Mitsubishi Grandis. Manual - part 878

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-22

2. Make sure that the rear bearing end play meets 

the standard value.

Standard value: 0 

− 0.12 mm

INSPECTION

M1222001700169

INPUT SHAFT

1. Check the outside diameter of the needle bearing 

mounting portion for damage, abnormal wear and 
seizure.

2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not 

damaged or worn.

NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the input 

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

2. Check the needle roller bearing cage for 

deformation.

SYNCHRONIZER RING

1. Check the clutch gear teeth for damage and 

broken.

2. Check internal surface for damage, wear and 

broken threads.

3. Force the synchronizer ring toward the clutch gear 

and check clearance "A." If "A" is less than the 
limit, replace the synchronizer ring.

Minimum limit: 0.5 mm

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.

SYNCHRONIZER SPRING

Check that the spring is not sagging, deformed or 
broken.

SPEED GEARS

1. Check that the helical and clutch gear tooth 

surfaces are not damaged or worn.

AK204201AC

AK204298AB

AK204307

A

Gear

Synchronizer
ring

AB

AK201697AD

Sleeve

Hub

AK204299AB

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-23

2. Check that the synchronizer cone surfaces are 

not roughened, damaged or worn.

3. Check that the gear inside diameter and front and 

rear surfaces are not damaged and worn.

OUTPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1222002200190

AK204392

20

22

24

4

26

1

19

18

21

23

13

27

29

25

28

30

31

32

33

36

35

34

5

2

3

4

6

7

8

9

11

14 10

12

17

15

16

13

AB

Apply gear oil to all
moving parts before
installation.

Disassembly steps

>>R<<

1.

Snap ring

<<A>>

>>Q<<

2.

Ball bearing

<<B>>

>>P<<

3.

Reverse gear sleeve

4.

Needle roller bearing

5.

Reverse gear

>>M<<

6.

Synchronizer ring

>>L<<

7.

Synchronizer spring

>>O<<

8.

Synchronizer sleeve

<<C>>

>>N<<

9.

5th speed-reverse synchronizer 
hub

>>M<<

10. Synchronizer ring

>>L<<

11. Synchronizer spring
12. 5th speed gear

13. Needle roller bearing

>>K<<

14. 5th speed gear sleeve

>>J<<

15. 4th speed gear

>>I<<

16. Snap ring

<<D>>

>>H<<

17. 3rd speed gear
18. 2nd speed gear
19. Needle roller bearing

<<E>>

>>G<<

20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring

>>D<<

24. Synchronizer spring

>>F<<

25. Synchronizer sleeve

Disassembly steps (Continued)

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-24

DISASSEMBLY SERVICE POINTS
<<A>> BALL BEARING REMOVAL

1. Using special tool Bearing remover (MD998917), 

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

2. Push down on the output shaft with the press, and 

remove the ball bearing.

<<B>> REVERSE GEAR BEARING 
SLEEVE REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the reverse gear, and then set them on 
the press.

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

remove the reverse gear bearing sleeve.

<<C>> 5TH SPEED-REVERSE 
SYNCHRONIZER HUB REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the 4th speed gear, and then set them on 
the press.

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

remove the 5th speed-reverse synchronizer hub.

<<D>> 3RD SPEED GEAR REMOVAL

1. Using special tool Bearing remover (MD998917), 

support the 2nd speed gear, and then set them on 
the press.

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

remove the 3rd speed gear.

<<E>> 2ND SPEED GEAR SLEEVE 
REMOVAL

>>E<<

26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring

>>D<<

28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing

<<F>>

>>C<<

33. 1st speed gear sleeve

>>B<<

34. Snap ring

<<G>>

>>A<<

35. Roller bearing inner race
36. Output shaft

Disassembly steps (Continued)

AK305134AB

MD998917

AK305135AB

MD998801

AK305136AB

MD998801

AK305137AB

MD998917

AK305138AB

MD998917

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-25

1. Using special tool Bearing remover (MD998917), 

support the 1st speed gear, and then set them on 
the press.

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

remove the 2nd speed gear sleeve.

<<F>> 1ST SPEED GEAR SLEEVE 
REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the 1st speed gear sleeve, and then set 
them on the press.

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

remove the 1st speed gear sleeve.

<<G>> ROLLER BEARING INNER RACE 
REMOVAL

1. Using special tool Bearing remover (MD998917), 

support the roller bearing inner race, and then set 
them on the press.

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

remove the roller bearing inner race.

REASSEMBLY SERVICE POINTS
>>A<< ROLLER BEARING INNER RACE 
INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the output shaft gear, and then set them 
on the press.

2. Using special tools, install the roller bearing inner 

race with the press.

• Installer cap (MD998812)

• Installer adapter (MD998818)

>>B<< SNAP RING INSTALLATION

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

the groove of output shaft.

2. Make sure that the front bearing inner race end 

play meets the standard value.

Standard value: 0 

− 0.12 mm

>>C<<1ST SPEED GEAR SLEEVE 
INSTALLATION

1. Set the output shaft on the press support stand.

AK305139AB

MD998801

AK305140AB

MD998917

AK305141AB

MD998801

MD998812

MD998818

AK305142AB

Snap ring