Mitsubishi Outlander (2003+). Manual - part 163

GENERAL SPECIFICATIONS

MANUAL TRANSMISSION OVERHAUL

22B-5

GENERAL SPECIFICATIONS

M1222000200202

TRANSMISSION MODEL TABLE

GEAR RATIO TABLE

SERVICE SPECIFICATIONS

M1222000300179

Transmission 
model

Speedomerter 
gear ratio

Final gear 
ratio

Vehicle model

Engine model

Transfer 
gear ratio

F5M42-2-Y4B1

27/36

4.625

CU2W

4G63-D4-MPI

−

W5M42-1-Z4B1

27/36

4.687

CU2W

4G63-D4-MPI

0.3018

W5M42-1-V4B1

27/36

4.352

CU5W

4G93-S4-MIVEC

0.3018

F5M42-2-Y4B1

W5M42-1-Z4B1

W5M42-1-V4B1

1st

3.583

2nd

1.947

3rd

1.379

4th

1.030

5th

0.820

Reverse

3.363

Item

Standard value

Minimum limit

Differential case preload

0.05 

−

 0.11 mm

−

Input shaft front bearing end play

0 

−

 0.12 mm

−

Input shaft 5th speed gear end play

0 

−

 0.09 mm

−

Input shaft rear bearing end play

0 

−

 0.12 mm

−

Synchronizer ring back surface to gear clearance

−

0.5 mm

Output shaft front bearing end play

0 

−

 0.12 mm

−

Output shaft 3rd speed gear end play

0 

−

 0.09 mm

−

Output shaft rear bearing end play

0 

−

 0.09 mm

−

Backlash between differential gear and pinion <F5M42> 0 

−

 0.15 mm

−

Backlash between center differential gear and pinion 
<W5M42>

0.025 

−

 0.150 mm

−

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT

MANUAL TRANSMISSION OVERHAUL

22B-6

SNAP RING, SPACER AND THRUST PLATE FOR 

ADJUSTMENT

M1222012000186

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>

SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD) <W5M42>

SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY) 

THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)

Thickness mm

Identification symbol

Thickness mm

Identification symbol

0.71

71

1.01

01

0.74

74

1.04

04

0.77

77

1.07

07

0.80

80

1.10

J

0.83

83

1.13

D

0.86

86

1.16

K

0.89

89

1.19

L

0.92

92

1.22

G

0.95

95

1.25

M

0.98

98

Thickness mm

Identification symbol

Thickness mm

Identification symbol

0.74

74

1.04

04

0.77

77

1.07

07

0.80

80

1.10

J

0.83

83

1.13

D

0.86

86

1.16

K

0.89

89

1.19

L

0.92

92

1.22

G

0.95

95

1.25

M

0.98

98

1.28

N

1.01

01

1.31

E

Thickness mm

Identification symbol

Thickness mm

Identification symbol

2.24

None 2.38

Brown

2.31

Blue

Thickness mm

Identification symbol

Thickness mm

Identification symbol

2.82

0

2.98

6

2.86

2

3.02

7

2.90

3

3.06

8

2.94

5

3.10

9

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT

MANUAL TRANSMISSION OVERHAUL

22B-7

SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY AND OUTPUT SHAFT 
FRONT BEARING END PLAY) 

SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)

SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)

SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION) 
<F5M42>

SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN CENTER DIFFERENTIAL SIDE GEAR AND 
PINION) <W5M42>

Thickness mm

Identification symbol

Thickness mm

Identification symbol

1.43

Green (2)

1.59

Yellow (2)

1.51

White (2)

Thickness mm

Identification symbol

Thickness mm

Identification symbol

2.81

Green

2.97

Orange

2.85

White

3.01

Red

2.89

Yellow

3.05

Pink

2.93

Black

3.09

Blue

Thickness mm

Identification symbol

Thickness mm

Identification symbol

2.31

Black (2)

2.55

Yellow

2.35

None

2.59

Black

2.39

Blue

2.63

Orange

2.43

Brown

2.67

Blue

2.47

Green

2.71

Brown

2.51

White

Thickness mm

Identification symbol

Thickness mm

Identification symbol

0.75 

−

 0.82

−

1.05 

−

 1.12

−

0.83 

−

 0.92

−

1.09 

−

 1.16

−

0.93 

−

 1.00

−

1.15 

−

 1.22

−

1.01 

−

 1.08

−

Thickness mm

Identification symbol

Thickness mm

Identification symbol

0.48 

−

 0.55

−

0.74 

−

 0.81

−

0.56 

−

 0.65

−

0.82 

−

 0.89

−

0.66 

−

 0.73

−

TORQUE SPECIFICATIONS

MANUAL TRANSMISSION OVERHAUL

22B-8

TORQUE SPECIFICATIONS

M1222012100138

Part

N

⋅

m

Transfer - clutch housing mounting bolt <W5M42>

69 

±

 10

Roll stopper bracket mounting bolt

70 

±

 10

Shift cable bracket mounting bolt

18 

±

 3

Select lever mounting bolt

18 

±

 3

Speedometer gear mounting bolt

3.9 

±

 1.0

Backup light switch

32 

±

 2

Poppet spring

32 

±

 2

Harness bracket bolt

18 

±

 3

Harness bracket bolt <Except 2.4L model>

3.9 

±

 1.0

Interlock plate bolt

30 

±

 3

Control housing mounting bolt

18 

±

 3

Under cover mounting bolt

6.9 

±

 0.9

Reverse idler gear shaft mounting bolt

48 

±

 6

Clutch housing-transaxle case mounting bolt

44 

±

 5

Front bearing retainer mounting bolt 

18 

±

 3

Select lever mounting nut

11 

±

 1

Stopper bracket mounting bolt

21.7 

±

 0.3

Clutch release bearing retainer mounting bolt

9.8 

±

 0.2

Differential drive gear mounting bolt

132 

±

 5

Transfer cover mounting bolt <W5M42>

23 

±

 3