Transmision Manual Mitsubishi l200 2.5 2011-2015

22C-14 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
Tool Number Name Use

MD998823 Installer adapter (48) Installation of rear output
shaft ball bearing
<V5MB1-J-ND2, NEZ,
PD2>
MD998830 Installer adapter (66) Installation of transfer

drive bearing <V5MB1-J-
ND2, NEZ, PD2>
MD998192 Counter shaft bearing Installation of transfer

puller drive bearing <V5MB1-J-
ND2, NEZ, PD2>
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001001925
1 3
35 ± 6 N·m
35 ± 6 N·m
AK500694AB
1. Spring pin 2. Transfer

3. Change shifter
MANUAL TRANSMISSION OVERHAUL <V5MB1> 22C-15
TRANSMISSION
44 ± 9 N·m 18 ± 3 N·m 22
34 ± 5 N·m 16
6 4
5
19
23
20 21
8 18 ± 5 N·m
18
17
16.5 ± 5.0 N·m
36 ± 7 N·m 37 ± 11 N·m
34 ± 6 N·m 7 37 ± 11 N·m
12 10
7
15
10
14 9
13 11 37 ± 11 N·m
18.5 ± 5.5 N·m
AK603025AH
4. Back-up lamp switch assembly 16. Wiring harness clamp bracket

5. Shift position switch assembly 17. Front bearing retainer
6. Clutch housing 18. Oil seal
7. Reverse restrict pin assembly 19. Shaft snap ring
8. Cover 20. Shaft snap ring
9. Wiring harness clamp bracket 21. Transmission case sub-assembly
10. Wiring harness clamp bracket 22. Intermediate plate with shaft sub-
11. Transfer adaptor sub-assembly assembly
12. Oil receiver pipe 23. Transmission magnet
13. Straight screw plug with head
14. Slotted spring pin
15. Reverse restrict pin assembly
TRANSMISSION
18.5 ± 5.5 N·m 33 ± 3 N·m

18.5 ± 5.5 N·m 24
26 25
29
26 27
30
28 27
28
32 35
19.5 ± 3.9 N·m
33
31
36
34
19.5 ± 3.9 N·m
39
38
37
46
44 43 47 41
40 42
50
45 48 49 AK603100AB
24. Control shaft assembly 39. Slotted spring pin

25. Shift lever housing 40. Gear shift fork shaft No.3
26. Straight screw plug with head 41. Gear shift fork No.3
27. Compression spring 42. Roller A
28. Ball 43. Ball
29. Shaft snap ring 44. Shaft snap ring
30. Gear shift fork shaft No.2 45. Gear shift fork shaft No.4
31. Gear shift fork No.2 46. Ball
32. Roller A 47. Compression spring
33. Shaft snap ring 48. E ring
34. Gear shift fork shaft No.1 49. Reverse shift arm
35. Straight pin 50. Reverse shift fork
36. Roller A
37. Gear shift fork No.1
38. Shaft snap ring
TRANSMISSION
68
18 ± 5 N·m
71
64 63
62
69
66
61 60
70
67
65
18 ± 5 N·m
51
Apply gear oil to
all moving parts
53
before installation. 54
56 52
59 57 58
55 AK603036AB
51. Shaft snap ring 64. Shaft snap ring

52. Transmission hub sleeve No.3 65. Reverse idler gear
53. Gear spline piece No.5 66. Cylindrical roller bearing
54. Synchronizer outer race No.3 67. Counter shaft sub-assembly
55. Counter shaft gear No.5 68. Input shaft sub-assembly
56. Shaft snap ring 69. Output shaft sub-assembly
57. Synchromesh shifting key spring 70. Reverse shift arm bracket
No.3 71. Intermediate plate
58. Synchromesh shifting key spring
No.3 DISASSEMBLY
59. Synchromesh shifting key No.3 1. Remove the spring pin.
60. Needle roller bearing
61. 5th gear thrust washer
2. Remove the transfer and the gear change shifter.
62. Straight pin
63. Rear bearing output shaft retainer
TRANSMISSION
6. Remove the cover.
Shift position switch

Back-up lamp switch assembly
assembly AK403771AB
AK403767AC
3. Remove the shift position switch assembly and 7. Remove the flange bolt.
the back-up lamp switch assembly.
AK403772
AK403768
8. Remove the control shaft assembly.
4. Remove the clutch housing.
AK501350AB
AK403769
9. Remove the shift lever housing.
5. Remove the reverse restrict pin assembly (2
places).
AK403776
10.Remove the transfer adaptor sub-assembly and

AK403770
the wiring harness clamp bracket (3 places).
TRANSMISSION
AK403777 AK403773
11.Remove the oil receiver pipe. 15.Remove the wiring harness clamp bracket.
AK403779 AK403774
12.Remove the straight screw plug with head. 16.Remove the front bearing retainer.
AK403780AB AK403775AC
13.Remove the slotted spring pin. 17.Remove the oil seal.
AK403781 AK403782
14.Remove the reverse restrict pin assembly. 18.Remove the shaft snap ring.
TRANSMISSION
AK403783 AK403788AB
19.Remove the shaft snap ring. 23.Remove the compression spring (3 places).
AK403784 AK403789AB
20.Remove the transmission case sub-assembly. 24.Remove the ball (3 places).
AK500257 AK403792 AB
21.Remove the transmission magnet. 25.Remove the shaft snap ring of the gear shift fork
shaft No.2 and the washer based hexagon bolt of
the gearshift fork No.2.
AK403786AB
22.Remove the straight screw plug with head (3 AK500259

places).
26.Remove the gear shift fork shaft No.2.
TRANSMISSION
AK500260 AK500270
27.Remove the gear shift fork No.2. 31.Remove the straight pin of the gear shift fork shaft
No.1.
AK500261
AK500264
28.Remove the roller A.
AK500262AB
AK500265
29.Remove the shaft snap ring of the gear shift fork
shaft No.1 and the washer based hexagon bolt of 33.Remove the gear shift fork No.1.
the gear shift fork No.1.
AK500266AB
AK500263
34.Remove the shaft snap ring of the gear shift fork
30.Remove the gear shift fork shaft No.1. shaft No.3.
TRANSMISSION
38.Remove the ball.
AK403790AB
AK500453AB
35.Remove the slotted spring pin of the gear shift
fork No.3 assembly. 39.Remove the shaft snap ring of the gear shift fork
shaft No.4.
Gear shift fork shaft No.3
Gear shift fork No.3
AK500461AB
AK403802
36.Remove the gear shift fork No.3 assembly and
the gear shift fork shaft No.3.
AK403803
AK403800
40.Remove the gear shift fork shaft No.4.
AK403804
AK403801
41.Remove the ball.
TRANSMISSION
AK403805 AK403807
42.Remove the compression spring. 46.Remove the shaft snap ring.
Transmission
hub sleeve No.3
AK403806 AK500269AB
43.Remove the reverse shift fork and the reverse 47.Remove the transmission hub sleeve No.3.
shift arm.
MB990811 MB990803
AK403982 AC
AK500455
48.Use special tools to remove the gear spline piece
44.Remove the E ring. No.5.
x Steering wheel puller (MB990803)
Reverse shift arm x Side bearing puller cup (MB990811)
Reverse shift fork
AK500454AB
45.Remove the reverse shift arm. AK403983
49.Remove the synchronizer outer race No.3.

TRANSMISSION
AK403984 AK500458
50.Remove the counter shaft gear No.5. 54.Remove the synchromesh shifting key No.3.
AK500526 AK500459
51.Remove the shaft snap ring. 55.Remove the needle roller bearing.
AK500456 AK403985
52.Remove the synchromesh shifting key spring 56.Remove the 5th gear thrust washer.
No.3.
AK403785AB
AK500457
57.Remove the straight pin.
53.Remove the synchromesh shifting key spring
No.3.
TRANSMISSION
AK403986 AK403991
58.Remove the rear bearing output shaft retainer. 62.Remove the input shaft sub-assembly.
AK403987 AK403992
59.Remove the snap ring. 63.Remove the output shaft sub-assembly.

