H330-H320

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transmission JW5F18C
H320H330RM2B/3/1

Daroupakhsh St.17th Km Karaj Makhsoos Road-TEHRAN-IRAN

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TRANSMISSION
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Transmission Specification

Overview
● Main purposes and applicable scope
JW5F18C series vehicle transmission is a transverse front-wheel driving transmission, which is designed
for matching Mitsubishi 4A9 series engine. This transmission is applicable for SUV and other cars, etc
carrying Mitsubishi 4A9 series engine.
● Operating conditions and environments applicable for products
This transmission can be applicable for all the operating conditions and environments of Mitsubishi 4A9
series engine and vehicle.
● Structural form and major technical parameters
1. Structural form
Five forward gears and one reverse gear. Reverse gear is a spur-gear constant-mesh drive, and five forward
gears are bevel-gear constant-mesh drives. Each of forward gears has a synchronizer, its I, II and III gears
are shifted by double-tapered synchronizer, which are flexible in shifting, good in hand-feeling, low in
noise, compact in structure, high in carrying capability, and excellent in sealing. The gear shift mechanism
is a pull-wire remote control mechanism.
Major technical parameters

Speed ratio Ⅰ
Torque capacity 180N.m
Form Manual
Drive mode Front dual-wheel drive
Number of speed gears 5
Variable-speed ratio See the specifications
Clutch control Hydraulic
Weight (kg) 41.5 (oil-free)
Specifications of transmission lubricating oil 75W/90(GL-4)
Filling method of transmission lubricating oil Fill in the required amount of oil from side plughole.
Filling capacity of transmission lubricating oil 2.3L

● Transport and storage

1. The transmission shall be protected with rust-proof measures to ensure that the transmission can’t
be rusted during the normal transport and storage.
2. The transmission shall be packed in the box before the transport, which shall ensure that the
transmission can’t be damaged during the normal transport.
3. The transmission shall be stored in the ventilated and dry warehouse.
● Control
Control the selector lever and shifting lever for gear shifting operation by controlling the control lever in
the cab. Make the different directions indicated by control lever ball head corresponding to different
indicated selected and shifted positions. After each gear pickoff, the control lever will return to neutral
position automatically; and the gear can be selected only when in neutral gear,
1. During the shifting operation, step down the disengaging pawl pedal fully to make the
transmission disengaged from the torque of engine and control the transmission lever quickly,
and put in slow speed gear during the start.
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Transmission Specification
2. In case of slope up, down or turning, put in slow speed gear, and don’t disengage the clutch for
slippage.
3. When it’s difficult to control the transmission lever, stop the vehicle to check its causes, and don’t
apply any excessive pulling force to it.
● Maintenance and service
1. The maintenance and service of transmission shall be subject to the requirements for maintenance
and service of commercial vehicle, which is commonly classified into three-stage technical
maintenance.
2. Check and change (or refill) the transmission lubricating oil at regular intervals.
Summary of periodic checks and maintenance for transmission
Check the distances indicated in the project, whichever comes first.
○ Checked position, tighten or adjust, change the lubricating oil if necessary; ★Change or refill the
lubricating oil.

Check and repair interval (subject to the odometer readings, whichever comes first)
Item Odometer 1 6 10 20 30 40 50 60 70 80 90
readings×1000km
Check inside the transmission
Common operating
○ ○ ○ ○ ○ ○ ○
Check the level of gear conditions
oil in the transmission. Severe operating
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
conditions
Common operating
Change the gear oil ★ ★ ★
conditions
inside the
transmission. Severe operating
★ ★ ★
conditions
Other checks
Common operating
Lubricant-applied ★ ★ ★ ★ ★
conditions
positions like
separating system, etc Severe operating
★ ★ ★ ★ ★ ★ ★ ★
conditions

Note: “Severe operating conditions” includes the following items.

• Driving in the dusty area, or frequently exposed in the salty air or salt water.
• Driving on rough or water-accumulated roads or mountain roads.
• Driving in cold areas.
• The engine is running at idle speed for long time or often drives for short distance in cold season.
• It’s frequently required to apply the brake and multi-function emergency brake.
• Traction of vehicle
• Used as a taxi or self-driving rental vehicle.
• Slow-driving time of vehicle in crowded urban at above 32℃ exceeds 50% of total driving time.

