22B-1 MANUAL TRANSMISSION- Thong tin tong quat

THONG TIN TONG QUAT

 MANUAL TRANSMISSION - Thong so ky thuat 22B-2

BANG MODEL CUA TRANSMISSION

Kieu Transmission Ty so Gear Ty so Speedometer gear

R5M21-A-DJYL A 30/8

CAC THONG SO TONG QUAT

Ty so truyen Gear A
So 1 4.330
So 2 2.355
So 3 1.509
So 4 1.000
So 5 0.833
So lui 4.142

CAC THONG SO KY THUAT BAO DNG, SA CHA

Hang muc Gia tr tieu chuan Gii han

o r cua Maindrive gear bearing mm 0-0.06 -
o r cua Maindrive gear mm 0-01 -
o r cua Synchronizer hub so 3 va so 4mm 0-0.08 -
o r cua Mainshaft rear bearing mm 0-0.13 -
o r cua Mainshaft rear snap ring mm 0.15-0.40 -
Khe h gia synchronizer ring va gear - 0.05
22B-3 MANUAL TRANSMISSION - Thong so ky thuat

CAC THONG SO LC XIET

Muc Nm
Speedometer gear 12
Backup lamp switch 30
Extension housing 19
Under cover 9
Counterahaft lock nut 175
Mainshaft lock nut 260
Slotted nut 40
Reverse idler gear shaft bolt 19
Rear bearing retainer bolt 19
Front bearing retainer nut 12

CHAT LAM KN, KEO VA M BOI TRN

Muc Cac chat lam kn, keo va m quy nh

Front bearing retainer Genuine sealant cua Mitsubishi so 997740 hoac tng
ng
Reverse idler gear shaft bolt Keo 3M so 4170 hoac tng ng
Rear bearing retainer bolt Keo 3M so 4170 hoac tng ng
Poppet plug Chat 3MATD so 8660 hoac tng ng
Extension housing gasket Genuine sealant cua Mitsubishi so 997740 hoac tng
ng
Control shaft cap Chat 3M ATD so 8660 hoac tng ng
Oil seal M cua Mitsubishi So 0101011 hoac tng ng
 MANUAL TRANSMISSION - Thong so ky thuat 22B-4

IEU CHNH SNAP RING VA SPACER

Ten bo phan Be day mm Nhan dang Ma so phu

tung
Snap ring 2.30 Trang MD701729
o r maindrive gear bearing mm 2.35 Nau MD701730
2.40 Khong MD701731
2.45 Xanh dng MD701732
2.50 Vang MD701733
o r maindrive gear mm 0.84 en MD701845
0.93 Khong MD701839
1.02 o MD701840
1.11 Trang MD701841
1.20 Vang MD701842
1.29 Xanh dng MD701843
1.38 Xanh la cay MD701844
o r speed sunchronizer hub 3 va so 4 mm 2.15 Xanh dng MD701761
2.22 Khong MD701762
2.29 Nau MD701763
2.36 Trang MD701764
o r mainshaft rear bearing mm 1.4 Khong MD703779
1.5 Nau MD703780
o r mainshaft rear snap ring mm 2.60 Trang MD723092
2.79 Xanh dng MD723093
2.98 Khong MD723094
3.17 en MD723095
3.36 o MD723096
3.55 Vang MD723099
22B-5 MANUAL TRANSMISSION - Dung cu chuyen dung

DUNG CU CHUYEN DUNG

Dung cu Ma so dung cu Ten dung cu S dung

MD998019 Lock pin extractor ong spring pin va lock pin

MD998020 Bearing puller Thao bearing va bearing sleeve

MD998028 Bearing puller adapter S dung vi dung cu MD998020

MD998192 Counter gear bearing Thao countershaft front bearing va

puller center bearing

MD998199 Countershaft bearing Dung e lap countershaft front bearing

installer

MD998200 Front bearing retainer oil Dung lap front bearing retainer oil seal
seal installer

MD998245 Lock pin installer Dung e ong spring pin va lock pin
 MANUAL TRANSMISSION - Dung cu chuyen dung 22B-6

Dung cu Ma so dung cu Ten dung cu S dung

MD998809 Lock nut wrench (41) Dung e thao mainshaft lock nut

MD998812 Installer cap Lap bearing

MD998813 Installer (100) Lap bearing

MD998814 Installer (200) Lap bearing

MD998816 Installer adapter Dung lap bearing

22B-7 MANUAL TRANSMISSION - Transmission

TRANSMISSION
THAO VA LAP

Cac bc thao ra
1. Sleeve clamp
uYt 2. Speedometer gear
3. Backup lamp switch
4. Gasket
5. Steel ball
6. Resistance spring
7. Steel ball
8. Seal plug
9. Spring

