Mitsubishi Grandis. Manual - part 879

 

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Mitsubishi Grandis. Manual - part 879

 

 

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-26

2. Using special tools, install the 1st speed gear 

sleeve with the press.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998825)

>>D<< SYNCHRONIZER SPRING 
INSTALLATION

Install the synchronizer spring onto the outer 
synchronizer ring as shown.

>>E<< 1ST-2ND SPEED SYNCHRONIZER 
HUB INSTALLATION

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

2. Check that the 1st-2nd speed synchronizer hub is 

in the correct installation direction, and put it on 
the output shaft.

3. Using special tools, install the 1st-2nd speed 

synchronizer hub with the press.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998825)

4. Make sure that the outer synchronizer ring on the 

1st speed gear side can rotate freely.

>>F<< SYNCHRONIZER SLEEVE 
INSTALLATION

1. Check that the synchronizer sleeve is in the 

correct direction for installation, and install it on 
the 1st-2nd 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).

AK305143AB

MD998812

MD998814

MD998825

AK305196AB

Synchronizer spring

AK305187

Installation
direction

Identification mark

AB

AK305146AB

MD998812

MD998814

MD998825

AK204296

Installation
direction

Identification groove

AD

AK204199AB

Projecting portion

Deep grooves

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-27

>>G<< 2ND SPEED GEAR SLEEVE 
INSTALLATION

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

2. Using special tools, install the 2nd speed sleeve 

onto the output shaft with the press.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998822)

>>H<< 3RD SPEED GEAR INSTALLATION

1. Check that the 2nd speed gear and the outer 

synchronizer ring have been properly installed. 
Also, make sure the claws on the synchronizer 
cone (four places) are correctly fitted into the 
holes in the 2nd speed gear (four places).

2. Using special tools, install the 3rd speed gear 

onto the output shaft with the press.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998822)

3. Make sure that the 2nd speed gear and the outer 

synchronizer ring can rotate freely.

>>I<< SNAP RING INSTALLATION

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

the groove of output shaft.

2. Make sure that the 3rd speed gear end play 

meets the standard value.

Standard value: 0 

− 0.09 mm

>>J<< 4TH SPEED GEAR INSTALLATION

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

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

the output shaft with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998819)

>>K<< 5TH SPEED GEAR SLEEVE 
INSTALLATION

Using special tools, install the 5th speed gear sleeve 
onto the output shaft with the press.

AK305147AB

MD998812

MD998814

MD998822

AK305148AB

MD998812

MD998814

MD998822

AK305149AB

Snap ring

AK305150AB

MD998812

MD998813

MD998819

AK305182AB

MD998812

MD998819

MD998813

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-28

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998819)

>>L<< SYNCHRONIZER SPRING 
INSTALLATION

Install the synchronizer spring onto the synchronizer 
ring as shown.

>>M<< SYNCHRONIZER RING 
INSTALLATION

CAUTION

There is a 5th speed synchronizer ring and a 
reverse synchronizer ring. Be careful not to 
confuse the two when installing, as a mistake can 
effect the shift feeling.

1. Check for the presence of identification notches 

on the synchronizer ring.

No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring 

2. Install the synchronizer ring so that it fits 

completely over the machined cone of the gear.

>>N<< 5TH SPEED-REVERSE 
SYNCHRONIZER HUB INSTALLATION

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

2. Make sure that the synchronizer ring is fitted 

correctly on the cone of the 5th speed gear.

3. Check that the 5th speed-reverse synchronizer 

hub is oriented correctly for installation, and fit it 
on the output shaft.

4. Using special tools, press install the 5th 

speed-reverse synchronizer hub with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998819)

5. Make sure that the synchronizer ring on the 5th 

speed gear side can rotate freely.

>>O<< SYNCHRONIZER SLEEVE 
INSTALLATION

1. Check that the synchronizer sleeve is in the 

correct direction for installation, and install it on 
the 5th speed-reverse synchronizer hub.

AK305144AB

Synchronizer spring

AK204393

Notch

AB

AK305188

Installation
direction

Identification mark

AB

AK305110AB

MD998812

MD998813

MD998819

AK305431AB

Identification groove

Installation
direction

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-29

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).

>>P<< REVERSE GEAR SLEEVE 
INSTALLATION

1. Make sure the synchronizer ring, reverse gear 

and needle roller bearing have been correctly 
installed.

2. Using special tools, press fit the reverse gear 

sleeve. Make sure that the reverse gear and the 
synchronizer ring can rotate freely during the 
pressing process.

• Installer cap (MD998812)

• Installer adapter (MD998818)

>>Q<< BALL BEARING INSTALLATION

1. Check the installation direction of the ball bearing.

2. Using special tools, install the ball bearing with the 

press.

• Installer cap (MD998812)

• Installer adapter (MD998818)

>>R<< SNAP RING INSTALLATION

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

the groove of output shaft.

2. Make sure that the rear bearing end play meets 

the standard value.

Standard value: 0 

− 0.09 mm

INSPECTION

M1222002300164

OUTPUT SHAFT

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

damaged or worn.

NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the 

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

2. Check the needle roller bearing cage for 

deformation.

AK204199AB

Projecting portion

Deep grooves

AK305151AB

MD998812
MD998818

AK305152AB

MD998812
MD998818

AK305153AB

Snap ring

AK204310AB

 

 

 

 

 

 

 

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