• Over 120km/hour high-speed driving time of vehicle at above 30℃ exceeds 50% of total driving time.
• Overload driving.
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● Common faults and their remedy methods
(For the abnormality and insolvable problems of transmission, contact with the authorized service
station or technicians. For the detailed disassembly drawings and part No.s, refer to the repair
manual)
Fault conditions
The vehicle jumps into
neutral gear while driving.
If the clutch has no faults, it’s
difficult to shift the gear,
serious impact noises or it’s
difficult to put in some gear.
Sounding of transmission
① Regular impact noises;
② Uniform noises
Abnormal noises of
separating system, including
the abnormal noises of
shifting fork and release
bearing
Speeage of oil
Abnormal damages of bearing
Transmission Specification
Possible causes
• Excessive wears of shifting fork
circular arc groove, elastic
deformations of lock ball spring.
• Excessive wears of shifting fork
working face.
• Excessive wears of toothed ring or
sleeve joint face
• Axial loosening of gear shaft.
Serious wears of synchronizer ring
• Breakage of individual gear teeth.
• Increase of backlash or damages
of gear.
• Wears of bearing.
• Insufficiency of lubricating oil.
• Wears of release bearing
• Wears of release lever pivot
• Wears of clutch
• Addition of excessive oil,
overhigh oil face.
• Excessive wears or damages of oil
seal
• Uneven painting of sealing gum or
damages of seal paper gasket.
• Failure of vent plug.
• The knock points of joint face
can’t be flattened in time.
(1)Too dirty lubricating oil.
(2)Insufficient lubrication or
unqualified lubricating oil, too
poor quality.
(3)Apply the unqualified bearing.
Judge and remove
(1) Check whether the control system pushes
the shifting rocker arm of transmission in
position, or remove the transmission and
replace it with a hand-pushed shifting fork to
put in gear, and check its engagement.
(2) If not fully engaged, check the shifting fork
for deformations or its working face for
excessive wears.
(3) If the toothed sleeve has been fully engaged,
check the back taper of toothed sleeve and
soldered teeth for wears.
(4) If you feel too large gap in shifting, check
the fork shaft groove or locating spring for
wears or failure.
Replace the synchronizer ring.
• Check and remove any caused part.
• Disassemble, check, clean and replace the
damaged gear or bearing.
• Change or add in new oil.
• Check and remove any caused part.
• Disassemble, check or replace the damaged
bearing, release lever pivot and clutch.
• Remove the filler plug, and check the oil face.
• Replace the oil seal.
• Remove each joint face part, check its knock
points, flatten them, and paint evenly.
• Replace the vent plug.
(1)Change the lubricating oil.
(2)Check the face of lubricating oil, add in or
change the lubricating oil.
(3)Replace the bearing.
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Transmission Specification
Sectional view of transmission

1 V driving gear assembly 9 Output shaft

2 III or IV gear synchronizer 10 Differential assembly
3 IV driving gear assembly 11 I driving gear assembly
4 III driving gear assembly 12 I or II gear synchronizer
5 Transmission housing 13 II driven gear assembly
6 Clutch housing 14 III driven gear
7 Release bearing 15 IV driven gear
8 Input shaft 16 V driven gear
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Transmission Specification
Drive ratio of JW5F18C series transmission

Model of transmission JW5F18C

Applicable engine Mitsubishi 4A9 series
Type V gear, gear shift by pull wire
I gear 3.583
II gear 1.947
III gear 1.379
Gear drive ratio
IV gear 1.030
V gear 0.767
Reverse gear 3.417
Final drive reduction ratio 4.053

Maintenance specifications

Item Allowable range Limit value

Axial clearance of input shaft front bearing mm －0.01～0.12 －

Axial clearance of input shaft rear bearing mm －0.01～0.09 －

Axial clearance of output shaft front bearing mm 0～0.12 －

Axial clearance of output shaft rear bearing mm 0.01～0.09 －

Axial clearance of output shaft III gear mm 0.01～0.09 －

Clearance of differential housing pinion mm 0.025～0.150 －

Pre-tightness of differential housing mm 0.05～0.17 －

Axial clearances of other gears 0.08-0.19 －

Clearance between synchronizer ring back face and

－ 0.05
gear mm

Remarks: standard clearance=0mm

Sealant, adhesive agent

Item Specified sealant and adhesive agent

Mating face of clutch housing-transmission housing
Mitsubishi pure sealant part No. MD997740 or
Mating face of clutch housing-transmission housing
equivalents
Mating face of clutch housing-transmission housing
3M SUPER WEATHERSTRIP NO.8001 or
Vent
equivalents
Differential drive gear bolt 3M STUD LOCKING NO.4170 or equivalents
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Transmission Specification

Chapter II JW5F18B/JW5F21 Manual Gearbox

Section I Specification

Transmission rate of gearbox of JW5F18B series

Specification JW5F18C/JW5F21A
Applicable engine 4A92/1.5T Engine
Model 5-gear, floor gear shift
1-gear 3.583
2-gear 1.947
3-gear 1.379
Gear transmission rate
4-gear 1.030
5-gear 0.767
Reverse gear 3.417
Final transmission reduction rate 4.053

Maintenance specification

Item Allowable range Limit value

Axial clearance of front bearing in input shaft (mm) -0.01-0.12 -
Axial clearance of rear bearing in input shaft (mm) -0.01-0.09 -
Axial clearance of front bearing in output shaft (mm) 0-0.12 -
Axial clearance of rear bearing in output shaft (mm) 0.01-0.09 -
Axial clearance of 3-gear gear wheel in output shaft (mm) 0.01-0.09 -
Gear backlash of small gear wheel in differential shell (mm) 0.025-0.150 -
Pretension degree of differential shell (mm) 0.05-0.17 -
Axial clearance of gear wheels in other gears 0.08-0.19 -
Clearance between synchronizer ring rear and gear wheel - 0.05
Note: standard clearance = 0mm

