Mitsubishi Grandis. Manual - part 877

 

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Mitsubishi Grandis. Manual - part 877

 

 

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-18

DISASSEMBLY SERVICE POINTS
<<A>> BALL BEARING REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the ball bearing, and then set them on the 
press.

2. Push down on the input shaft with the press and 

remove the ball bearing.

<<B>> THRUST PLATE STOPPER 
REMOVAL

Using a screwdriver, pry up at the position shown in 
the illustration and remove the thrust plate stopper.

<<C>> 5TH SPEED GEAR REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the 5th speed gear, and then set them on 
the press.

2. Push down on the input shaft with the press and 

remove the 5th speed gear.

<<D>> 4TH SPEED GEAR SLEEVE 
REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the 3rd speed gear, and then set them on 
the press.

2. Push down on the input shaft with the press and 

remove the 4th speed gear sleeve.

<<E>> BALL BEARING REMOVAL

Disassembly steps

>>M<<

1.

Snap ring

<<A>>

>>L<<

2.

Ball bearing

<<B>>

>>K<<

3.

Thrust plate stopper

>>J<<

4.

Thrust plate

<<C>>

>>I<<

5.

5th speed gear

6.

4th speed gear

7.

Needle roller bearing

<<D>>

>>H<<

8.

4th speed gear sleeve

>>E<<

9.

Synchronizer ring

>>D<<

10. Synchronizer spring

>>G<<

11. Synchronizer sleeve

>>F<<

12. 3rd-4th speed synchronizer hub

>>E<<

13. Synchronizer ring

>>D<<

14. Synchronizer spring
15. 3rd speed gear
16. Needle roller bearing

>>C<<

17. Snap ring

<<E>>

>>B<<

18. Ball bearing

>>A<<

19. Oil seal
20. Input shaft

AK305121AB

MD998801

AK305175AB

AK305122AB

MD998801

AK305123AB

MD998801

AK305124AB

MD998801

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-19

1. Using special tool Bearing remover (MD998801), 

support the ball bearing, and then set them on the 
press.

2. Push down on the input shaft with the press and 

remove the ball bearing.

REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION

Install the oil seal into the end of the input shaft as 
shown.

>>B<< BALL BEARING INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press. 

2. Using special tools, press install the ball bearing 

with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998816)

>>C<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in 

the snap ring groove of input shaft.

2. Make sure that the front bearing end play meets 

the standard value.

Standard value: 0 

 0.12 mm

>>D<< SYNCHRONIZER SPRING 
INSTALLATION

Install the synchronizer spring onto the synchronizer 
ring as shown. 

>>E<< SYNCHRONIZER RING 
INSTALLATION

CAUTION

There are 3rd speed and 4th speed synchronizer 
rings, if the wrong one is installed it will effect 
the shift feeling.

AK204243

3.5 mm

Oil seal

AC

AK305126AB

MD998801

MD998812

MD998813

MD998816

AK305127 AB

Snap ring

AK305144AB

Synchronizer spring

AK204312

Notch

AB

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-20

1. Ascertain whether or not there are identification 

notches on the synchronizer ring.

Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring

2. Install the synchronizer ring so that it completely 

fits over the machined cone of the gear. 

>>F<< 3RD-4TH SPEED SYNCHRONIZER 
HUB INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press.

2. Make sure that the synchronizer ring has been 

perfectly matched to the 3rd speed gear cone.

3. Check the installation direction of the 3rd-4th 

speed synchronizer hub, and put it on the input 
shaft. 

4. Using special tools, press install the 3rd-4th 

speed synchronizer hub with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998825)

5. Make sure that the synchronizer ring can rotate 

freely.

>>G<< SYNCHRONIZER SLEEVE 
INSTALLATION

1. Check the installation direction of the 

synchronizer sleeve, and install it onto the 3rd-4th 
speed synchronizer hub.

2. Install the synchronizer sleeve so that the areas 

with teeth that have raised tips (three areas total) 
are aligned with the areas on the synchronizer 
hub that have deep grooves between the teeth 
(three areas total).

>>H<< 4TH SPEED GEAR SLEEVE 
INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press.

2. Using special tools, install the 4th speed gear 

sleeve with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

AK305177

Installation
direction

Identification mark

AB

AK305128AB

MD998801

MD998812

MD998813

MD998825

AK305178AB

Identification groove

Installation
direction

AK204199AB

Projecting portion

Deep grooves

AK305129AB

MD998801

MD998812

MD998813

MD998824

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-21

• Installer adapter (MD998824)

>>I<< 5TH SPEED GEAR INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press.

2. Using special tools, install the 5th speed gear onto 

the input shaft with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998824)

>>J<< THRUST PLATE INSTALLATION

1. Install the thickest thrust plates that can be fitted 

in the groove of the input shaft. Install the thrust 
plate so the surface stamped with the 
identification mark is facing up. 

2. Make sure that the 5th speed gear end play meets 

the standard value.

Standard value: 0 

 0.09 mm

>>K<< THRUST PLATE STOPPER 
INSTALLATION

Install the thrust plate stopper by pressing special 
tools, by hand. Make sure that it is not tilted.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998824)

>>L<< BALL BEARING INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press.

2. Using special tools, install the ball bearing onto 

the input shaft with the press. 

• Installer cap (MD998812)

• Installer adapter (MD998818)

>>M<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in 

the groove of the input shaft.

AK305130AB

MD998801

MD998812

MD998813

MD998824

AK305131AB

Surface stamped with 
identification mark 

Thrust plate

AK305176AB

MD998812

MD998813

MD998824

AK305132AB

MD998801

MD998812
MD998818

AK305133AB

Snap ring

 

 

 

 

 

 

 

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