Reverse idler gear Reverse idler
sub-assembly gear shaft
AK403989 AB AK403993
60.Remove the reverse idler gear shaft and reverse 64.Remove the reverse shift arm bracket.
idler gear sub-assembly.
REASSEMBLY
AK403990
AK403993
61.Remove the counter gear sub-assembly and
cylindrical roller bearing. 1. Set the reverse shift arm bracket to the
intermediate plate and tighten the bolts to the
specified torque of 18 r 5 Nm.
TRANSMISSION
5. Install the reverse idler gear shaft and reverse

idler gear sub-assembly to the intermediate plate.
AK403992
2. Install the output shaft sub-assembly to the

AK403987
intermediate plate.
6. Install the shaft snap ring to the radial ball bearing
of the input shaft sub-assembly.
AK403991
3. Install the input shaft sub-assembly to the output

AK403986AB
shaft sub-assembly.
7. Set the rear bearing output shaft retainer and
Cylindrical roller
bearing tighten the bolts to the specified torque of 18 r 5
Nm.
NOTE: Fit the rear bearing output shaft retainer
Counter gear
sub-assembly into the reverse idler gear shaft slot.
AK403990AB
4. Insert the counter gear sub-assembly into the

intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.
AK403785AB
Reverse idler gear Reverse idler
sub-assembly gear shaft 8. Install the straight pin.
AK403989 AB
TRANSMISSION
Installtion 5th gear

direction thrust
washer
Penetration
groove
Straight pin
AK501229AB AK500457
12.Install the synchromesh shifting key spring No.3

to the counter shaft gear No.5.
AK403985
9. Check the installation direction of 5th gear thrust

AK500456
washer, and install it.
13.Install the synchromesh shifting key spring No.3
to the counter shaft gear No.5.
AK500459
10.Install the needle roller bearing.

AK500526
14.Install the shaft snap ring to the counter shaft gear

No.5.
AK500458
11.Install the synchromesh shifting key No.3 to the

counter shaft gear No.5.
AK403984
15.Install the counter shaft gear No.5.

TRANSMISSION
CAUTION 18.Check the installation direction of the

Fit the protrusions of synchronizer ring between transmission hub sleeve No.3 and install it on the
keys. counter shaft.
NOTE: After installation, check the sleeve operate
smoothly.
Protrusion
Key
AK403983AB
16.Install the synchronizer outer race No.3.

AK403807
19.Select a snap ring to secure the thrust clearance.

Install it into the counter gear sub-assembly.
Standard value: 0 0.1 mm
Reverse shift arm

Reverse shift fork
MD998827 MD998812
MD998813
AK404049AB
17.Using special tools to install the gear spline piece

No.5.
x Installer cap (MD998812)
x Installer-100 (MD998813) AK500454AB
x Installer adapter (56) (MD998827)

20.Install the reverse shift arm to the reverse shift
fork.
Installation
direction
AK500610 AB
AK500455
Transmission 21.Install the E ring.

hub sleeve No.3
AK500269AB
TRANSMISSION
CAUTION
Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc-
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
AK403806
22.Install the reverse shift fork and the reverse shift

arm to the intermediate plate.
AK403803
AK403805
23.Install the compression spring into the reverse

shift fork.
AK403802
25.Install the gear shift fork shaft No.4 into the

intermediate plate and the reverse shift fork.
AK403804
24.Install the ball into the reverse shift fork.
AK500453AB
26.Install the shaft snap ring into the gear shift fork
shaft No.4.
AK403801
TRANSMISSION
27.Install the ball into the reverse shift fork. 31.Install the snap ring to the gear shift fork shaft
No.3.
AK403800
AK500265
28.Install the roller A to the intermediate plate.
32.Install the gear shift fork No.1 on the reverse gear.
Gear shift fork shaft No.3
Gear shift fork No.3
AK500461AB
AK500264
29.Install the gear shift fork No.3 assembly on the
transmission hub sleeve No.3 and hold it. Insert 33.Install the roller A to the intermediate plate.
the gear shift fork shaft No.3 into the gear shift
fork No.3 assembly, the intermediate plate and
the reverse shift fork.
AK500270
34.Install the straight pin to the gear shift fork shaft

AK500267
No.1.
30.Install the slotted spring pin to the gear shift fork

No.3 assembly.
AK500263
35.Install the gear shift fork shaft No.1 to the

AK500266AB
intermediate plate and the gear shift fork No.1.
TRANSMISSION
AK500262AB AK403792 AB
36.Install the shaft snap ring to the gear shift fork 40.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5 r 3.9 Nm. bolt to the specified torque of 19.5 r 3.9 Nm.
AK500261 AK403789AB
37.Install the roller A to the intermediate plate. 41.Install the ball to the intermediate plate (3 places).
AK500260 AK403788AB
38.Install the gear shift fork No.2 on the transmission 42.Install the compression spring to the intermediate
hub sleeve No.2. plate (3 places).
AK500259 AK403786AB
39.Install the gear shift fork shaft No.2 to the 43.Apply sealant to the threads. Tighten the straight
intermediate plate, the gear shift fork No.1 and the screw plug with head to the specified torque of
gear shift fork No.2. 18.5 r 5.5 Nm (3 places).
TRANSMISSION
Special sealant: Mitsubishi genuine sealant

Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403783
48.Install the snap ring to the cylindrical roller

bearing.
AK500257
44.Install the transmission magnet to the

intermediate plate.
AK403782
49.Install the snap ring to the radial ball bearing.
AK500527AB MB990938
45.Completely degrease the FIPG-applied surface

so that water and oil including the old sealant
cannot adhere to the surface coated with the
sealant.
Never touch the degreased surface by hand. MB990929
46.Apply a 1.2 mm diameter bead of liquid gasket to
AK600320 AB
the intermediate plate mounting surface of the
transmission case sub-assembly.
50.Using special tool install the oil seal to the front
Special sealant: Mitsubishi genuine sealant bearing retainer.
Part No. MD974421 or equivalent x Installer adapter (MB990929)
x Installer bar (MB990938)
AK500560
AK403775AB
47.Install the transmission case sub-assembly to the
intermediate plate.
TRANSMISSION
51.Completely degrease the FIPG-applied surface 54.Install the wiring harness clamp bracket to the
so that water and oil including the old sealant transmission case sub-assembly and tighten the
cannot adhere to the surface coated with the bolt to the specified torque of 18 r 3 Nm.
sealant.
Never touch the degreased surface by hand.
the transmission case sub-assembly mounting
surface of the front bearing retainer sub-assembly
with seal.
AK403781
CAUTION
Do not damage to the oil seal lip during the 55.Install the reverse restrict pin assembly to the
installation. transfer adaptor sub-assembly.
AK403774 AK403780AB
53.Apply sealant to the threads. Install the front 56.Install the slotted spring pin to the reverse restrict
bearing retainer to the transmission case sub- pin assembly.
assembly and tighten the bolts to the specified
torque of 16.5 r 5.0 Nm.
AK403779
57.Apply sealant to the threads. Tighten the straight

screw plug with head to the specified torque of
18.5 r 5.5 Nm.
AK403773
TRANSMISSION
CAUTION
When installing the shift lever housing, securely
fit the shift lever housing into the head of the fork
shaft.
Transfer
adaptor
AK403777
58.Install the oil receiver pipe into the transfer

adaptor sub-assembly.
AK500256AB
AK500527AB
59.Completely degrease the FIPG-applied surface AK501350AB

cannot adhere to the surface coated with the 62. Install the shift lever housing to the transfer
sealant. adaptor sub-assembly.
the intermediate plate mounting surface of the
transfer adaptor sub-assembly.
AK403772
63.Install the control shaft assembly to the transfer

adaptor sub-assembly and the shift lever housing.
AK403776
61.Install the transfer adaptor sub-assembly. Install

the wiring harness clamp bracket (3 places) and
tighten the bolts to the specified torque of 37 r 11
Nm.
AK403771AB
64.Tighten the flange bolt to the specified torque of