Sealant and binder

Item Specified sealant and binder

Mating surface of clutch shell and gearbox shell
Mitsubishi Pure sealant part No. MD997740 or
Mating surface of control shell and gearbox shell
equivalent
Mating surface of bottom cap and gearbox shell
Ventage 3M SUPER WEATHERSTRIP NO.8001 or equivalent
Drive gear bolt of gearbox 3M STUD LOCKING NO.4170 or equivalent
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Transmission Specification

Site-molding sealant (FIPG)

Site-molding sealant (FIPG) is applied in many parts of gearbox. In applying, in order to perfect sealing effects,
the applying volume, position and status of coating surface should be emphasized. Less applying volume may
result in leakage while excess volume will lead to overflow to block or narrow the passage of water or oil.
Therefore, to avoid leakage on the mating surface, it is necessary to control the applying volume and ensure no
disconnection.
Hardening occurs when RTV (hardening sealant in room temperature) is mixed with moisture in the air; thus,
RTV is usually adopted in the metal flange.

Disassembly
Parts assembled by sealant can be easily disassembled without any special methods. But in certain conditions, a
mallet or similar tool should be used to slightly knock the part and break down the sealant on the mating surface,
or a smooth thin sealant scraper should be used to cut into the mating surface slightly; making sure that the
mating surface should not be damaged.

Sealing surface cleanup

Clean the sundries on the sealing surface with a sealant scrapper or wire brush; ensure that the sealing surface is
smooth without grease or foreign matters; don’t forget to remove the used sealant in the mounting hole and
screw hole.

Main points of sealant applying

Items should be focused when assembling parts with FIPG.
Apply sealant evenly on the specified diameter to enclose mounting hole. Remove the unhardened sealant. Install
the parts on the specified position when the sealant is wet (within 15min). During installation, prevent sealant
from contacting with unnecessary places. After installation, no action is allowed before the sealant is fully
hardened (about one hour). Do not apply oil or water to the sealed part or start the engine during this period.
The applying steps of FIPG sealant vary due to different shapes of parts. Please refer to the applying method
described in the text.

Lubricating Grease

Item Specified lubricating grease

Oil-sealed lip of drive shaft
Oil-sealed lip of input shaft
Selector rod slider
Hypoid gear oil SAE 75W/85W which meet the GL-4
or above in API classification
Mitsubishi pure lubricating grease part No. 0101011
or equivalent
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Transmission Specification

Adjusting Snap Ring and Adjusting Gasket

Identification
Part name Thickness (mm) Part code
mark
Snap ring (for adjusting the axial clearance 2.24 None JW5F23-1701112-01
of front bearing in input shaft) 2.31 Blue JW5F23-1701112-02
2.38 Brown JW5F23-1701112-03
Snap ring 2.22±0.04 None JW5F18-1701119-01
(for adjusting the axial clearance of rear 2.30±0.04 JW5F18-1701119-02
Blue
bearing in input shaft)
2.38±0.04 Brown JW5F18-1701119-03
2.46±0.04 Green JW5F18-1701119-04
2.54±0.04 White JW5F18-1701119-05
2.62±0.04 Yellow JW5F18-1701119-06
2.70±0.04 Black JW5F18-1701119-07
2.78±0.04 Orange JW5F18-1701119-08
2.86±0.04 Blue JW5F18-1701119-09
2.94±0.04 Brown JW5F18-1701119-10
Snap ring 2.16±0.04 Black JW5F18-1701221-01
(for adjusting the axial clearance of rear 2.24±0.04 None JW5F18-1701221-02
bearing in output shaft)
2.32±0.04 Blue JW5F18-1701221-03
2.40±0.04 Brown JW5F18-1701221-04
2.48±0.04 Green JW5F18-1701221-05
2.56±0.04 White JW5F18-1701221-06
2.64±0.04 Yellow JW5F18-1701221-07
Snap ring 1.43 Green (2) JW5F23-1701110-01
(for adjusting the axial clearance of front 1.51 White (2) JW5F23-1701110-02
bearing in output shaft) 1.59 Yellow (2) JW5F23-1701110-03
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Transmission Specification

Part name Thickness (mm) Identification mark Part code

Snap ring 2.8±0.04 Green JW5F18-1701211-01
(for adjusting the axial clearance 2.86±0.04 White JW5F18-1701211-02
of 3-gear gear wheel in output
2.96±0.04 Yellow JW5F18-1701211-03
shaft)
3.04±0.04 Black JW5F18-1701211-04
3.12±0.04 Orange JW5F18-1701211-05
3.2±0.04 Red JW5F18-1701211-06
Adjusting gasket 0.71 71 JW5F23-1701521-01
(for adjusting the pretension of 0.74 74 JW5F23-1701521-02
differential shell)
0.77 77 JW5F23-1701521-03
0.80 80 JW5F23-1701521-04
0.83 83 JW5F23-1701521-05
0.86 86 JW5F23-1701521-06
0.89 89 JW5F23-1701521-07
0.92 92 JW5F23-1701521-08
0.95 95 JW5F23-1701521-09
0.98 98 JW5F23-1701521-10
1.01 01 JW5F23-1701521-11
1.04 04 JW5F23-1701521-12
1.07 07 JW5F23-1701521-13
1.10 J JW5F23-1701521-14
1.13 D JW5F23-1701521-15
1.16 K JW5F23-1701521-16
1.19 L JW5F23-1701521-17
1.22 G JW5F23-1701521-18
1.25 M JW5F23-1701521-19
Thrust plate of gear wheel in 1.07-1.11 1 JW5F23-2302313-01
differential 0.98-1.02 2 JW5F23-2302313-02
(for adjusting the gear backlash
0.9-0.94 3 JW5F23-2302313-03
of differential shell)
0.8-0.84 4 JW5F23-2302313-04
1.16-1.2 5 JW5F23-2302313-05
0.85-0.9 6 JW5F23-2302313-06
0.74-0.79 7 JW5F23-2302313-07
1.02-1.06 8 JW5F23-2302313-08
1.12-1.16 9 JW5F23-2302313-09
0.94-0.98 11 JW5F23-2302313
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Transmission Specification

