22B-TRANSAXLE (TRANSMISSION) DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY

			Disassembly steps
		1.	Control cable bracket
		2.	Wiring harness clamp
<<A>>	>>H<<	3.	Back-up light switch
		4.	Drain plug
		5.	Gasket
		6.	Filler plug
		7.	Gasket
		8.	Control bell crank dust cover
		9.	Selecting bell crank assembly

			Disassembly steps
<<B>>		10.	Lock ball assembly
	>>G<<	11.	Shift and select lever shaft assembly
		12.	Compression spring
<<C>>	>>F<<	13.	Flange bolt
		14.	Gasket
<<D>>	>>E<<	15.	Transaxle case assembly
	>>D<<	16.	Shim (Input shaft radial ball bearing axial play adjustment)
		17.	Reverse shaft arm bracket assembly
	>>C<<	18.	Reverse idler gear shaft
	>>C<<	19.	Reverse idler gear sub-assembly

			Disassembly steps
<<E>>		20.	Gear shift fork number 1
	>>B<<	21.	Slotted spring pin
		22.	Gear shift head number 1
		23.	Shaft snap ring
		24.	Gear shift fork shaft number 1
	>>B<<	25.	Straight pin
		26.	Shaft snap ring
	>>B<<	27.	Slotted spring pin
		28.	Gear shift head number 3
		29.	Shaft snap ring
		30.	Compression spring
	>>B<<	31.	Straight pin
		32.	Gear shift fork number 3
		33.	Gear shift fork shaft number 3
		34.	Shaft snap ring
		35.	Reverse shift fork
		36.	Shaft snap ring
		37.	Gear shift fork number 2
		38.	Gear shift fork shaft number 2
<<E>>	>>A<<	39.	Input shaft assembly
<<E>>	>>A<<	40.	Output shaft assembly
		41.	Differential assembly
		42.	Clutch housing assembly

Required Special Tools:

MD998773: Knock Sensor Wrench
MD998245: Installer Lock Pin

DISASSEMBLY SERVICE POINTS

<<A>> BACK-UP LIGHT SWITCH REMOVAL

Using the special tool MD998773, remove the back-up light switch from the transaxle case assembly.

<<B>> LOCK BALL ASSEMBLY REMOVAL

Remove the lock ball assembly from the transaxle case.

<<C>> FLANGE BOLT REMOVAL

Reverse idler gear shaft installation flange bolt is removed.

<<D>> TRANSAXLE CASE ASSEMBLY REMOVAL

1. Using the tire-lever large remove the transaxle case assembly.

<<E>> GEAR SHIFT FORK NUMBER 1/INPUT SHAFT ASSEMBLY/OUTPUT SHAFT ASSEMBLY REMOVAL

Remove the gear shift fork number 1, input shaft assembly and output shaft assembly together.

ADJUSTMENT BEFORE ASSEMBLY

SELECTING THE INPUT SHAFT RADIAL BALL BEARING AXIAL PLAY ADJUSTMENT SHIM

1. Set the input shaft assembly to the clutch housing assembly.

2. Put the clutch housing assembly on the surface table and measure the dimension "A" which is from the mating surface of the clutch housing assembly to the end surface of the bearing outer race, with a height gauge.

3. Put the straight edge on the mating surface of the transaxle case assembly and measure the dimension "B" with a vernier caliper.

4. Calculate thickness "C" of the required shim by the following formula. Select a shim which most closely matches this thickness.

With in 0 to 0.1 mm (0 to 0.004 inch) = "B" - "A" - "C"

ASSEMBLY SERVICE POINTS

>>A<< OUTPUT SHAFT ASSEMBLY/INPUT SHAFT ASSEMBLY INSTALLATION

Install the input shaft assembly and output shafts assembly together.

>>B<< STRAIGHT PIN/SLOTTED SPRING PIN INSTALLATION

1. Align the pin holes in the shift rail and shift fork.

2. Using the installer lock pin special tool (MD998245) insert the new slotted pin and slotted spring pin.

>>C<< REVERSE IDLER GEAR SUB-ASSEMBLY/REVERSE IDLER GEAR SHAFT INSTALLATION

1. Install the reverse idler gear sub-assembly and reverse idler gear shaft to the clutch housing assembly.

2. Before installing the transaxle case assembly, confirm that the reverse idler gear addition mark is positioned as show in the illustration.

>>D<< SHIM (INPUT SHAFT RADIAL BALL BEARING AXIAL PLAY ADJUSTMENT) INSTALLATION

Install the shim selected in "ADJUSTMENT BEFORE REASSEMBLY" to the input shaft installation surface of the transaxle case assembly.

>>E<< TRANSAXLE CASE ASSEMBLY INSTALLATION

caution

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

1. Apply a 1.2 mm (0.05 inch) diameter bead of specified sealant as illustrated onto the transaxle case assembly.

Specified sealant: MITSUBISHI GENUINE PART Number MZ100388 or equivalent

note	Be sure to install the transaxle case assembly onto the clutch housing case while the sealant is still wet (within 10 minutes).

2. Tighten the transaxle case mounting bolts to the specified torque.

Tightening torque: 30 ± 5 N·m (22 ± 3 ft-lb).

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

>>F<< FLANGE BOLT INSTALLATION

Using screwdriver [8 mm (0.3 inch) in shank diameter], align the flange bolt installation holes of transaxle case and reverse idler gear shaft and tighten the flange bolt to the specified torque.

Tightening torque: 30 ± 8 N·m (22 ± 5 ft-lb).

>>G<< SHIFT AND SELECT LEVER SHAFT ASSEMBLY INSTALLATION

caution

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

1. Apply a 1.2 mm (0.05 inch) diameter bead of sealant as illustrated onto the control shaft cover of the shift and select lever shaft assembly.

Specified sealant: MITSUBISHI GENUINE PART Number MZ100388 or equivalent

note	Be sure to install the shift and select lever shaft assembly to the transaxle case quickly while the sealant is still wet (within 10 minutes).

2. Install the shift and select lever shaft assembly to the transaxle case assembly and tighten the bolts to specified torque.

Tightening torque: 18 ± 3 N·m (13 ± 23 ft-lb)

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

>>H<< BACK-UP LIGHT SWITCH INSTALLATION

1. Using the special tool MD998773, tighten the back-up light switch to specified torque.

Tightening torque: 41 ± 11 N·m (30 ± 8 ft-lb)