33 r 3 Nm.
TRANSMISSION
68.Tighten the reverse restrict pin assembly to the

specified torque of 37 r 11 Nm (2 places).
CAUTION
Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.
AK500528AB
65.Completely degrease the FIPG-applied surface

cannot adhere to the surface coated with the
sealant.
66.Apply a 1.2 mm diameter bead of liquid gasket to AK500460AB
the case mounting surface of the transfer adaptor
sub-assembly. 69.Install the clutch housing into the transmission
Special sealant: Mitsubishi genuine sealant case sub-assembly. Tighten the bolt with washer
Part No. MD974421 or equivalent to the specified torque of 36 r 7 Nm (7 places).
Tighten the bolt with washer (with sealant) to the
specified torque of 34 r 6 Nm (2 places).
AK403770
67.Install the cover to the transfer adaptor sub-

assembly and tighten the bolt with washer to the
Shift position switch
specified torque of 18 r 5 Nm. Back-up lamp switch assembly
assembly
AK403767AC
CAUTION
Install the reverse restrict pin assembly carefully 70.Tighten the shift position switch assembly to the
in the accordance with the identification color as specified torque of 34 r 5 Nm.
shown in the illustration. 71.Tighten the back-up lamp switch assembly to the
specified torque of 44 r 9 Nm.
Identification Identification 72.Install the transfer and the gear change shifter.
color: black color: white Tighten the bolts to the specified torque of 35 r 6
Nm.
73.Install the spring pin.
AK403769 AB
TRANSMISSION
INSPECTION 2. Check that the sleeve is free from damage at its

M1222001100899 inside splines ends.
BACK-UP LAMP SWITCH
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
Standard value: 0.52 1.88 mm
Limit: 0.52 mm
NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the shaft
and gear, and check that it rotates smoothly
without noise or play.
AK500505 2. Check the needle roller bearing cage for
Check for the continuity between the connector ter- deformation.
minals.
COUNTER SHAFT GEAR No.5
Switch Connector Continuity
THRUST CLEARANCE
condition terminals
Inspect the thrust clearance of counter shaft gear
Switch end 12 Conductive No.5.
pressed
Switch end 12 Open Limit: 0.35 mm
released
RADIAL CLEARANCE
SHIFT POSITION SWITCH
1. Fix the output shaft in a vice.
2. Inspect the radial clearance of counter shaft gear
No.5.
Limit: 0.068 mm
INSIDE DIAMETER
AK501632
Check for the continuity between the connector ter-

minals.
condition terminals
Switch end 12 Open
pressed AK404027
Switch end 12 Conductive
Using the cylinder gauge, check the inside diameter
released
of the counter shaft gear No.5.
SYNCHRONIZER SLEEVE AND HUB Standard value: 38.015 38.040 mm
1. Combine the synchronizer sleeve and hub, and Limit: 38.040 mm
check that they slide smoothly.
INPUT SHAFT
INPUT SHAFT
M1222001600526
Apply gear oil to

all moving parts
before installation.
5
2
4
3
AK500516 AB
Disassembly steps REASSEMBLY SERVICE POINTS

>>B<< 1. Shaft snap ring >>A<< RADIAL BALL BEARING INSTALLATION
<<A>> >>A<< 2. Radial ball bearing
3. Synchronizer ring No. 2
5. Input shaft sub-assembly
Installation
direction
DISASSEMBLY SERVICE POINT
<<A>> RADIAL BALL BEARING REMOVAL
AK500606AB
MD998801
1. Check the installation direction of the radial ball
bearing, and put it on the input shaft.
CAUTION
AK403995AC Never push on the sealing area when installing.
Using special tool Bearing remover (MD998801),
MD998812
support the radial ball bearing and remove it.
MD998814
MD998823
AK403996 AB
INPUT SHAFT
2. Using special tools to install the radial ball SYNCHRONIZER RING No.2
bearing.
x Installer-200 (MD998814)
>>B<<SNAP RING INSTALLATION
AK500676AB
1. Check the clutch gear on the synchronizer ring for

damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
AK403997 ridges are intact.
1. Select a snap ring to secure the standard

clearance between the radial ball bearing and the
input shaft sub-assembly.
2. Install the selected snap ring.
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
3. After applying oil to the taper portion on gear,

press and fit the synchronizer ring by hand.
Confirm the synchronizer ring cannot be rotated.
AK500677AB
1. Check the helical gear teeth and clutch gear teeth

of each input shaft sub-assembly for damage and
excessive wear.
AK403999
2. Check the synchronizer cone surface of each
input shaft sub-assembly for roughness, damage, 4. Using the thickness gauge, check the clearance
and excessive wear. between the synchronizer ring and the 4th gear.
3. Check the inside surface and front and back sides Standard value: 0.70 1.70 mm
of each input shaft sub-assembly for damage and Minimum limit: 0.70 mm
excessive wear.
1. Combine the needle roller bearing with the input
shaft, and check that it rotates smoothly without
noise or play.
OUTPUT SHAFT
2. Check the needle roller bearing cage for

deformation.
OUTPUT SHAFT
M1222002100160
Apply gear oil to

23
all moving parts
22
19
21
20
18
15
17 16
26
25 6
24
12 1
2
13 5 3
7
8
4
10 9
14 11
AK500517AB
Disassembly steps Disassembly steps (Continued)

>>G<< 1. Shaft snap ring <<C>> >>C<< 13. Compression spring
<<A>> >>F<< 2. 5th gear <<C>> >>C<< 14. Transmission clutch No. 1 hub
<> >>E<< 3. Radial ball bearing <<C>> >>C<< 15. Synchronizer ring set No. 1
<> >>E<< 4. 1st gear sub-assembly <<C>> >>C<< 16. 2nd gear sub-assembly
5. 1st gear thrust washer 17. Needle roller bearing
6. Straight pin >>B<< 18. Shaft snap ring
7. Needle roller bearing <<D>> >>A<< 19. Transmission hub sleeve No. 2
8. D spacer <<D>> >>A<< 20. Synchronizer shifting key No. 2
9. Synchronizer ring set No. 1 <<D>> >>A<< 21. Compression spring
>>D<< 10. Shaft snap ring <<D>> >>A<< 22. Transmission clutch No. 2 hub
<<C>> >>C<< 11. Reverse gear <<D>> >>A<< 23. Synchronizer ring set No. 2
<<C>> >>C<< 12. Synchronizer shifting key No. 1 <<D>> >>A<< 24. 3rd gear sub-assembly
OUTPUT SHAFT
Disassembly steps (Continued) DISASSEMBLY SERVICE POINTS

<<A>> 5TH GEAR REMOVAL
26. Output shaft
INSPECTION BEFORE DISASSEMBLY

THRUST CLEARANCE FOR EACH GEAR
2nd 1st MD998801
AK404004AB

support the 5th gear and remove it.
3rd
AK404000AB
<> RADIAL BALL BEARING / 1ST GEAR SUB-
Inspect the thrust clearance of each gear.
ASSEMBLY REMOVAL
Gear Standard value mm Limit mm
1st 0.20 0.45 0.45
2nd 0.10 0.25 0.25
3rd 0.10 0.25 0.25 MD998801
RADIAL CLEARANCE FOR EACH GEAR
AK404006AB

support the 1st gear sub-assembly and remove the
radial ball bearing and the 1st gear sub-assembly.
<<C>> REVERSE GEAR / SYNCHRONIZER