Specification of Tightening Moment

Item Torque N.m (kgf)

Bolt of oil-inlet and oil-outlet 29.4-34.4 (3-3.51)
Interlocking bolt 26.5-33.3 (2.704-3.398)
Mounting bolt of clutch shell and gearbox shell 38.2-49 (3.898-5)
Mounting bolt of release bearing retainer of clutch 7.8-11.8 (0.796-1.204)
Clutch release rod fulcrum 29.4-41.2 (3-4.204)
Pipe support bolt of clutch 14.7-21.6 (1.5-2.204)
Controller body bolt 14.7-21.6 (1.5-2.204)
Mounting bolt of bracket of shifting wire 14.7-21.6 (1.5-2.204)
Bolts of rotating speed sensor 4-8 (0.408-0.816)
Spacing steel ball component 29.4-34.3 (3-3.51)
Bolts of speed sensor 2.9-4.9 (0.296-0.5)
Bolt of release steel components 14.7-21.6 (1.5-2.204)
Mounting bolt of drive gear in differential 127.5-137.5 (13.01-14.03)
Reversing lamp switch 29.4-34.3 (3-3.51)
Countersunk adhesive screw 17-22 (1.735-2.245)
Lifting spring component 29.4-34.3 (3-3.51)
Mounting bolt of reverse gear shaft 41.2-53.9 (4.204-5.5)
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Section II Disassembly and Assembly of Gearbox
(1) Gearbox assembly
Disassembly and assembly

Disassembly steps
1. Clutch release cylinder component 8. Lifting spring component
2. Wire harness bracket 9. Washer
3. Clutch hydraulic pipeline 10. Clutch hydraulic pipeline bracket
4. Selector rod 11. Bolt with washer
[L] 5. Shifting wire bracket component 12. Speed sensor
[M] 6. Assembly of rear lamp switch 13. Bolt with gasket
7. Gasket 14. Support
15. Bolt
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During re-assembly,
lubricate all internal parts
with gear oil

Disassembly steps
12. Interlocking bolt [C][G] 20. Reverse idle gear shaft
13. Gasket 21. Reverse idle gear
[K] 14. Control shell 22. Reverse and shift rod
15. Neutral return spring 23. Assembly of gear reverse and shift arm
[J] 16. Bolt of reverse idle gear shaft [F] 24. Oil-guiding groove
17. Gasket 25. Magnetic plug socket
18. Plug cap 26. Magnetic plug
[A][I] 19. Gearbox shell [E] 27. Adjusting gasket
[B][H] 28. Stud bolt
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During re-assembly,
lubricate all internal parts
with gear oil

[D] 28. Spring pin [D][C] 37. Reverse interlocking shaft

29. 1/2-gear shift sliding subcomponent [D][C] 38. Steel ball
30. 1/2-gear shift fork [D][C] 39. 3/4-gear shift sliding subcomponent
[D] 31. Spring pin [D][C] 40. 3/4-gear shift fork
[D] 32. Spring pin [B] 41. Front bearing pedestal
[D][C] 33. 5-gear shift sliding subcomponent [E][A] 42. Input shaft assembly
34. 5-gear shift fork [B][A] 43. output shaft assembly
[D][C] 35. Shifting arm of gear reversing 44. Differential component
[D][C] 36. Spacing snap ring 45. Clutch shell
[D][C]
Main points of disassembly:
[A] Disassembly of plug cap

Plug cap
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[B] Disassembly of gearbox shell
Expand the snap ring and remove it from the snap ring groove of ball bearing
Note: If the snap ring is expanded, the snap ring groove will shift due to the self-weight of input shaft.

Snap ring

[C] Disassembly of reverse idle gear shaft

Move the 3-4 gear synchronizer bush to 4-gear

3-4 synchronizer
bush

[D] Disassembly of 3-4 gear shift slide track/3-4 gear shift fork/5-gear shift fork/spacing snap ring/reverse
shifting arm/5-gear shift slide track/steel ball/reverse interlocking shaft
(1) Move the reverse shifting arm towards the direction as indicated in the drawing while
disassembling 5-gear shift fork slide track and reverse shifting arm, spacing snap ring, steel ball
and reverse interlocking shaft.

