Mitsubishi 380. Manual - part 977

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-21

REASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION

AK204243

3.5 mm

Oil seal

AC

Make sure that the oil seal is pressed into the position shown in 
the illustration.

.

>>B<< TAPER ROLLER BEARING INSTALLATION

AK201653

MD998801

MD998812

MD998819

AD

Taper

roller

bearing

1. Using Bearing remover (MD998801), support the output 

shaft gear, and then set them on the press.

2. Using special tools, press install the taper roller bearing with 

the press.

• Installer cap (MD998812)

• Installer adapter (MD998819)

.

>>C<<1ST SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.

AK201654

MD998364

MD998812

MD998814

MD998824

1st speed

gear sleeve

AD

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

with the press.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998824)

• Camshaft oil seal installer (MD998364)

.

>>D<< SYNCHRONIZER SPRING INSTALLATION

AK201638AD

Synchronizer spring

Install the synchronizer spring to the illustrated position of the 
outer synchronizer ring.

.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-22

>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB 
INSTALLATION
1. Set the output shaft on the press support stand.

AK302754

Installation

direction

Groove

AB

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

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

AK201655

MD998812

MD998814

MD998824

MD998364

AD

1st-2nd speed

synchronizer

hub

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

synchronizer hub with the press.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998824)

• Camshaft oil seal installer (MD998364)

4. Make sure that the outer synchronizer ring on the 1st speed 

gear side can rotate freely.

.

>>F<< SYNCHRONIZER SLEEVE INSTALLATION

AK302755

Installation

direction

Groove

AB

1. Check that the synchronizer sleeve is in the correct direction 

for installation, and install it on the 1st-2nd speed 
synchronizer hub.

AKX00928AD

Teeth with

raised tips

Deep grooves 

between the teeth

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).

.

>>G<< 2ND SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.

AK201656

MD998812

MD998814

MD998824

MD998364

2nd speed

gear sleeve

AD

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-23

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

the output shaft.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998824)

• Camshaft oil seal installer (MD998364)

.

>>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).

AK201657

MD998812

MD998814

MD998824

MD998364

AD

3rd speed

gear

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

output shaft.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998824)

• Camshaft oil seal installer (MD998364)

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

synchronizer ring can rotate freely.

.

>>I<< SNAP RING INSTALLATION

AK201658AD

Snap ring

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.

AK201659

MD998812

MD998813
MD998821

MD998364

AD

4th speed

gear

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-24

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

output shaft.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998821)

• Camshaft oil seal installer (MD998364)

.

>>K<< 5TH SPEED GEAR SLEEVE INSTALLATION

AK201660

MD998812

MD998813

MD998821

MD998364

AD

5th speed

gear sleeve

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

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998821)

• Camshaft oil seal installer (MD998364)

.

>>L<< SYNCHRONIZER SPRING INSTALLATION

AK305144AB

Synchronizer spring

Install the synchronizer spring to the illustrated position of the 
synchronizer ring.

.

>>M<< 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.

AK302758

Installation

direction

Groove

AB

3. Check that the 5th speed-reverse synchronizer hub is 

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