AK404001AB SHIFTING KEY No. 1 / COMPRESSION SPRING /
TRANSMISSION CLUTCH No. 1 HUB /
1. Fix the output shaft by a vice. SYNCHRONIZER RING SET No. 1 / 2ND GEAR
2. Inspect the radial clearance of each gear. SUB-ASSEMBLY REMOVAL
1st 0.020 0.073 0.073
2nd 0.015 0.068 0.068
3rd 0.015 0.068 0.068 MD998801
AK404014 AB
OUTPUT SHAFT

support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No. 1, com- MD998812
pression spring, the transmission clutch No. 1 hub,
synchronizer ring set No. 1 and the 2nd gear sub- MD998813
assembly.
MD998823
<<D>> TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 /
COMPRESSION SPRING / TRANSMISSION HUB AK404029AC
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY REMOVAL 2. Using special tools to install the transmission
clutch hub No. 2, synchronizer shifting key No. 2,
compression spring, the transmission hub sleeve
No. 2, synchronizer ring set No. 2 and the 3rd
MD998801 gear sub-assembly.
AK404020AB

support the 3rd gear sub-assembly and remove the
transmission clutch hub No. 2, synchronizer shifting
key No. 2, compression spring, the transmission hub
sleeve No. 2, synchronizer ring set and the 3rd gear
sub-assembly.
AK500508
REASSEMBLY SERVICE POINTS 3. Confirm the thrust clearance of the 3rd gear sub-
>>A<< TRANSMISSION CLUTCH HUB No. 2 / assembly is within the standard value.
SYNCHRONIZER SHIFTING KEY No. 2 / COM- Standard value: 0.10 0.25 mm
PRESSION SPRING / TRANSMISSION HUB Limit: 0.25 mm
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY INSTALLATION
>>B<< SHAFT SNAP RING INSTALLATION
Installation
direction
AK500607AB
AK404019
1. Check the installation direction of the transmission 1. Select a shaft snap ring to secure the standard
clutch hub No. 2, and put it on the output shaft. clearance between the transmission clutch hub
No.2 and the output shaft.
2. Install the selected snap ring.
OUTPUT SHAFT
>>C<< REVERSE GEAR / SYNCHRONIZER

SHIFTING KEY No. 1 / COMPRESSION SPRING / >>D<< SHAFT SNAP RING INSTALLATION
TRANSMISSION CLUTCH No. 1 HUB /
SYNCHRONIZER RING SET No. 1 / 2ND GEAR
SUB-ASSEMBLY INSTALLATION
Installation
direction
AK404031
1. Select a snap ring to secure the standard

clearance between the transmission clutch No. 1
AK500608 AB
hub and the output shaft.
1. Check the installation direction of the reverse Standard value: 0 0.1 mm
gear, and put it on the output shaft. 2. Install the selected snap ring.
MD998812
>>E<< RADIAL BALL BEARING / 1ST GEAR SUB-
MD998813
ASSEMBLY INSTALLATION
MD998814
MD998823 Installation
direction
AK404030AC
2. Using special tools to install the reverse gear,

synchronizer shifting key No. 1, compression
spring, the transmission clutch No. 1 hub, AK500606AB
synchronizer ring set No. 1 and the 2nd gear sub-

1. Check the installation direction of the radial ball
assembly.
bearing, and put it on the output shaft.
x Installer-200 (MD998814) CAUTION
x Installer adapter (48) (MD998823) Never push on the sealing area when installing.
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
Limit: 0.25 mm x Installer-200 (MD998814)
OUTPUT SHAFT
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
M1222002300261
Installation SYNCHRONIZER RING
direction
AK500609AB
1. Check the installation direction of the 5th gear,

and put it on the output shaft.
AK500672AB
MD998812
CAUTION
MD998814
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
MD998823 1. Check to ensure that the clutch gear tooth surface
and cone surface are not damaged and broken.
AK404039AB
2. Using special tools to install the 5th gear.

AK500603
2. After applying oil to the taper portion on each

gear, press and fit the synchronizer ring by hand.
OUTPUT SHAFT

1. Combine the needle roller bearing with the output
shaft and gear, and check that it rotates smoothly
without noise or play.
2. Check the needle roller bearing cage for
deformation.
SYNCHRONIZER KEYS
AK404022
3. Using the thickness gauge, check the clearance

1st 0.65 1.75 0.65
2nd 0.65 1.75 0.65
3rd 0.65 1.75 0.65
AK500680AB
HUB SLEEVE AND SHIFTFORK
Check the synchronizer hub contact surfaces of each
synchronizer key for damage and excessive wear.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404023
CAUTION
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
Using the thickness gauge, check the clearance
between the sleeve and the shift fork.
A B C
sleeve Standard Limit mm
AK404024AB
value mm
No.1 0.15 0.41 0.41 1. Using the micrometer, check the outer shape of
No.2 0.15 0.35 0.35 the needle roller bearing race.
No.3 0.26 0.84 0.84 Measurement Standard value mm Limit mm
part
SYNCHRONIZER SLEEVE AND HUB A 37.984 38.000 37.984

1. Combine the synchronizer sleeve and hub, and B 46.984 47.000 46.984
check that they slide smoothly. C 38.979 38.995 38.979
2. Check that the sleeve is free from damage at its
inside splines ends.
COUNTERSHAFT
3. Using the dial gauge and V-block, check the

output shaft runout.
Limit: 0.015 mm Max
AK404025
2. Using the slide gauge, check the flange thickness.

Minimum limit: 4.800 mm
AK404027
4. Using the cylinder gauge, check the inside

diameter of each gear.
1st 46.015 46.040 46.040
2nd 53.015 53.040 53.040
3rd 44.015 44.040 44.040
AK404026
COUNTERSHAFT
M1222007300158
Apply gear oil to

all moving parts
AK500518AB
COUNTERSHAFT
Disassembly steps 2. Using special tools to install the cylindrical roller

>>B<< 1. Shaft snap ring bearing.
<<A>> >>A<< 2. Cylindrical roller bearing x Installer cap (MD998812)
3. Counter gear x Installer-100 (MD998813)
<<A>> CYLINDRICAL ROLLER BEARING >>B<< SHAFT SNAP RING INSTALLATION
REMOVAL
MD998801
AK404042
AK404043 AB
Using special tool Bearing remover (MD998801), 1. Select a snap ring to secure clearance of standard
support the cylindrical roller bearing and remove it. value between the cylinder roller bearing and
counter shaft.
REASSEMBLY SERVICE POINTS Standard value: 0 0.1 mm
>>A<< CYLINDRICAL ROLLER BEARING 2. Install the selected snap ring.
INSTALLATION
INSPECTION
M1222007400025
COUNTER GEAR
Installation
direction
D E
AK500644 AB
1. Check the installation direction of the cylindrical

AK404041AB
roller bearing, and put it on the counter shaft.
Using the micrometer, check the outer shape of the
CAUTION needle roller bearing race.
Never push the sealing area at the press fit.
Measurement Standard value Limit mm
MD998812
part mm
D 34.000 34.105 34.000
MD998813 E 29.984 30.000 29.984
MD998817
AK404046AB
REVERSE IDLER GEAR
REVERSE IDLER GEAR

M1222012500233
Apply gear oil to

all moving parts
1
AK500519AB
Disassembly steps INSPECTION

1. Reverse idler gear sub-assembly M1222012400076
2. Reverse idler gear shaft REVERSE IDLER GEAR SUB-ASSEMBLY
AK500525AB
Check the radial clearance of the reverse idler gear.

