Mitsubishi Outlander (2003+). Manual - part 167

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-21

ADJUSTMENT BEFORE REASSEMBLY

SPACER SELECTION FOR DIFFERENTIAL CASE 
PRELOAD ADJUSTMENT 

1. Put solders (1.6 mm diameter, about 10 mm long) 

in the illustrated positions of the transaxle case.

2. Install the taper bearing outer race and differential 

assembly into the transaxle case. 
NOTE:  If necessary, replace the differential case 
and taper bearing before carrying out these 
adjustments.

3. Install the clutch housing and tighten the bolts to 

the specified torque.

Tightening torque: 44 

±

 5 N

⋅

m

4. Remove the clutch housing, and then remove the 

differential assembly.

5. Remove the outer race and take out crushed 

solders.

6. Measure the thickness of the crushed solder with 

a micrometer and select a spacer that will provide 
the standard preload value.

Standard value: 0.05 

−

 0.11 mm preload

REASSEMBLY SERVICE POINTS

>>A<< OUTPUT SHAFT/INPUT SHAFT 
INSTALLATION

Install the input and output shafts together.

>>B<< 5TH SPEED-REVERSE SHIFT FORK/5TH 
SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED 
SHIFT FORK/3RD-4TH SPEED SHIFT RAIL 
INSTALLATION

1. Shift the 3rd-4th speed synchronizer sleeve and 

5th speed-reverse synchronizer sleeve in the 
direction shown.

2. Assemble the 3rd-4th speed shift rail and fork, 

and the 5th speed-reverse shift rail and fork.

AK204227

Solders

AB

AKX00953

AK204224

Input shaft

Output shaft

AB

AK204229AB

3rd-4th speed
synchronizer
sleeve

5th speed-
reverse
synchronizer
sleeve

AK204230

3rd-4th speed shift rail

3rd-4th speed
shift fork

5th speed-
reverse
shift rail

5th speed-
reverse
shift fork

AB

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-22

3. While fitting each shift fork in the groove of 

synchronizer sleeve, slide the shift rails in the 
direction shown and install.

4. Insert the 3rd-4th speed shift rail and 5th 

speed-reverse shift rail into the rail hole in the 
clutch housing.

>>C<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork.

2. Insert the new spring pin. Push it in as shown  so 

that the slit and center axis of the rail are aligned.

>>D<< SPACER AND OUTER RACE 
INSTALLATION
1. Install the spacer selected in the section 

"ADJUSTMENT BEFORE REASSEMBLY."

2. Using special tools, press the outer race into the 

transaxle case.

•

Installer adapter (MB990935)

•

Handle (MB990938)

>>E<< TRANSAXLE CASE INSTALLATION

CAUTION

Squeeze sealant evenly onto the transaxle 
housing. Do not leave gaps or excess amounts, 
otherwise oil leaks are likely. 

1. Apply a 2 mm diameter bead of sealant 

(Mitsubishi Genuine Part number MD997740 or 
equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto 
the transaxle housing while the sealant is still wet 
(within 15 minutes).

2. Align the transaxle case and expand the snap 

ring. After the case is on far enough for the snap 
ring to ride on the bearing, release the snap ring. 
Push down on the transaxle case, twisting it from 
side to side until the case contacts the  housing. 

3. Tighten the transaxle case mounting bolts to the 

specified torque.

Tightening torque: 44 

±

 5 N

⋅

m

4. Place the transaxle upside down and let the snap 

ring fit in the groove by the output shaft's own 
weight.  
NOTE: After installation, keep the sealed area 
away from oil for approximately one hour.

AK204223

5th speed-
reverse
shift rail

3rd-4th speed
shift rail

AC

AK204302

Shift fork

2.5 mm

Shift rail

Spring pin

AC

AK204231 AB

MB990938

MB990935

AK204232AB

AK204226

Snap ring

AB

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-23

>>F<< SEALING CAP INSTALLATION

1. Using special tools, press install the sealing cap 

onto the case.

•

Installer adapter (MB990927)

•

Handle (MB990938)

2. Evenly press the sealing cap so it is fully seated 

and not at an angle. 

>>G<< UNDER COVER INSTALLATION

CAUTION

Squeeze sealant onto the case. Do not leave 
gaps or excess amounts, otherwise oil leaks are 
likely. 

1. Apply a 2 mm diameter bead of sealant 

(Mitsubishi Genuine Part number MD997740 or 
equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the 
case quickly while the sealant is still wet (within 15 
minutes).

2. Install the under cover to the transaxle case and 

tighten the bolts to specified torque.

Tightening torque: 6.9 

±

 0.9 N

⋅

m

NOTE: After installation, keep the sealed area 
away from oil for approximately one hour.

>>H<< CONTROL HOUSING INSTALLATION

CAUTION

Squeeze sealant onto the case. Do not leave 
gaps or excess amounts, otherwise oil leaks are 
likely. 

1. Apply a 0.2 mm diameter bead of sealant 

(Mitsubishi Genuine Part number MD997740 or 
equivalent) as llustrated onto the control housing.
NOTE: Be sure to install the housig to the case 
quickly while the sealant is still wet (within 15 
minutes).

2. Install the control housing to the transaxle case 

and tighten the bolts to specified torque.

Tightening torque: 18 

±

 3 N

⋅

m

NOTE: After installation, keep the sealed area 
away from the oil for approximately one hour.

AK204234

MB990938

MB990927

AB

AK204233

Sealing cap

AB

AK204235AB

AK204236AB

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-24

>>I<< SPEEDOMETER GEAR INSTALLATION

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 

75W-85W conforming to API classification GL-4) 
to the O-ring of the speedometer gear. Install into 
the transaxle housing. 

2. Tighten the bolt to specified torque.

Tightening torque: 3.9 

±

 1.0 N

⋅

m

>>J<< SELECT LEVER INSTALLATION

1. Apply grease (Mitsubishi Genuine Part number 

0101011 or equivalent) to the control shaft sliding 
portion of the select lever shoe.

2. Install the select lever and tighten the bolts to 

specified torque.

Tightening torque: 18 

±

 3 N

⋅

m

INSPECTION

M1222001100101

BACKUP LIGHT SWITCH

Check for continuity between terminals.

AK204237

O-ring

AB

AK204238

Control shaft

Select lever
shoe

AB

SWITCH CONDITION

CONTINUITY

Pressed

Open

Released

Conductive

AKX00952