Mitsubishi L200. Manual - part 253

AK404025

COUNTERSHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-37

2. Using the slide gauge, check the flange thickness.

Minimum limit: 4.800 mm 

AK404026

3. Using the dial gauge and V-block, check the 

output shaft runout.

Limit: 0.015 mm

AK404027

4. Using the cylinder gauge, check the inside 

diameter of each gear.

Gear

Standard value mm

Limit mm

1st

46.015 

− 46.040

46.040

2nd

53.015 

− 53.040

53.040

3rd

44.015 

− 44.040

44.040

COUNTERSHAFT

DISASSEMBLY AND REASSEMBLY

M1222007300158

AK500518

Apply gear oil to
all moving parts
before installation.

AB

1

2

3

Disassembly steps 

>>

B

<<

1.

Shaft snap ring

<<

A

>>

>>

A

<<

2.

Cylindrical roller bearing

3.

Counter gear

COUNTERSHAFT

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-38

DISASSEMBLY SERVICE POINT

<<A>> CYLINDRICAL ROLLER BEARING 
REMOVAL

AK404043

MD998801

AB

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

REASSEMBLY SERVICE POINTS

>>A<< CYLINDRICAL ROLLER BEARING 
INSTALLATION

AK500644

Installation
direction

AB

1. Check the installation direction of the cylindrical 

roller bearing, and put it on the counter shaft.

CAUTION

Never push the sealing area at the press fit.

AK404046

AB

MD998812

MD998817

MD998813

2. Using special tools to install the cylindrical roller 

bearing.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (34) (MD998817)

>>B<< SHAFT SNAP RING INSTALLATION

AK404042

1. Select a snap ring to secure clearance of standard 

value between the cylinder roller bearing and 
counter shaft.

Standard value: 0 

− 0.1 mm

2. Install the selected snap ring.

INSPECTION

M1222007400025

COUNTER GEAR

AK404041

AB

D

E

Using the micrometer, check the outer shape of the 
needle roller bearing race.

Measurement 
part

Standard value 
mm

Limit mm

D

34.000 

− 34.105

34.000

E

29.984 

− 30.000

29.984

REVERSE IDLER GEAR

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-39

REVERSE IDLER GEAR

DISASSEMBLY AND REASSEMBLY

M1222012500233

AK500519

Apply gear oil to
all moving parts
before installation.

AB

1

2

Disassembly steps 

1.

Reverse idler gear sub-assembly

2.

Reverse idler gear shaft

INSPECTION

M1222012400076

REVERSE IDLER GEAR SUB-ASSEMBLY

AK500525AB

Check the radial clearance of the reverse idler gear.

Standard value: 0.040 

− 0.082 mm

Limit: 0.082 mm

EXTENSION HOUSING

MANUAL TRANSMISSION OVERHAUL <R5MB1>

22B-40

EXTENSION HOUSING

DISASSEMBLY AND REASSEMBLY

M1222004300074

AK500815AB

11 ± 4 N·m

1

3

2

4

5

6

33 ± 3 N·m

Disassembly steps 

1.

Oil receiver pipe

2.

Extension housing oil deflector

>>

A

<<

3.

Oil seal

4.

Shift & select lever

5.

Shift lever housing

6.

Extension housing

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

AK500819AB

MB990699

Oil seal

Using the special tool Differential oil seal installer 
(MB990699), install the oil seal.