Reverse
shifting arm

(2) Move the 3-4 gear shift slide track towards the direction as indicated in the drawing and
disassemble it together with the shift fork .simultaneously

3/4 gear shift

slide track
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[E] Disassembly of input shaft/output shaft
Disassemble the input and output shafts at the same time.

Input shaft
Output shaft

Adjustment before re-assembly:

Select the gasket to adjust the axial clearance of the differential
(1) Place soldering (10 mm in length and 1.6 mm in diameter) in the position of differential as
indicated in the drawing, and then install the differential.

Soldering

(2) Install the clutch shell and screw down the bolt to the specified moment.
(3) If the soldering has not been pressed to one side, repeat the above (1) and (2) steps with a thicker
soldering.
(4) Measure the thickness (T) of the pressed soldering with a micrometer, and select the gasket
according to the following formula.
Thickness of the selected gasket:
(T-0.05mm) to (T-0.17mm)

Main points of re-assembly:

[A] Installation of input shaft/output shaft
Install the input and output shafts at the same time.
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Input shaft
Output shaft

[B] Installation of front bearing pedestal

Apply the sealant on the installation bolt (only on the countersunk head screw) of front bearing
pedestal.
Specified sealant: 3M STUD LOCKING NO.4170 or equivalent

[C] Installation of reverse interlocking shaft/steel ball/5-gear shift slide track/reverse shifting arm/spacing
snap ring/5-gear shift fork/3-4 gear shift fork/3-4 gear shift slide track
(1) Install 3-4 gear shift slide track and shift fork

3-4 gear shift

slide track
3-4 gear shift
fork

(2) Install reverse interlocking shaft, steel ball, 5-gear shift slide track, 5-gear shift fork, reverse
shifting arm, circlip in the positions as indicated in the drawing.

5-gear shift fork

5-gear shift
slide track
Reverse interlocking
shaft
Steel ball
(inner side)
Reverse shifting arm

Spacing snap ring

(3) Move the reverse shifting arm towards the direction as indicated in the drawing while installing
5-gear shift fork, slide track and reverse shifting arm, spacing snap ring, steel ball and reverse
interlocking shaft.
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Reverse shifting arm Reverse interlocking

shaft

Reverse shifting
arm

Steel ball
5-gear shift slide
track

[D] Installation of spring pin

Slide track Shift fork

Spring pin

Opening

[E] Installation of snap ring

Install the snap ring selected in the step of “Adjustment before re-assembly”
[F Installation of oil-guiding groove

Oil-guiding
groove

[G] Installation of reverse idle gear shaft

(1) Move the 3-4 gear synchronizer bush to 4-gear

3-4 synchronizer
bush

(2) Direct bolt on the reverse idle gear shaft as indicated in the drawing.
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Reverse idle gear
shaft

[H] Installation of gearbox shell

(1) Squeeze out sealant on the specific position of gearbox shell as indicated in the drawing.
Specified sealant:
Mitsubishi Pure sealant part No. MD997740 or equivalent
Notes:
1. The sealant line should be squeezed out evenly and continuously without disconnection or
over-applying.
2. The gearbox shell should be installed immediately when the sealant is still wet (within 15
min).
3. The sealed part should be prevented from oil within about 1 hour after installation.

(2) Install gearbox shell and expand the snap ring.

Snap ring

(3) Screw down the gearbox shell with specified moment.

Remarks:
Reverse the gearbox to make the spring snap ring inserted into the groove automatically by means of
the weight of output shaft.
[I] Installation of sealed cap
Press it firmly into the position as indicated in the drawing.
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Sealed cap

[J] Installation of reverse idle gear shaft

Find out the screw hole center with screwdriver (8 mm of rod diameter)

[K] Installation of control shell

Squeeze out sealant on the specific position of gearbox shell as indicated in the drawing.
Specified sealant:
Mitsubishi Pure sealant part No. MD997740 or equivalent
Notes:
1. The sealant line should be squeezed out evenly and continuously without disconnection or
over-applying.
2. The gearbox shell should be installed immediately when the sealant is still wet (within 15 min).
3. The sealed part should be prevented from oil within about 1 hour after installation.

[L] Installation of speed sensor

Gearbox oil:
Apply gearbox oil on the O-ring of the speed sensor
Gearbox oil:
Hypoid gear oil SEA75W-85W which meet APIGL-4 or above
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O-shaped seal ring

[M] Installation of selector rod

Specified lubricating grease:
Apply the lubricating grease on the slipping part of brake shaft in selector rod

Control shaft

Selector rod

Slide block
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(2) Input shaft
Disassembly and re-assembly

During re-assembly,
lubricate all internal parts
with gear oil

Detailed steps: [D] 15. Synchronizer spring

[L] 1. Snap ring [F] 16. Synchronizer gear bush

[A][K] 2. Radial ball bearing [E] 17. 3/4 synchronizer hub
3. Circlip for input shaft 18. Synchronizer outer ring
[J] 4. 5/R synchronizer gear bush [D] 19. Synchronizer spring
[B][I] 5. 5/R gear synchronizer hub 20. Synchronizer cone
6. Synchronizer lever [M] 21. Synchronizer inner ring
[N] 7. Lever gear ring 22. 3-gear drive gear component
8. 5-gear drive gear component 23. Needle bearing
[C][I] 9. Needle bearing [C] 24. Snap ring of input shaft
10. 5-gear drive gear bush [E][B] 25. Front bearing
[C][H] 11. 4-gear drive gear component [A] 26. Oil seal
12. Needle bearing 27. Input shaft
[D][G] 13. 4-gear drive gear bush
14. Synchronizer ring
[A] Disassembly of radial ball bearing
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[B] Disassembly of 5/R gear synchronizer hub

Install the special tool onto the 5-gear drive gear component and disassemble the 5/R synchronizer
hub.