Limit: 0.082 mm
TRANSFER
TRANSFER
M1222008800327
<V5MB1-J-NEG, JER>
35 ± 6 N·m 34 ± 5 N·m
3
6
35 ± 6 N·m 8
7 4
9
5
32 ± 2 N·m
12
34 ± 5 N·m
13
1
16
19 ± 3 N·m
15
14
22 ± 2 N·m
Apply gear oil to

all moving parts
AKA00412 AB

1. 4WD operation detection switch >>T<< 8. Spring
2. Gasket 9. Steel ball
3. High range/Low range detection >>U<< 10. Plug
switch 11. Gasket
4. Gasket 12. Vehicle speed sensor
5. Steel ball 13. Speedometer sleeve clamp
>>U<< 6. Plug >>S<< 14. Speedometer driven gear sleeve
>>U<< 7. Plug assembly
TRANSFER
Apply gear oil to 35 ± 6 N·m

all moving parts
23
28
29
30 24
25
26
27
22
16
19 20 21
35 ± 6 N·m 15 32 ± 2 N·m
35 ± 6 N·m
18
17
35 ± 6 N·m
AK900792AB

15. Bracket 23. Connector bracket
>>R<< 16. Transfer case plate 24. Harness bracket
>>Q<< 17. Countershaft gear >>O<< 25. Rear cover
>>P<< 18. Spacer >>N<< 26. Oil cover
19. Sealing cap >>M<< 27. Spacer
20. Needle bearing 28. Dust seal cover
>>U<< 21. Plug >>L<< 29. Oil seal
>>U<< 22. Plug >>K<< 30. Spring pin
TRANSFER
50
49
47
Apply gear oil to
48 all moving parts
55 49
52
35 ± 6 N·m
38
34 35
54
53 45
31 36
42 44
51
43
41
40
39
46 37
32
33 58
56 57
AK503417AF

<<A>> >>J<< 31. H-L shift rail <> >>B<< 46. Front output shaft
32. H-L shift fork 47. 2-4WD shift fork
>>I<< 33. H-L clutch sleeve 48. Snap ring
34. Harness bracket 49. Spring retainer
35. Harness bracket 50. Return spring
36. Harness bracket 51. 2-4WD shift lug and shift rail
>>H<< 37. Chain cover assembly
38. Interlock plunger >>F<< 52. Spring pin
39. Wave spring 53. 2-4WD shift lug
>>D<< 40. Snap ring 54. Distance piece
>>C<< 41. H-L clutch hub 55. 2-4WD shift rail
42. Low speed gear 56. Dust seal guard
43. Needle bearing >>A<< 57. Oil seal
<> >>B<< 44. Rear output shaft 58. Transfer case
<> >>B<< 45. Chain
TRANSFER
<V5MB1-J-ND2, NEZ,PD2>
5 34 ± 5 N·m 26
34 ± 5 N·m
4 6
35 ± 6 N·m
34 ± 5 N·m
35 ± 6 N·m
12
2 34 ± 5 N·m
34 ± 5 N·m
7 31
9
35 ± 6 N·m
<V5MB1-J-PD2>
10
1 8 13 27
11 14
<V5MB1-J-
ND2,NEZ>
32
19 ± 3 N·m
3
28
29
33 30 19 18
25 17 25 ± 4 N·m
20 24 15
16 32 ± 2 N·m
23 Apply gear oil to

22 all moving parts
21
35 ± 6 N·m AK900860AC

>>V<< 1. Center differential lock detection 17. Vehicle speed sensor
switch 18. Speedometer clamp
>>V<< 2. 2WD/4WD detection switch >>S<< 19. Speedometer driven gear sleeve
3. Gasket assembly
>>V<< 4. Center differential lock operation 20. Bracket
detection switch >>R<< 21. Transfer case plate
>>V<< 5. 4WD operation detection switch >>Q<< 22. Countershaft gear
>>V<< 6. High range/Low range detection >>P<< 23. Spacer
switch 24. Sealing cap
7. Gasket 25. Needle bearing
8. Steel ball 26. Connector bracket
>>U<< 9. Plug 27. Harness bracket
>>T<< 10. Spring >>O<< 28. Rear cover
11. Steel ball 29. Oil cover
12. 4LLc operation detection switch >>M<< 30. Spacer
13. Plug 31. Dust seal cover
14. Gasket >>L<< 32. Oil seal
15. Plug >>K<< 33. Spring pin
16. Gasket
TRANSFER
52
Apply gear oil to
all moving parts
51
53
43
57 60
55 45 39
59 41 35 ± 6 N·m
47 44
58
38
56 34
46 37
61
54 63
50
62
64
40
65
48
35
42
49
36
AK801157AE

<<A>> >>J<< 34. H-L shift rail 51. E-ring
35. H-L shift fork 52. Spring seat
>>I<< 36. H-L clutch sleeve 53. Spring
37. Harness bracket 54. 2-4WD shift lug and shift rail
38. Harness bracket assembly
39. Harness bracket >>F<< 55. Spring pin
>>H<< 40. Chain cover 56. 2-4WD shift lug
41. Interlock plunger 57. Spring seat
42. Wave spring 58. Spring
43. Rear output shaft 59. 2-4WD shift rail
44. Needle bearing 60. 2-4WD shift fork
45. Needle bearing 61. 2-4WD synchronizer sleeve
46. Center differential case 62. Spacer
<<C>> >>G<< 47. 2-4WD synchronizer 63. Steel ball
<<C>> >>G<< 48. Chain >>E<< 64. Snap ring
<<C>> >>G<< 49. Front output shaft 65. Differential lock hub
50. Needle bearing
TRANSFER
70
Apply gear oil to
all moving parts
71
20 ± 2 N·m
9.0 ± 1.0 N·m
72
69
68 75
67 74
66
73 AK503403AJ
Disassembly steps 1. Fix the H-L shift rail at the high position.
>>D<< 66. Snap ring 2. Shift the 2-4WD shift rail at the 4WD position.
>>C<< 67. H-L clutch hub
68. Low speed gear
NOTE: If the 2-4WD shift rail is at the 2WD posi-
69. Needle bearing tion, the chain cover cannot be removed because
70. Rear bearing retainer interlock is actuated.
71. Transfer drive shaft
72. Oil pool cover <> REAR OUTPUT SHAFT / CHAIN/FRONT
73. Dust seal guard OUTPUT SHAFT REMOVAL
>>A<< 74. Oil seal
75. Transfer case
DISASSEMBLY SERVICE POINTS

<<A>> H-L SHIFT RAIL REMOVAL
AK500492
Remove the rear output shaft, chain and front output

shaft as a set.
2-4WD shift rail
AK503405 AB
TRANSFER
<<C>> 2-4WD SYNCHRONIZER / CHAIN/FRONT >>B<< FRONT OUTPUT SHAFT / CHAIN / REAR
OUTPUT SHAFT REMOVAL OUTPUT SHAFT INSTALLATION
AK101119 AK500492
Remove the 2-4WD synchronizer, chain and front 1. Engage the chain precisely with the sprocket of
output shaft as a set. the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch
ADJUSTMENT BEFORE REASSEMBLY sleeve. While passing them beside the 2-4WD
Spacer selection for adjustment of counter shaft end shift rail, install the front output shaft, and chain
play. (Refer to ADJUSTMENT OF TRANSFER - and rear output shaft.
SPACER SELECTION FOR ADJUSTMENT OF
COUNTER SHAFT END PLAY P.22C-59 >>C<< H-L CLUTCH HUB INSTALLATION
REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION
Transfer front side Installation

direction
MB990931 MB990938
AK503408 AB
Check that the H-L clutch hub is in the correct direc-

