembly is within the standard value.

Standard value: 0.10

− 0.25 mm

Limit: 0.25 mm

>>B<< SHAFT SNAP RING INSTALLATION

AK404019

1. Select a shaft snap ring to secure the standard

clearance between the transmission clutch hub
No.2 and the output shaft.

Standard value: 0

− 0.1 mm

2. Install the selected snap ring.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-34

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

AK500608

Installation
direction

1. Check the installation direction of the reverse

gear, and put it on the output shaft.

AK404030

MD998812

MD998823

MD998813

MD998814

2. Using special tools to install the reverse gear,

synchronizer shifting key No. 1, compression
spring, the transmission clutch No. 1 hub,
synchronizer ring set No. 1 and the 2nd gear sub-
assembly.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer-200 (MD998814)

•

AK404032

Installer adapter (48) (MD998823)

3. Confirm the thrust clearance of the 2nd gear sub-

assembly is within the standard value.

Standard value: 0.10

− 0.25 mm

Limit: 0.25 mm

>>D<< SHAFT SNAP RING INSTALLATION

AK404031

1. Select a snap ring to secure the standard

clearance between the transmission clutch No. 1
hub and the output shaft.

Standard value: 0

− 0.1 mm

2. Install the selected snap ring.

>>E<< RADIAL BALL BEARING / 1ST GEAR SUB-
ASSEMBLY INSTALLATION

AK500606AB

Installation
direction

1. Check the installation direction of the radial ball

bearing, and put it on the output shaft.

CAUTION

Never push on the sealing area when installing.

AK404038

MD998812

MD998823

MD998814

2. Using special tools to install the radial ball bearing

and the 1st gear sub-assembly.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (48) (MD998823)

AK500513

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-35

3. Confirm the thrust clearance of the 1st gear sub-

assembly is within the standard value.

Standard value: 0.20

− 0.45 mm

Limit: 0.45 mm

>>F<< 5TH GEAR INSTALLATION

AK500609

Installation
direction

1. Check the installation direction of the 5th gear,

and put it on the output shaft.

AK404039

MD998812

MD998823

MD998814

2. Using special tools to install the 5th gear.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (48) (MD998823)

>>G<< SHAFT SNAP RING INSTALLATION

AK404040

1. Select a shaft snap ring to secure the standard

clearance between the 5th gear and the output
shaft

Standard value: 0

− 0.1 mm

2. Install the selected snap ring.

INSPECTION

M1222002300261

SYNCHRONIZER RING

CAUTION

When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.

AK500672AB

1. Check to ensure that the clutch gear tooth surface

and cone surface are not damaged and broken.

AK500603

2. After applying oil to the taper portion on each

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

AK404022

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-36

3. Using the thickness gauge, check the clearance

between the synchronizer ring and the gear.

Gear

Standard value mm

Limit mm

1st

0.65

− 1.75

0.65

2nd

0.65

− 1.75

0.65

3rd

0.65

− 1.75

0.65

HUB SLEEVE AND SHIFT FORK

CAUTION

When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.

AK404023

Using the thickness gauge, check the clearance
between the sleeve and the shift fork.

sleeve

Standard
value mm

Limit mm

No.1

0.15

− 0.41

0.41

No.2

0.15

− 0.35

0.35

No.3

0.26

− 0.84

0.84

SYNCHRONIZER SLEEVE AND HUB
1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.

2. Check that the sleeve is free from damage at its

inside splines ends.

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

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

2. Check the needle roller bearing cage for

deformation.

SYNCHRONIZER KEYS

AK500680AB

Check the synchronizer hub contact surfaces of each
synchronizer key for damage and excessive wear.

COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.

OUTPUT SHAFT

AK404024

1. Using the micrometer, check the outer shape of

the needle roller bearing race.

Measurement
part

Standard value mm Limit mm

37.984

− 38.000

37.984

46.984

− 47.000

46.984

38.979

− 38.995

38.979

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