[C] Disassembly of 5-gear drive gear bush

Install the special tool into the 4-gear drive gear and disassemble the drive gear bush of 5-gear
synchronizer.

[D] Install the special tool into the 3-gear drive gear and disassemble the drive gear bush of 4-gear
synchronizer.

[E] Front bearing

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Main points of re-assembly:

[A] Installation of oil seal
Knock it firmly into the position as indicated in the drawing

Oil seal

[B] Installation of front bearing

[C] Installation of input shaft snap ring

Select and install the snap ring of input shaft to adjust the clearance of front bearing in input shaft to
the standard value.
Standard value: -0.01 - 0.12mm

Snap ring of input

shaft

[D] Installation of synchronizer spring

Install it firmly to make it in the position of synchronizer ring as indicated in the drawing.
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Synchronizer spring

[E] Installation of 3-4 gear synchronizer hub

Install the synchronizer hub to the position as indicated in the drawing
Installation direction

Identification mark

Note: Press the hub to make the synchronizer ring pressed-in instead of being engaged-in.

[F] Installation of synchronizer slide bush

(1) Install the slide bush in the direction as indicated in the drawing.

Identification groove

Installation direction

(2) Align the projection of the slide bush with the deep groove of synchronizer hub, and then install
it.
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Synchronizer gear bush

Synchronizer hub

[G] Installation of 4-gear drive gear bush

[H] Installation of 5-gear drive gear bush

Synchronizer hub

[I] Installation of 5/R gear synchronizer hub

Installation direction

Note: Press the hub to make the synchronizing ring pressed-in instead of being engaged-in.
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Installation direction

[J] Installation of synchronizer gear bush

(1) Install the gear bush in the direction as indicated in the drawing.

Identification groove

Installation direction

(2) Align the projection of the gear bush with the deep groove of synchronizer hub, and then install
it.

Synchronizer gear bush

Synchronizer hub

[K] Installation of radial ball bearing

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[L] Installation of input shaft snap ring
Select and install the input shaft to adjust the clearance of front bearing in input shaft to the standard
value.
Standard value: -0.01 - 0.09mm

Synchronizer hub

[M] Installation of synchronizer ring group

Install it firmly to make it in the position of synchronizer ring as indicated in the drawing.

Synchronizer cone
Inner ring

Outer ring

Ring group

[N] Installation of synchronizer lever and lever gear ring

Place the lever gear ring into the input shaft and then press the synchronizer lever and 5/R
synchronizer hub & bush into the input shaft.

Lever gear ring

Synchronizer
lever

Installation
direction

5/R
synchronizer
hub and bush
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(3) Input shaft
Disassembly and re-assembly:
During re-assembly,
lubricate all internal parts
with gear oil
Detailed steps:
[J] 1. Snap ring
[A][I] 2. Ball bearing
3. Input shaft circlip
4. 5-gear driven gear
5. 4-gear driven gear
[H] 6. Snap ring
7. 3-gear driven gear
8. Assembly of 2-gear driven gear
9. Needle bearing
[B][G] 10. 2-gear driven gear bush
11. Synchronizer inner ring
[K] 12. Synchronizer cone
13. Synchronizer outer ring
[D] 14. Synchronizer spring
[F] 15. 1/2 synchronizer gear bush
[E] 16. 1/2 gear synchronizer hub
17. Synchronizer outer ring
[D] 18. Synchronizer spring
19. Synchronizer cone
20. Synchronizer inner ring
[C][C] 21. Assembly of 1-gear driven gear
[B] 22. Needle bearing
23. 1-gear driven gear
[D][A] 24. Snap ring
25. Inner ring of roller bearing
26.Output shaft
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Main points of disassembly:
[A] Disassembly of ball bearing

Ball bearing

[B] Disassembly of 2-gear driven gear bush

Place the special tool into the gear bush of synchronizer and disassemble the gear bush of 2-gear
driven gear.

Synchronizer gear
bush

[C] Disassembly of 1-gear driven gear bush

1-gear driven
gear bush

[D] Disassembly of inner ring of roller bearing

Inner ring
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Main points of re-assembly
[A] Installation of inner ring of roller bearing

Inner ring

[B] Installation of snap ring

Select and install the snap ring, making the clearance of front bearing in input shaft meet the standard
value.
Standard value: 0 - 0.12mm

Snap ring

[C] Installation of 1-gear driven gear bush

1-gear driven gear

bush

[C] Installation of 1/2 gear synchronizer hub

Installation
direction
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Note: Press the hub to make the synchronizing ring pressed-in instead of being engaged-in.

[F] Installation of 1/2 gear synchronizer bush

(1) Install the gear bush in the direction as indicated in the drawing.