Transfer case
tion for installation.
AK403501 AC
>>D<< SNAP RING INSTALLATION

1. Use special tools to install the oil seal.
x Installer adapter (MB990931)
2. Apply the specified grease to the lip of oil seal.
Specified lubricant: Mitsubishi Part No.
0101011 or equivalent
AK500493
1. Install the thickest snap ring that can be fitted in

the snap ring groove of the rear output shaft.
2. Make sure that the H-L clutch hub end play meets
the standard value.
TRANSFER
>>E<< SNAP RING INSTALLATION
AK101124
AK503398
3. Place the chain in tight mesh with the 2-4WD
1. Install the thickest snap ring that can be fitted in synchronizer and front output shaft sprockets.
the snap ring groove of the transfer drive shaft. 4. With both sprockets spaced the farthest apart,
2. Make sure that the differential lock hub end play install them on the transfer case simultaneously.
meets the standard value.
Standard value: 0 0.08 mm >>H<< CHAIN COVER INSTALLATION
CAUTION
>>F<< SPRING PIN INSTALLATION Squeeze the sealant out evenly to apply it in
an unbroken, non-excessive quantity.
2 mm Diameter
AK503410
AK403508AB
1. Align the e2-4WD shift lug with the 2-4WD shift
rail spring pin hole. 1. Completely degrease the FIPG-applied surface so
2. Hammer in the spring valve so that the spring pin that water and oil including the old sealant cannot
slit matches the center of the shift rail shaft. adhere to the surface coated with the sealant.
>>G<< 2-4WD SYNCHRONIZER/CHAIN/FRONT 2. Apply sealant to the chain cover, and then install
OUTPUT SHAFT INSTALLATION the chain cover.
Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent
>>I<< H-L CLUTCH SLEEVE INSTALLATION
Identification groove
AK101123
1. Make a white paint mark on the deep groove Installation

direction
portions (three places) of the 2-4WD
synchronizer.
2. Make a white paint mark on the portions (three AK500678AB
places) of the 2-4WD synchronizer sleeve splines.

TRANSFER
Check that the H-L clutch sleeve is in the correct 1. Align the spring pin holes on the shift rail with the
direction for installation. shift fork. Then tap in the spring pin so that the slit
of the spring pin is facing the shaft center of the
>>J<< H-L SHIFT RAIL INSTALLATION shift rail.
>>L<< OIL SEAL INSTALLATION

<V5MB1-J-NEG, JER>
MB990938
MB990932
H-L shift rail
2-4WD shift rail
Interlock plunger
H-L shift rail
AK403510AQ
<V5MB1-J-ND2, NEZ, PD2>
MB990938
MB990929
2-4WD shift rail

AK503411AB
1. Tilt the transfer case with the 2-4WD shift rail AK403510AR
downward as shown in the illustration.

1. Use special tools to install the oil seal.
2. Move the 2-4WD shift rail in the direction of the
x Installer adapter (MB990932) <V5MB1-J-NEG,
arrow fully.
JER>
3. After making sure that the plunger is not exposed x Installer adapter (MB990929) <V5MB1-J-ND2,
out of the H-L shift rail hole in the transfer case, NEZ, PD2>
install the H-L shift rail. x Installer bar (MB990938)
2. Apply the specified grease to the lip of oil seal.
>>K<< SPRING PIN INSTALLATION
AK503412
TRANSFER
>>M<< SPACER INSTALLATION 2. Subtract A from B and let the answer be C. Select
a spacer so that the subtracted value will be the
<V5MB1-J-NEG, JER>
A
Rear cover standard value shown below.
Standard value:
0 0.1 mm <V5MB1-J-NEG, JER>
0.025 0.150 mm <V5MB1-J-ND2, NEZ, PD2>
B
>>N<< OIL COVER INSTALLATION
Oil hole
Spacer
Oil cover
AK403729 AC
In case of <V5MB1-J-NEG, JER> type, install the oil

cover so that the oil hole shown in the illustration.
AK403504AJ
>>O<< REAR COVER INSTALLATION
<V5MB1-J-ND2, NEZ, PD2>
Rear cover CAUTION
A Squeeze the sealant out evenly to apply it in
2 mm
Diameter
AKX00172 AC
Spacer 1. Completely degrease the FIPG-applied surface so

that water and oil including the old sealant cannot
adhere to the surface coated with the sealant.
2. Apply the sealant to the chain cover.
AK503414AJ Specified sealant: Mitsubishi genuine seal-
1. Measure projection A of the rear output shaft
bearing and depth B of the second stage of the
rear cover. >>P<< SPACER INSTALLATION
Install the previously selected spacer (Refer to
ADJUSTMENT BEFORE ASSEMBLY).
TRANSFER
>>Q<< COUNTER SHAFT GEAR INSTALLATION >>S<< SPEEDOMETER DRIVEN GEAR SLEEVE
Notched selection
ASSEMBLY INSTALLATION
Mating marks
Counter shaft
Input gear AK503394AB

AK503942AB
1. Turn the input gear’s notched selection surface
toward the counter shaft mounting surface. then Match the mating marks to the number of teeth.
install the counter shaft.
>>T<< SPRING INSTALLATION
>>R<< TRANSFER CASE PLATE INSTALLATION
CAUTION
Squeeze the sealant out evenly to apply it in
2 mm Diameter
AK403513
Install the spring with its tapered end toward the ball.
>>U<< PLUG INSTALLATION

AK403617AC
1. Completely degrease the FIPG-applied surface so

that water and oil including the old sealant cannot
adhere to the surface coated with the sealant.
2. Apply the sealant to the transfer case plate.
Specified sealant: Mitsubishi genuine seal-
AK403514AB
CAUTION
The transfer case plate must be installed Apply the sealant to the threads.
smooth and straight to get a good seal. Specified sealant: 3M AAD Part No. 8672 or
3. Install the transfer case plate together with the equivalent
input gear and countershaft. NOTE: .
The new plug is precoated with sealant, so seal-
ant does not need to be applied.
TRANSFER
>>V<< DETECTION SWITCH INSTALLATION 1. Put solders (1.0 mm diameter, about 10 mm long)
V V V V
in the illustrated positions of the transfer case
A housing.
B 2. Install the counter shaft into the transfer case.
C 3. Install the transfer case plate and tighten the bolts
E to the specified torque of 35 r 6 Nm.
D 4. Remove the transfer case plate and the counter
1
2 shaft, and then take out crushed solders.
4 6 5 3 5. If the solders have not crushed, use thicker
F
solders (1.6 mm diameter, about 10 mm long) and
AK801184AB repeat steps 2 to 4.
Install with care. Do not make mistake when locating
each switch.
Detection switch name Connector
No./Color
A Center differential lock 1/Brown
detection switch
B 2WD/4WD detection switch 2/Black
C Center differential lock 4/Blown
operation detection switch AK305233
D 4WD operation detection switch 5/Black

