Mitsubishi Outlander (2003+). Manual - part 159

TROUBLESHOOTING

MANUAL TRANSMISSION (FF)

22A-7

INSPECTION PROCEDURE 4: Jumps Out of Gear

DIAGNOSIS

STEP 1. Check the transmission control

Q: Are the shift cable and the select cable in good 

condition?

YES : 

Go to Step 2 .

NO : 

Repair or replace the shift cable and the 
select cable. Refer to 

P.22A-8

. Then go to 

Step 6 .

STEP 2. Remove and disassemble the 
transmission. Check the poppet spring for 
breakage.

Q: Is the poppet spring broken?

YES : 

Replace the poppet spring. Refer to 

GROUP 22B, Transmission 

P.22B-14

. Then 

go to Step 6 .

NO : 

Go to Step 3 .

STEP 3. Check the control housing.

Q: Is the control housing in good condition?

YES : 

Go to Step 4 .

NO : 

Repair or replace the control housing. Refer 
to GROUP 22B, Transmission 

P.22B-14

. 

Then go to Step 6 .

STEP 4. Check the gear shift forks for wear.

Q: Is the gear shift forks worn?

YES : 

Replace the gear shift fork. Refer to 

GROUP 22B, Transmission 

P.22B-14

. Then 

go to Step 6 .

NO : 

Go to Step 5 .

STEP 5. Check the clearance.

Q: Is the clearance between the synchronizer hub and 

sleeve excessive?

YES : 

Replace the synchronizer hub or sleeve. 

Refer to GROUP 22B, Input Shaft 

P.22B-25

, Output Shaft 

P.22B-32

. Then go 

to Step 6.

NO : 

Go to Step 6 .

STEP 6. Retest the system.

Q: Does the transmission still jump out of gear?

YES : 

Return to Step 1 .

NO : 

The procedure is complete.

ON-VEHICLE SERVICE

MANUAL TRANSMISSION (FF)

22A-8

ON-VEHICLE SERVICE

TRANSMISSION OIL LEVEL CHECK

M1221000900479

1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of 

the filler plug hole.

3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.

Tightening torque: 32 

±

 2 N

⋅

m

TRANSMISSION OIL REPLACEMENT

M1221001000402

1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.

Tightening torque: 32 

±

 2 N

⋅

m

4. Fill with gear oil API classification GL-4 SAE 

75W-85W or 75W-90 until the level comes to the 
lower portion of filler plug hole.
Quantity: 2.2 L <2WD>
Quantity: 2.3 L <4WD>

5. Tighten the filler plug to the specified torque.

Tightening torque: 32 

±

 2 N

⋅

m

TRANSFER OIL CHECK

M1221001100108

1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of 

the filler plug hole.

3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.

Tightening torque: 32 

±

 2 N

⋅

m

TRANSFER OIL REPLACEMENT

M1221001200086

1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.

Tightening torque: 32 

±

 2 N

⋅

m

4. Fill with hypoid gear oil API classification GL-5 

SAE90 until the level comes to the lower portion 
of filler plug hole.

Quantity: 0.55 L

5. Tighten the filler plug to the specified torque.

Tightening torque: 32 

±

 2 N

⋅

m

AC210553 AB

Filler plug hole

Filler plug

Transmission oil

AC210554

Drain plug

Filler plug

AB

AC210553AC

Filler plug hole

Filler plug

Transfer oil

AC210555

Filler plug

Drain plug

AB

TRANSMISSION CONTROL

MANUAL TRANSMISSION (FF)

22A-9

TRANSMISSION CONTROL

REMOVAL AND INSTALLATION

M1221003800578

WARNING

Be careful not to subject the SRS-ECU to any shocks during removal and installation of the 
shift cable and select cable assembly.

Pre-removal and Post-installation Operation

•

Air Cleaner Assembly Removal and Installation (Refer to 

GROUP 15, Air Cleaner 

P.15-3

<4G63>, 

P.15-4

<4G69>).

•

Battery and Battery Tray Removal and Installation.

AC309478AB

1

12 ± 2 N·m

12 ± 2 N·m

11

4

5

3

6

12

7

8

N

10

7

9

2

Gearshift cable and select cable 
assembly removal steps

1.

Gearshift lever knob

2.

Sleeve

•

Front floor console (Refer to 
GROUP 52A 

P.52A-14

).

3.

Select cable connection (Gearshift 
lever side)

>>B<<

4.

Gearshift cable clip

5.

Gearshift cable connection 
(Gearshift lever side)

•

SRS-ECU (Refer to GROUP 52B 

P.52B-178

).

6.

Console side cover bracket

7.

Snap pin

<<A>> >>A<<

8.

Gearshift link clip

<<A>> >>A<<

9.

Select cable connection 
(Transmission side)

<<A>> >>A<<

10. Gearshift cable connection 

(Transmission side)

>>A<<

11. Gearshift cable and select cable 

assembly
Gearshift lever assembly 
removal steps

1.

Gearshift lever knob

2.

Sleeve

•

Front floor console (Refer to 
GROUP 52A 

P.52A-14

).

3.

Select cable connection (Gearshift 
lever side)

>>B<<

4.

Gearshift cable clip

5.

Gearshift cable connection 
(Gearshift lever side)

12. Gearshift lever assembly

Gearshift cable and select cable 
assembly removal steps 

TRANSMISSION CONTROL

MANUAL TRANSMISSION (FF)

22A-10

REMOVAL SERVICE POINTS

<<A>> GEARSHIFT LINK CLIP/SELECT CABLE 
CONNECTION (TRANSMISSION SIDE)/GEAR 
SHIFT CABLE CONNECTION (TRANSMISSION 
SIDE) REMOVAL

Push up the claws of the gearshift link clip using a 
screwdriver, etc., and then remove the gearshift link 
clip from the bracket together with the cables.

INSTALLATION SERVICE POINTS

>>A<< GEARSHIFT CABLE AND SELECT CABLE 
ASSEMBLY/GEARSHIFT CABLE CONNECTION 
(TRANSMISSION SIDE)/SELECT CABLE 
CONECTION (TRANSMISSION SIDE)/GEARSHIFT 
LINK CLIP INSTALLATION

1. Set the transmission side shift lever and the 

passenger compartment side shift lever to the 
neutral position.

2. Install the painted part of the shift cable end 

(transmission side) and painted part of the select 
cable (transmission side) facing the snap pin.

CAUTION

Insert thoroughly the gearshift link clip, shift 
cable and select cable until they click in place.
3. After installing the new gearshift link clip to the 

cable bracket of the transmission, install the shift 
cable and select cable to the cable bracket.
NOTE: The clip is reversible.

4. Move the shift lever to all positions and check that 

the operation is smooth.

AC210556

Gearshift link clip

Gearshift cable, 
Select cable

Claws

AB

AC210557AB

Neutral position

Select lever

AC210558

Shift cable, Select cable

New gearshift 
link clip

Cable bracket

AB