Installation
direction

(2) Align the projection of the gear bush with the deep groove of synchronizer hub, and then install
it.
Synchronizer gear bush

Synchronizer hub

[G] Installation of 2-gear driven gear bush

[H] Installation of snap ring

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Select and install the snap ring, making the axial clearance of 3-gear gear wheel in output shaft meet
the standard value.
Standard value: -0.01 - 0.09mm

Snap ring

[I] Installation of ball bearing

Note: Install it with its snap ring groove upward.

[J] Installation of snap ring

Select and install the snap ring, making the clearance of rear bearing in output shaft meet the standard
value.
Standard value: -0.01 - 0.09mm
[K] Installation of synchronizer ring group
Install it firmly to make it in the position of synchronizer ring as indicated in the drawing.

Inner ring Synchronizer cone

Outer ring

Ring group
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(4). Speed sensor
Disassembly and re-assembly

Lubricate all inner parts with

gear oil during assembly

Detailed steps:
1. E-shaped clip
2. Speed sensor gear
3. O-ring
4. Speed sensor
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(5). Selector rod
Disassembly and re-assembly

[A] 1. Dust cover 6. Selector rod slide box

2. Nut 7. Selector rod
3. Spring washer 8. Selector rod bush
4. Washer [A] 9. Dust cover
5. Selector rod bush 10. Selector rod shaft

Main points of re-assembly

[J] Installation of dust cover

Dust cover
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(6) Control shell
Disassembly and re-assembly

Detailed steps: 10. Neutral return spring

[A][F] 1. Fitting pin 11. Neutral return spring base
2. Interlocking board 12. Control shaft
3.Control claw [C] 13. Breather pipe
4. Pin 14. Control shaft cover
5. Return spring [B] 15. Oil seal
6. Spacing board [A] 16. Needle bearing
[E] 7. Spring pin 17. Spring washer
8. Stopper bracket 18. Control shell
9. Stopper body

Main points of disassembly:

[A] Disassembly of fitting pin
Beat out the fitting pin in the direction as indicated in the drawing
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Fitting pin

Control claw

Beating direction

Main points of re-assembly:

[A] Installation of needle bearing
Press it to the position 0-0.5 from the inner end face with the model mark outward.

Needle bearing

Control shell

[B] Installation of oil seal

Apply gearbox oil on the oil seal lip
Gearbox oil:
Hypoid gear oil SAE 75W-85W
Meet API GL-4 or above

[C] Installation of breather pipe

(1) Apply sealant on the outskirts of the inserted part
Specified sealant:
3M SUPER WEATHERSTRIP NO.8001 or equivalent
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(2) Install it with its projection in the direction as indicated in the drawing

[D] Installation of spring pin

Slide track Shift fork

Pressing direction

Opening

Spring pin

[F] Installation of fitting pin

Pressing direction
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(7). Clutch shell
Disassembly and re-assembly

Detailed steps: 7. Clutch shell

1. Release bearing carrier of clutch 8. Engine oil pipe
[D] 2. Oil seal 9. Roller bearing
[C] 3. Oil seal 10. Release fork cover
[A][B] 4. Return clip 11. Release fork component
5. Release bearing of clutch [E] 12. Choke
[A] 6. Bush 13. Clutch release rod fulcrum

* The main points for installation should be followed only when the clutch shell is replaced
Main points of disassembly
[A] Disassembly of outer ring of roller bearing

Outer race

Main points of re-assembly:

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[A] Installation of bush
Press the bush down to the position as indicated in the drawing and ensure that its grooving surface
does not contact the air bleeding groove.

Grooving end
Air bleeding
groove

[B] Installation of outer ring of roller bearing

Press the outer ring with its model mark facing the direction as indicated in the drawing
Pressing position of

Model mark side

outer ring

Engine oil pipe

[C] Installation of oil seal

Apply gearbox oil on the oil seal lip
Gearbox oil:
Hypoid gear oil SAE 75W-85W
Meet API GL-4 or above

[D] Installation of oil seal

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[E] Installation of choke

Choke
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(8). Gearbox shell
Disassembly and re-assembly

Detailed steps: 7. Washer

[C] 1. Oil seal 8. Oil-drain plug screw
[B] 2. Needle bearing* 9. Washer
3. Engine oil pipe 10. Refueling plug screw
4. Snap ring 11. Engine oil tank cover
[A] 5. Bush
6. Gearbox shell
* The main points for installation should be followed only when the clutch shell is replaced
Main points of re-assembly
[A] Installation of bush
Press the bush down to the position as indicated in the drawing and ensure that its grooving
surface does not contact the air bleeding groove.
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Grooving end

Air bleeding
groove

[B] Installation of needle bearing

Press it down with its model mark in the position as indicated in the drawing

Pressing position of needle bearing

Model mark should be outward

[C] Installation of oil seal

Apply gearbox oil on the oil seal lip
Gearbox oil:
Hypoid gear oil SAE 75W-85W
Meet API GL-4 or above
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(9) Differential
Disassembly and re-assembly