6. Measure the thickness of the crushed solder with
E High range/Low range detection 3/white a micrometer and select a spacer that will provide
switch the standard value.
F 4LLc operation detection switch 6/white Spacer thickness: (T 0) to (T 0.15)
<V5MB1-J-PD2> T: The crushed solder thickness
ADJUSTMENT OF TRANSFER
M1222016700013
<Measurement using Plastigage>
SPACER SELECTION FOR ADJUST-
MENT OF COUNTER SHAFT END PLAY
<Measurement using a solder>
CAUTION
x f soft solder is not available, select the spacer
in accordance with Plastigage method.
x If the spacer appropriate for the standard
value cannot be selected using soft solder,
select the spacer in accordance with Plasti-
Plastigage
gage method. AK403499AC
1. Put plastigage (about 10 mm long) in the

illustrated positions of the transfer case housing.
2. Install the adjusting spacer having the minimum
thickness.
3. Install the counter shaft into the transfer case.
4. Install the transfer case plate and tighten the bolts
to the specified torque of 35 r 6 Nm.
Solder 5. Remove the transfer case plate and the counter
AK403499AB shaft, and then take out crushed solders.
6. If the Plastigages have not crushed, replace the
spacer with a thicker one and repeat steps 3 to 5.
TRANSFER

minals.
condition terminals
Switch end 12 Open
pressed
Plastigage released
Spacer AK402081 AB
4LLc OPERATION DETECTION SWITCH
7. Measure the width of the crushed Plastigage at its
widest part using a scale printed on the Plastigage
package.
INSPECTION
M1222008900153
4WD DETECTION SWITCH
4WD operation detection switch
AK503422

minals.
condition terminals
Switch end 1 Body earth Open
pressed
AK500505AB
Switch end 1 Body earth Conductive
Check for the continuity between the connector ter- released
minals.
Switch Connector Continuity DETECTION SWITCH
condition terminals
pressed
Switch end 12 Open
released
HIGH RANGE/LOW RANGE DETECTION SWITCH

High range/low range detection
switch
AK503422

minals.
condition terminals
Switch end 1 Body earth Open
pressed
AK500510AB
Switch end 1 Body earth Conductive
released
TRANSFER CASE PLATE
TRANSFER CASE PLATE

M1222009100086
Apply gear oil to 19 ± 3 N·m

all moving parts
1
5
4
AK500691AD
Disassembly steps Specified lubricant: Mitsubishi Part No.

>>C<< 1. Seal bolt 0101011 or equivalent
2. Bearing retainer 2. Use socket wrench to install the oil seal.
3. Transfer input gear
>>B<< 4. Oil seal
5. Baffle plate >>B<< OIL SEAL INSTALLATION
>>A<< 6. Oil seal
7. Transfer case plate MB990938
MB990933
>>A<< OIL SEAL INSTALLATION
socket wrench
AKX00216 AD
1. Apply specified grease to the lip of the oil seal.

AK500692 AB 2. Use special tools to install the oil seal.
1. Apply specified grease to the lip of the oil seal. x Installer adapter (MB990933)
TRANSFER INPUT GEAR
>>C<< SEAL BOLT INSTALLATION 1. Apply the specified sealant to the threads.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
AK403506 AB
TRANSFER INPUT GEAR

M1222009400139
Apply gear oil to

all moving parts
AK800993AB
Disassembly steps DISASSEMBLY SERVICE POINT

>>B<< 1. Snap ring <<A>> BALL BEARING REMOVAL
<<A>> >>A<< 2. Ball bearing
3. Transfer input gear
MD998801
AK601073 AC
COUNTERSHAFT
Use special tool, Bearing remover (MD998801),

remove the ball bearing. >>B<< SNAP RING INSTALLATION
Ball bearing
Standard value
>>A<< BALL BEARING INSTALLATION
Snap ring
MD998812
MD998826
AK500699AB

the snap ring groove of the transfer input gear.
AK703391 AB
2. Make sure that the transfer input gear bearing end
Use special tools to install the ball bearing. play meets the standard value.
x Installer cap (MD998812) Standard value: 0 0.06 mm
COUNTERSHAFT
M1222007300062
Apply gear oil to

all moving parts
AK500663 AB

<<A>> >>C<< 1. Ball bearing <> >>A<< 3. Roller bearing
>>B<< 2. Snap ring 4. Counter shaft gear
COUNTERSHAFT
DISASSEMBLY SERVICE POINTS 1. Use special tools to install the roller bearing.
<<A>> BALL BEARING REMOVAL x Installer cap (MD998812)
2. Install the spacer.
MD998801
>>B<< SNAP RING INSTALLATION
AKX00257 AC
Use special tool Remover (MD998801) to remove

the ball bearing.
AKX00260
<> ROLLER BEARING REMOVAL
1. Install the thickest snap ring that can be fitted into
MD998801
MD998368 the snap ring groove of the counter shaft gear.
2. Make sure that the counter shaft gear roller
bearing end play meets the standard value.
>>C<< BALL BEARING INSTALLATION
AKX00258 AC
Use special tools to remove the roller bearing. MD998812

x Remover (MD998801)
x Bearing installer (MD998368) MD998818

>>A<< ROLLER BEARING INSTALLATION
AKX00261AC
Use special tools to install the ball bearing.

MD998812 x Installer cap (MD998812)
MD998818 x Installer adapter (38) (MD998818)
AKX00259 AC
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>

M1222010900020
7
Apply gear oil to
all moving parts
9
8
6 10
5
4
3
9
2
AK503423AB

>>C<< 1. Snap ring >>A<< INNER SYNCHRONIZER RING INSTALLA-
2. 2-4WD Synchronizer hub TION
3. 2-4WD Synchronizer spring
>>B<< 4. Outer synchronizer ring
5. Synchronizer cone
>>A<< 6. Inner synchronizer ring
7. Drive sprocket
8. Bearing spacer
9. Needle bearing
10. Front side gear
AK503426AB
Apply oil the synchronizer ring cone surface before

installation.
>>B<<OUTER SYNCHRONIZER RING CAUTION

INSTALLATION When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
1. Check to ensure that the clutch gear tooth surface
and cone surface are not damaged and broken.
AK503427AB
Apply oil the synchronizer ring cone surface before

installation.
>>C<<SNAP RING INSTALLATION AK503424
2. After applying oil to the taper portion on each

gear, press and fit the synchronizer ring by hand.
Snap ring
AK101272AD
Select and install the snap ring which adjusts the 2-

4WD synchronizer hub end play to standard value.
AK503425
INSPECTION 3. Using the thickness gauge, check the clearance

M1222011000020
SYNCHRONIZER RING
Limit: 0.3 mm
AK500672AB
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>

M1222010600041
Apply gear oil to

all moving parts
4
6
4
3 3
2
3
69 ± 10 N·m 4
4
1
AK503428 AB
Disassembly steps REASSEMBLY SERVICE POINT

>>A<< 1. Center differential case A >>A<<CENTER DIFFERENTIAL CASE B INSTAL-
2. Dowel pin LATION
3. Differential pinion
4. Thrust washer
5. Pinion shaft
6. Center differential case B Dowel pin
Dowel pin
AK101274AD
Pay attention to the position of the dowel pins when

reassembling, and make sure that the match marks
on the outside circumference are in alignment.
H-L SHIFT FORK
H-L SHIFT FORK

M1222009700022
2
3
4
5
1
6
9.0 ± 2.0 N·m
AK500689AB
Disassembly steps REASSEMBLY SERVICE POINT

>>A<< 1. Return spring plug >>A<< RETURN SPRING PLUG INSTALLATION
2. Return spring
3. Return spring Plunger boss
4. Select plunger
5. Plunger boss
6. High & low shift fork
Return spring plug
AK500693 AC
Apply the sealant to the thread and screw the return

spring plug to be an even surface between the
plunger boss end face and the return spring plug.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
REAR OUTPUT SHAFT <V5MB1-J-NEG, JER>

M1222010300181
14
15
16
17
18
255 ± 10 N·m
12 9
11 3
13 4
6
8 7 Apply gear oil to
all moving parts
10 before installation.
AK500645AB

<<A>> >>E<< 1. Lock nut 11. Synchronizer cone <V5MB1-J-
<> >>D<< 2. Ball bearing NEG>
3. Oil guide 12. Synchronizer outer ring <V5MB1-
4. Sprocket spacer J-NEG>
5. Steel ball 13. Synchronizer spring <V5MB1-J-
6. Drive sprocket NEG>
7. Needle bearing >>C<< 14. Clutch sleeve
8. Sprocket sleeve <<C>> >>B<< 15. Clutch hub
9. Steel ball <<C>> >>A<< 16. Stopper plate
10. Synchronizer inner ring <V5MB1- <<C>> >>A<< 17. Ball bearing
J-NEG> 18. Rear output shaft
DISASSEMBLY SERVICE POINTS NOTE: .