10. Neutral plunger A

11. Neutral plunger B
A
t u X
u t 12. Extension housing
uWt 13. Extension housing gasket
 MANUAL TRANSMISSION - Transmission 22B-8

Cac bc thao ra
14. Under cover
15. Under cover gasket
uVt 16. Snap ring
17. Mainshaft rear bearing
18. Poppet plug 25. 3rd-4th speed shift rail
u Ut 19. Poppet spring 26. OD-R shift fork
u Ut 20. Steel ball 27. Interlock plunger
uT t 21. Spring pin for 3rd - 4th speed shift fork uRt 28. Countershaft lock nut
tBu 22. Spring pin for 1st - 2nd speed shift fork uQt 29. Countershaft rear bearing
tCu 23. Spring pin for OD-R shift fork 30. Counter overdrive gear
uSt 24. OD-R shift rail 31. 1st-2nd speed shift rail
22B-9 MANUAL TRANSMISSION - Transmission

Cac bc thao ra
32. Snap ring
33. Spacer
34. Steel ball
35. Overdrive gear
36. Needle bearing 48. Needle bearing
37. Bearing spacer K
u t 49. Bearing sleeve
tDu uPt 38. Mainshaft lock nut 50. Spacer
39. Spacer 51. Split pin
40. Counter reverse gear 52. Slotted nut
41. Spacer 53. Thrust washer
uOt 42. OD-R synchronizer ring 54. Reverse idler gear
uL t 43. OD-R synchronizer sleeve 55. Needle bearing
uNt 44. OD-R synchronizer spring I
u t 56. Bolt
uNt 45. OD-R synchronizer key F
t u uJt 57. Reverse idler gear shaft
uL t 46. OD-R synchronizer hub u It 58. Bolt
47. Reverse gear 59. Rear bearing retainer
 MANUAL TRANSMISSION - Transmission 2 2 B-1 0

Cac bc thao ra
tGu uHt 60. Countershaft center bearing
uHt 61. Mainshaft center bearing
uGt 62. Front bearing retainer
uFt 63. Front bearing retainer gasket
uEt 64. Oil seal
t Iu uDt 65. Countershaft front bearing
uCt 66. Spacer
uBt 67. Snap ring
tJu uAt 68. Snap ring
69. Maindrive gear bearing
70. Maindrive gear
71. Countershaft
72. 3rd-4th speed shift fork
73. 1st-2nd speed shift fork
74. Mainshaft front bearing
75. Mainshaft assembly
76. Transmission case
2 2 B-1 1 MANUAL TRANSMISSION - Transmission
CAC IEM CHU Y KHI THAO THAO RA

A
t u THAO EXTENTION HOUSING (TRANSFER ADAPTER)

(1) Keo extension housing hng ve pha sau trong khi ay change
shifter sang ben trai.

B
t u THAO SPIRING PIN

C
t u THAO SPRING PIN

tDu THAO MAINSHAFT LOCK NUT

 MANUAL TRANSMISSION - Transmission 2 2 B-1 2
t u F THAO REVERSE IDLER GEAR SHAFT
Reverse idler
gear shaft

Brass bar

tGu THAO COUNTERSHAFT CENTER BEARING

tHu THAO MAINSHAFT REAR BEARING

t u I THAO COUNTERSHAFT FRONT BEARING

t u J THAO MAINDRIVE GEAR BEARING

2 2 B-1 3 MANUAL TRANSMISSION - Transmission

CAC IEM CHU Y KHI LAP

A
u t LAP MAIN DRIVE GEAR BEARING

B
u t LAP SNAP RING

(1) La chon va lap snap ring e cho o r cua main drive gear
bearing at gia tr chuan.
Gia tr chuan:
0 - 0.06 mm

C
u t LAP SPACER

(1) at hai mieng ch han co ng knh 1.6mm va dai 10 mm len

Ch han vong ngoai cua bac an nh trong hnh ve.
(2) Lap front bearing retainer va xiet cac ai oc en lc xiet quy
nh.
(3) Thao front bearing retainer va thao lay mieng ch ra.
LU Y
Neu mieng ch han co ng knh 1.6 mm khong b ep, th s
dung mot mieng co ng knh 3 mm.
(4) o be day cua mieng ch han b ep bang Panme e chon va lap
vong em co be day thch hp e at gia tr o r chuan.
Gia tr chuan;
0 - 0.1 mm

uDt LAP COUNTERSHAFT FRONT BEARING

 MANUAL TRANSMISSION - Transmission 2 2 B-1 4
E
u t LAP OIL SEAL

(1) Sau khi boi dau hop so vao phan mep cua oil seal, th s dung
dung cu chuyen dung e lap oil seal.

