Mitsubishi L200. Manual - part 262

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-33

51.Completely degrease the FIPG-applied surface

so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand.

52.Apply a 1.2 mm diameter bead of liquid gasket to

the transmission case sub-assembly mounting
surface of the front bearing retainer sub-assembly
with seal.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

CAUTION

Do not damage to the oil seal lip during the
installation.

AK403774

53.Apply sealant to the threads. Install the front

bearing retainer to the transmission case sub-
assembly and tighten the bolts to the specified
torque of 16.5

± 5.0 N⋅m.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

NOTE: The new bolt does not require sealant
application as it is precoated with sealant.

AK403773

54.Install the wiring harness clamp bracket to the

transmission case sub-assembly and tighten the
bolt to the specified torque of 18

± 3 N⋅m.

AK403781

55.Install the reverse restrict pin assembly to the

transfer adaptor sub-assembly.

AK403780

56.Install the slotted spring pin to the reverse restrict

pin assembly.

AK403779

57.Apply sealant to the threads. Tighten the straight

screw plug with head to the specified torque of
18.5

± 5.5 N⋅m.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

NOTE: The new bolt does not require sealant
application as it is precoated with sealant.

AK403777

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-34

58.Install the oil receiver pipe into the transfer

adaptor sub-assembly.

AK500527

59.Completely degrease the FIPG-applied surface

so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand.

60.Apply a 1.2 mm diameter bead of liquid gasket to

the intermediate plate mounting surface of the
transfer adaptor sub-assembly.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

AK403776

61.Install the transfer adaptor sub-assembly. Install

the wiring harness clamp bracket (3 places) and
tighten the bolts to the specified torque of 37

± 11

⋅m.

CAUTION

When installing the shift lever housing, securely
fit the shift lever housing into the head of the fork
shaft.

AK500256AB

Transfer
adaptor

AK501350

62. Install the shift lever housing to the transfer

adaptor sub-assembly.

AK403772

63.Install the control shaft assembly to the transfer

adaptor sub-assembly and the shift lever housing.

AK403771

64.Tighten the flange bolt to the specified torque of

± 3 N⋅m.

AK500528

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-35

65.Completely degrease the FIPG-applied surface

so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand.

66.Apply a 1.2 mm diameter bead of liquid gasket to

the case mounting surface of the transfer adaptor
sub-assembly.

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

AK403770

67.Install the cover to the transfer adaptor sub-

assembly and tighten the bolt with washer to the
specified torque of 18

± 5 N⋅m.

CAUTION

Install the reverse restrict pin assembly carefully
in the accordance with the identification color as
shown in the illustration.

AK403769

Identification
color: black

Identification
color: white

68.Tighten the reverse restrict pin assembly to the

specified torque of 37

± 11 N⋅m (2 places).

CAUTION

Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.

AK500460AB

69.Install the clutch housing into the transmission

case sub-assembly. Tighten the bolt with washer
to the specified torque of 36

± 7 N⋅m (7 places).

Tighten the bolt with washer (with sealant) to the
specified torque of 34

± 6 N⋅m (2 places).

Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent

AK403767

Shift position switch
assembly

Back-up lamp switch
assembly

70.Tighten the shift position switch assembly to the

specified torque of 34

± 5 N⋅m.

71.Tighten the back-up lamp switch assembly to the

specified torque of 44

± 9 N⋅m.

72.Install the transfer and the gear change shifter.

Tighten the bolts to the specified torque of 35

± 6

⋅m.

73.Install the spring pin.

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-36

INSPECTION

M1222001100899

BACK-UP LAMP SWITCH

AK500505

Check for the continuity between the connector ter-
minals.

Switch
condition

Connector
terminals

Continuity

Switch end
pressed

− 2

Conductive

Switch end
released

− 2

Open

SHIFT POSITION SWITCH

AK501632

Check for the continuity between the connector ter-
minals.

Switch
condition

Connector
terminals

Continuity

Switch end
pressed

− 2

Open

Switch end
released

− 2

Conductive

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.

3. Using the thickness gauge, check the clearance

between the synchronizer ring and the gear.

Standard value: 0.52

− 1.88 mm

Limit: 0.52 mm

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

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

2. Check the needle roller bearing cage for

deformation.

COUNTER SHAFT GEAR No.5
THRUST CLEARANCE
Inspect the thrust clearance of counter shaft gear
No.5.

Standard value: 0.10

− 0.35 mm

Limit: 0.35 mm

RADIAL CLEARANCE
1. Fix the output shaft in a vice.
2. Inspect the radial clearance of counter shaft gear

No.5.

Standard value: 0.015

− 0.068 mm

Limit: 0.068 mm

INSIDE DIAMETER

AK404027

Using the cylinder gauge, check the inside diameter
of the counter shaft gear No.5.

Standard value: 38.015

− 38.040 mm

Limit: 38.040 mm

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