Detailed steps: [A] 6. Washer

[D] 1. Drive gear of differential [A] 7. Differential side gear
[A][C] 2. Cone roller bearing [A] 8. Gear thrust plate of differential
[B] 3. Fitting pin 9. Differential shell
[A] 4. Gear shaft
[A] 5. Differential gear
Main points of disassembly
[A] Disassembly of cone roller bearing

Main points of re-assembly

[A] Assembly of gear thrust plate of differential/side gear/washer/differential gear/gear shaft
(1) Place the in the back of side gear and then install the side gear into differential shell.
Note: Please adopt thrust plate with medium thickness (0.93-1.00mm) when installing new side gear.
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(2) Install the washer to the back of differential gear, engaged with side gear on No. “7” position;
install it to the specified position when revolving it.
(3) Insert the gear shaft

(4) Measure the clearance between side gear and differential gear
Standard value: 0.025 - 0.15mm

(5) If gear backlash exceeds the standard value, select an appropriate thrust plate and measure its
gear backlash
Note: Adjust the thrust plate to make the gear backlashes in both sides equal.
[B] Installation of fitting pin
Install it in the direction as indicated in the drawing.
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Differential shell

Fitting pin

Gear shaft

[C] Installation of cone roller bearing

Cone roller
bearing

[D] Installation of differential drive gear

(1) Apply sealant on the entire threaded part of bolt
Specified sealant:
Mitsubishi Pure sealant part No. MD997740 or equivalent

(2) Screw down it to the specified moment in the order indicated in the drawing
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Check and maintenance
1) Gearbox assembly
Assembly of rear lamp switch:
Check the conducting status of each end.
Item Conducting status
Press the switch Non-conducting
Loosen the switch Conducting

2) Input shaft
1. Input shaft
(1) The ex-circle of installation part in the rolling needle should be free from damage, abnormal wear
and burn.
(2) Check whether there is burn or wear of spline.

2. Needle bearing
(1) Check whether combined input shaft, bush and gear are smooth or whether there is any unusual
noise when they revolve
(2) Check whether instrument is deformed.
3. Synchronizer ring
(1) The tooth surface of synchronizer ring is free from damage or breakage.
(2) The inner surface of cone should be free from damage or wear, or the screw thread should not be
in fracture
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(3) Push the synchronizer ring to the gear and check clearance “A”. Replace it when clearance “A” is
below the limit value.
Limit value: 0.5mm

Gear
Synchronizer ring

4. Synchronizer gear bush and spline hub

(1) Ensure that combined synchronizer gear bush and spline hub can slide smoothly without block.

Synchronizing gear bush

Synchronizing hub

(2) The front and rear ends of inner surface of the gear bush should be free from damages.
Note: The synchronizer gear bush and spline hub should be replaced as a whole.
5. Synchronizer spring
The spring should be free from deformation or breakage, and its elasticity should not be attenuated.
6. Speedometer gear
(1) The tooth surface of spiral gear and synchronizer ring should be free from damage or wear
(2) Conical surface of synchronizer should be free of roughness, damage or wear.
(3) The inner surface and front and rear side of gear should be free from damage or wear.
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7. Synchronizer ring group

(1) The tooth surface of outer ring of synchronizer should be free from damage or breakage.
(2) The outer ring, inner ring and inner surface of cone of synchronizer should be free of damage or wear,
or the screw thread should not be in fracture.
(3) Push the outer ring of synchronizer to the gear and check clearance “A”. Replace it when clearance
“A” is below the limit value.
Limit value: 0.5mm

Gear

Synchronizer ring group

8. Lever gear ring

The inner and outer surfaces of gear ring should be free from damages.
3) Output shaft
1. Output shaft
Check the damage and wear state of spline.

2. Needle bearing
(1) Check whether combined input shaft, bush and gear are smooth or whether there is any unusual
noise when they revolve
(2) Check whether instrument is deformed.
3. Synchronizer ring group
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(1) The tooth surface of outer ring of synchronizer should be free from damage or breakage.
(2) The outer ring, inner ring and inner surface of cone of synchronizer should be free of damage or
wear, or the screw thread should not be in fracture.
(3) Push the synchronizer ring to the gear and check clearance “A”. Replace it when clearance “A” is
below the limit value.
Limit value: 0.5mm

Gear

Synchronizer
ring group

4 Synchronizer spring
The spring should be free from deformation or breakage, and its elasticity should not be attenuated.
5. Synchronizer gear bush and hub
(1) Ensure that combined the synchronizer gear bush and hub can slide smoothly without block.
(2) The front and rear ends of inner surface of the gear bush should be free from damages.
Note: The synchronizer gear bush and hub should be replaced as a whole.
6. Speedometer gear
(1) The tooth surface of spiral gear and synchronizer ring should be free from damage or wear
(2) Conical surface of synchronizer should be free of roughness, damage or wear.
(3) The inner surface and front and rear side of gear should be free from damage or wear.
4). Speedometer gear
(1) The tooth surface of spiral gear should be free from damage or wear.
(2) The inner surface and front and rear side of gear should be free from damage or wear.
5) Selector rod
6) Control shell
7) Clutch shell
8) Gearbox shell
9) Differential
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H330-H320

transmission JW5F18C

Daroupakhsh St.17th Km Karaj Makhsoos Road-TEHRAN-IRAN