(2) Ch ngoai tr la seal tren maindrive gear bearing. Trong trng

hp nay, boi m vao mep cua oil seal.
M quy nh:
Loai m ac biet cua Mitsubishi so 0101011 hoac tng
Boi m ng

u t F BOI CHAT LA M KN VAO FRONT BEARING RETAINER

Apply sealant GASKET
(Ca hai mat)
Chat lam kn:
Chat lam kn cua Mitsubishi so 997740 hoac
tng ng

uGt LAP MAINSHAFT CENTER BEARING

uHt LAP COUNTERSHAFT CENTER BEARING

2 2 B-1 5 MANUAL TRANSMISSION - Transmission
I
u t BOI KEO LEN BOLT

Boi keo
Chat dnh quy nh:
Chat keo ren 3M so 4170 hoac
tng ng

Reverse idler
J
u t LAP REVERSE IDLER GEAR SHAFT
gear shaft (1) S dung bolt (M8 x 50 mm) nh la mot bo dan hng e lap
reverse idler gear shaft.

Bolt

K
u t LAP REVERSE GEAR BEARING SLEEVE

L
u t LAP SYNCHRONIZER HUB / OD-R SYNCHRONIZER SLEEVE

(1) Lap synchronizer hub va synchronizer sleeve. Phai bao am cho

synchronizer hub va synchronizer sleeve trt nhe nhang.
(2) Lap ba chot vao trong ranh moay . Lap cac chot nh trong
Tr c hnh bi v no co mot hng quy nh e rap

Hub
Sleeve

Tr c

Hub
Sleeve
 MANUAL TRANSMISSION - Transmission 2 2 B-1 6
uNt LAP SYNCHRONIZER KEY VA SYNCHRONIZER SPRING
Key
(1) Khi lap cac spring, th can phai lap cho cac ranh bat tren cac
spring trc va sau c at tren synchronizer key, nhng khong
chem cung chot.
Step of spring

Step of spring

O
u t LAP SYNCHRONIZER RING

(1) Lap synchronizer ring vao banh rang so OD nh c cho

trong hnh minh hoa trc khi lap banh rang so OD vao va phai
bao am rang co khe h A.
Neu kch thc A vt qua gii han, th thay the ring hoac
banh rang.
Gii han: 0.5 mm
Synchronizering Gear

P
u t LAP MAIN SHAFT LOCK NUT

(1) Dung dung cu chuyen dung xiet chat main shaft lock nut.

(2) ong lock nut nh trong hnh minhhoa

Lock (3) Phai bao am rang banh rang so OD quay nhe nhang
nut

uQt LAP COUNTER REAR BEARING

2 2 B-1 7 MANUAL TRANSMISSION - Transmission
uRt LAP COUNTERSHAFT LOCK NUT

(1) Xiet chat countshaft lock nut en lc xiet quy nh

(2) ong vao ni c cho trong hnh can than tranh sai sot lam
Lock nut h ren cua ai oc.
(3) Bao am rang banh rang OD quay trn.

S
u t LAP SPRING PIN

u t T LAP CAC SPRING PIN CHO CAN GAT SO 3 VA SO 4, SO 1

VA SO 2.

u t U LAP STEEL BALL VA POPPET SPRING (BI VA LO XO)

(1) An poppet spring vi au nho nam ve ben vien bi.

Vien bi Lo xo chan

au nho
 MANUAL TRANSMISSION - Transmission 2 2 B-1 8
(2) Lam kn plug head bang chat lam kn
Chat lam kn quy nh:
Chat lam kn 3MATD so 8660 hoac tng ng

Gia tr chuan
V
u t LAP SNAP RING
MAINSHAFT
REAR BEARING Chon snap ring ung va lap vao e cho o r gia mainshaft near
bearing va snap ring thoa gia tr chuan.
Gia tr chuan: 0 - 0.13 mm
SNAP RING

uWt LAP SPEEDOMETER GEAR

Sleeve
Extension (1) Xoay cho cac dau lap trung vi nhau theo so cua rang.
housing

Cac dau lap

X
u t BOI CHAT LAM KN VAO CASE GASKET
Boi chat lam kn
(Ca hai mat)
Chat lam kn quy nh:
Chat lam kn ac biet cua Mitsubishi so 997740 hoac tng
ng

