Mitsubishi Outlander (2003+). Manual - part 168

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-25

INPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1222001600173

AK204391

9

10

11

12

14

13

15

16

18

2

19

4

20

6

7

1

8

3

17

16

5

AB

AB

Apply gear oil to all
moving parts before
installation.

Disassembly steps

>>M<<

1.

Snap ring

<<A>>

>>L<<

2.

Ball bearing

<<B>>

>>K<<

3.

Thrust plate stopper

>>J<<

4.

Thrust plate

<<C>>

>>I<<

5.

5th speed gear

6.

4th speed gear

7.

Needle roller bearing

<<D>>

>>H<<

8.

4th speed gear sleeve

>>E<<

9.

Synchronizer ring

>>D<<

10. Synchronizer spring

>>G<<

11. Synchronizer sleeve

>>F<<

12. 3rd-4th speed synchronizer hub

>>E<<

13. Synchronizer ring

>>D<<

14. Synchronizer spring
15. 3rd speed gear
16. Needle roller bearing

>>C<<

17. Snap ring

<<E>>

>>B<<

18. Ball bearing

>>A<<

19. Oil seal
20. Input shaft

Disassembly steps (Continued)

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-26

DISASSEMBLY SERVICE POINTS

<<A>> BALL BEARING REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the ball bearing, and then set them on the 
press.

2. Push down on the input shaft with the press and 

remove the ball bearing.

<<B>> THRUST PLATE STOPPER REMOVAL

Using a screwdriver, pry up at the position shown in 
the illustration and remove the thrust plate stopper.

<<C>> 5TH SPEED GEAR REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the 5th speed gear, and then set them on 
the press.

2. Push down on the input shaft with the press and 

remove the 5th speed gear.

<<D>> 4TH SPEED GEAR SLEEVE REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the 3rd speed gear, and then set them on 
the press.

2. Push down on the input shaft with the press and 

remove the 4th speed gear sleeve.

<<E>> BALL BEARING REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the ball bearing, and then set them on the 
press.

2. Push down on the input shaft with the press and 

remove the ball bearing.

AK204239

MD998801

AB

AK204293AB

AK204240

MD998801

AB

AK204241

MD998801

AB

AK204242

MD998801

AB

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-27

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

Install the oil seal into the end of the input shaft as 
shown.

>>B<< BALL BEARING INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press. 

2. Using special tools, press install the ball bearing 

with the press.

•

Installer cap (MD998812)

•

Installer-100 (MD998813)

•

Installer adapter (MD998816)

>>C<< SNAP RING INSTALLATION

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

the snap ring groove of input shaft.

2. Make sure that the front bearing end play meets 

the standard value.

Standard value: 0 

−

 0.12 mm

>>D<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring onto the synchronizer 
ring as shown. 

>>E<< SYNCHRONIZER RING INSTALLATION

CAUTION

There are 3rd speed and 4th speed synchronizer 
rings, if the wrong one is installed it will effect 
the shift feeling.

1. Ascertain whether or not there are identification 

notches on the synchronizer ring.

Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring

2. Install the synchronizer ring so that it completely 

fits over the machined cone of the gear. 

AK204243

3.5 mm

Oil seal

AC

AK204244

MD998812

MD998813

MD998801

MD998816

AC

AK204245

Snap ring

AB

AK204263

SYNCHRONIZER
SPRING

AB

Synchrnizer
spring

AK204312

Notch

AB

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-28

>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB 
INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press.

2. Make sure that the synchronizer ring has been 

perfectly matched to the 3rd speed gear cone.

3. Check the installation direction of the 3rd-4th 

speed synchronizer hub, and put it on the input 
shaft. 

4. Using special tools, press install the 3rd-4th 

speed synchronizer hub with the press.

•

Installer cap (MD998812)

•

Installer-100 (MD998813)

•

Installer adapter (MD998825)

5. Make sure that the synchronizer ring can rotate 

freely.

>>G<< SYNCHRONIZER SLEEVE INSTALLATION

1. Check the installation direction of the 

synchronizer sleeve, and install it onto the 3rd-4th 
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).

>>H<< 4TH SPEED GEAR SLEEVE 
INSTALLATION

1. Using special tool Bearing remover (MD998801), 

support the 2nd speed gear portion of the input 
shaft, and then set them on the press.

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

sleeve with the press.

•

Installer cap (MD998812)

•

Installer-100 (MD998813)

•

Installer adapter (MD998824)

AK204295

Installation
direction

Groove

AB

AK204246

MD998812

MD998813

MD998825

MD998801

AC

AK204296

Identification
groove

Installation
direction

AC

AK204199AB

Projecting portion

Deep grooves

AK204247

MD998812

MD998813

MD998824

MD998801

AC