Y
u t LAP EXTENTION HOUSING (TRANSFER ADAPTER)
Control shaft
Control finger
(1) Xoay cho control shaft ngc chieu kim ong ho va lap nap ay
(2) Xoay control shaft cung chieu kim ong ho va an au ieu khien
Shift lug
vao ranh cua shift lug.
2 2 B-1 9 MANUAL TRANSMISSION - Extension Housing
EXTENTION HOUSING

Cac bc thao ra
1. Lock pin
uCt 2. Spring pin
3. Control shaft
4. Neutral return finger
5. Change shifter
6. Dust seal guard
uBt 7. Control shaft cap
uAt 8. Oil seal
9. Extension housing
MANUAL TRANSMISSION - Extension Housing 2 2 B-2 0
CAC IEM CHU Y KHI LAP

A
u t LAP OIL SEAL
Oil seal
(1) Sau khi lap, cho m vao gia cac mieng cua oil seal.
Loai m quy nh:
Apply grease
Loai m ac biet cua Mitsubishi so 0101011 hoac tng
ng

Chat lam kn B
u t LAP CONTROL SHAFT CAP

(1) Boi chat lam kn vao toan bo chu vi cua control shaft cap va ep
nap vao trong en khi no nam bang phang vi extension
housing.
Control shaft
cap Chat lam kn quy nh:
3M ATD so 8660 hoac tng ng

C
u t LAP SPRING PIN
2 2 B-2 1 MANUAL TRANSMISSION - Mainshaft

MAINSHAFT

Cac bc thao ra
1. Spacer 13. 2nd speed gear
2. 1st speed gear 14. Needle bearing
3. Needle bearing C
u t 15. Snap ring
4. Bearing sleeve B
u t 16. Synchronizer spring
5. 1st-2nd speed synchronizer sleeve uBt 17. Synchronizer key
6. Synchronizer ring uAt 18. 3rd-4th speed synchronizer hub
7. Synchronizer outer ring 19. Synchronizer ring
8. Synchronizer cone A
u t 20. 3rd-4th speed synchronizer sleeve
9. Synchronizer inner ring 21. Needle bearing
uBt 10. Synchronizer spring 22. 3rd speed gear
uBt 11. Synchronizer key 23. Mainshaft
12. 1st-2nd speed synchronizer hub
 MANUAL TRANSMISSION - Mainshaft 2 2 B-2 2
KIEM TRA
(1) Kiem tra synchronizer e xem co mon va cac rang ben trong
h hay khong.
(2) Vi bo ong toc c lap vao vong con cua cac banh rang,
kiem tra kch thc A. Neu kch thc A vt qua gii han, th
thay the vong ong toc va/hoac banh rang.
Gii han: 0.5 mm

Gear
Synchronizer
ring

CAC IEM CHU Y KHI LAP

Hub
A
u t LAP SYNCHRONIZER SLEEVE SO 3 VA SO 4 VA
SYNCHRONIZER HUB

(1) Lap synchronizer hub va synchronizer sleeve. Phai bao am

Steeve
rang synchronizer hub va synchronizer sleeve trt nhe nhang.

Key
B
u t LAP SYNCHRONIZER KEY VA SYNCHRONIZER SPRING

(1) Lap hai synchronizer spring. Khi lap cac lo xo phai bao am
rang cac ranh bac cac lo xo trc va sau c at tren chot
synchronizer key, nhng khong chem cung chot.
Ranh bac
cua spring

Ranh bac cua spring

Mainshaft
Synchronizer
C
u t LAP SNAP RING
hub (1) Chon va snap ring e cho o r cua synchronizer hub at c
gia tr chuan.
Snap ring
Gia tr chuan: 0 - 0.08 mm
2 2 B-2 3 MANUAL TRANSMISSION - Mainshaft

B gay rang

B gay rang
SYNCHRONIZER OUTER RING, INNER RING VA CONE

(1) Kiem tra xem cac rang cua banh rang an khp vao be mat con
co b h hong khong

B gay rang

Outer ring
(2) Lap outer ring, inner ring va cone. ay chung vao trong banh
Cone
rang va o khe h A. Neu A nho hn gia tr gii han, th thay
the chung.
Gii han; 0.5 mm
Gear
Chu y
Outer ring, inner ring va cone phai c thay the ca bo khi
thay the.
Inner ring
 MANUAL TRANSMISSION - Speedometer Gear 2 2 B-2 4

SPEEDOMETER GEAR

Cac bc thao ra
uAt 1. Spring pin

2. Driven gear
3. Sleeve
4. O-ring
5. O-ring

O-ring IEM CHU Y KHI LAP

A
u t LAP SPRING PIN

(1) ong spring pin vao, trong khi o phai bao am cho ranh cua
chot khong hng ve gear shaft.
Spring pin

O-ring

Ranh che