<<A>> LOCK NUT REMOVAL The bearing may fit loosely on the shaft, so that
removal is possible without using a press.
<<C>> CLUTCH HUB / STOPPER PLATE / BALL

BEARING REMOVAL
2-4WD clutch hub

MD998801
AK403516
Ball bearing
1. Remove the lock nut from the shaft.
AK403520 AB
MB991013
1. Place special tool Remover (MD998801) so that
the load is applied at the bearing.
2. Use a press to push at the rear end of the rear
output shaft, and then remove the clutch hub and
ball bearing.
NOTE: .
AK500495AB
The clutch hub may fit loosely on the shaft, so
that removal is possible without using a press.
2. Hold the drive sprocket in a soft-jaw vice.
3. Shift the clutch sleeve to the drive sprocket side. REASSEMBLY SERVICE POINTS
4. Use special tool Power steering lock nut special >>A<< BALL BEARING / STOPPER PLATE
spanner (MB991013) to remove the lock nut. INSTALLATION
<> BALL BEARING REMOVAL MD998812

MD998813
MD998814
MD998801
MD998829
Ball bearing
MD998801
AK403521AB
1. Fit the ball bearing and stopper plate onto the rear
AK403518AB
output shaft.
1. Use special tool Remover (MD998801) to support 2. Use special tools to press in the ball bearing.
the ball bearing. x Remover (MD998801)
2. Use a press to push at a rear end of the rear x Installer cap (MD998812)
output shaft, and then remove the radial ball x Installer-100 (MD998813)
bearing. x Installer-200 (MD998814)
>>B<< CLUTCH HUB INSTALLATION x Installer cap (MD998812)

MD998812
MD998813
MD998814
NOTE: .
The ball bearing may be fitted loosely on the
MD998821
shaft, so that installation is possible without using a
Installation
direction 2-4WD clutch hub press
MD998801 >>E<< LOCK NUT INSTALLTION
AK500686 AB
MB991013
1. Confirm the clutch hub installation direction, and
fit onto the rear output shaft.
2. Use special tools press in the clutch hub.
x Installer-200 (MD998814) AK500495AB
NOTE: . 1. Hold the drive sprocket in a soft-jaws vice.
The clutch hub may fit loosely on the shaft, so that 2. Shift the clutch sleeve to the drive sprocket side.
installation is possible without using a press. 3. Using special tool Power steering lock nut special
spanner (MB991013) tighten the lock nut to the
>>C<< CLUTCH SLEEVE INSTALLTION specified torque of 255 r 10 Nm.
Installation
direction
AK500685AB AK403516
Check that the clutch sleeve is in the correct direc- 4. Stake the two places of the lock nut as shown in
tion for installation. illustration.
>>D<< BALL BEARING INSTALLATION

INSPECTION
MD998812 M1222010400036
MD998814
Ball bearing
MD998821
MD998801
AK403526AD
Use special tools to install the radial ball bearing. AK403556

REAR OUTPUT SHAFT <V5MB1-J-ND2, NEZ, PD2>
1. Push the synchronizer outer ring, synchronizer Limit: 0.3 mm

cone and the synchronizer inner ring to the drive 2. In case that value is out of limit, exchange as the
sprocket in combined state, and then measure the synchronizer ring set.
indicated dimension of the drive sprocket and
synchronizer outer ring.

M1222010300114
Apply gear oil to

all moving parts
1
4
AK101106 AC
Disassembly steps
>>B<< 1. Snap ring
3. Viscous coupling
4. Rear output shaft
DISASSEMBLY SERVICE POINT Use special tools to install the ball bearing.
<<A>> BALL BEARING REMOVAL x Installer cap (MD998812)
>>B<< SNAP RING INSTALLATION

MD998917
AK101110 AF
Use special tool Bearing remover (MD998917) to

remove the ball bearing.
AK101112

>>A<< BALL BEARING INSTALLATION the snap ring groove of the rear output shaft.
2. Make sure that the rear output shaft bearing end
MD998812 play meets the standard value.
MD998814 Standard value: 0 0.08 mm
MD998823
AK101111 AC
TRANSFER DRIVE SHAFT <V5MB1-J-ND2, NEZ, PD2>
TRANSFER DRIVE SHAFT <V5MB1-J-ND2, NEZ, PD2>

M1222011200057
Apply gear oil to

all moving parts
AK503431AB
DIsassembly steps
<<A>> >>A<< 1. Ball bearing REASSEMBLY SERVICE POINT
2. Transfer drive shaft
>>A<< BALL BEARING INSTALLATION
DISASSEMBLY SERVICE POINT MD998812
<<A>> BALL BEARING REMOVAL MD998814
MD998830
MD998192
MD998801
AK503430 AB
Use special tools to install the inner race.

AK503429 AB
Use special tool Remover (MD998801) to remove x Counter shaft bearing puller (MD998192)
the ball bearing.
FRONT OUTPUT SHAFT
FRONT OUTPUT SHAFT

M1222011500025
Apply gear oil to

all moving parts
1
2
AKX00425 AC

<<A>> >>B<< 1. Ball bearing >>A<< BALL BEARING INSTALLATION
3. Front output shaft
MD998812
MD998818
<<A>> BALL BEARING REMOVAL
MD998801
MD998801
MD998801
AK403462 AB
1. Use special tool Remover (MD998801) to support

the front output shaft.
2. Use special tools to install the ball bearing.
AK403522AB x Installer cap (MD998812)
the ball bearing.
2. Press the front output shaft with a press and
remove the ball bearings.
>>B<< BALL BEARING INSTALLATION

SPEEDOMETER GEAR

MD998812
MD998813
MD998818
MD998801
AK403523 AB

the front output shaft.
2. Use special tools to install the ball bearing.
SPEEDOMETER GEAR
M1222003400175
Apply gear oil to

all moving parts
1 before installation.
3
2
AKX00429 AC

1. O-ring 4. O-ring
>>A<< 2. Spring pin 5. Sleeve
3. Driven gear
SPEEDOMETER GEAR
REASSEMBLY SERVICE POINT Drive the spring pin in, while making sure that slit
>>A<< SPRING PIN INSTALLATION does not face gear shaft.
Slit
Spring pin
AK403524 AB

Transmision Manual Mitsubishi l200 2.5 2011-2015

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Transmision Manual Mitsubishi l200 2.5 2011-2015

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22C-14 MANUAL TRANSMISSION OVERHAUL <V5MB1>

Tool Number Name Use

MD998830 Installer adapter (66) Installation of transfer

MD998192 Counter shaft bearing Installation of transfer

1. Spring pin 2. Transfer

4. Back-up lamp switch assembly 16. Wiring harness clamp bracket

18.5 ± 5.5 N·m 33 ± 3 N·m

24. Control shaft assembly 39. Slotted spring pin

51. Shaft snap ring 64. Shaft snap ring

6. Remove the cover.

Shift position switch

10.Remove the transfer adaptor sub-assembly and

13.Remove the slotted spring pin. 17.Remove the oil seal.

20.Remove the transmission case sub-assembly. 24.Remove the ball (3 places).

22.Remove the straight screw plug with head (3 AK500259

38.Remove the ball.

Gear shift fork No.3

42.Remove the compression spring. 46.Remove the shaft snap ring.

45.Remove the reverse shift arm. AK403983

49.Remove the synchronizer outer race No.3.

59.Remove the snap ring. 63.Remove the output shaft sub-assembly.

5. Install the reverse idler gear shaft and reverse

2. Install the output shaft sub-assembly to the

3. Install the input shaft sub-assembly to the output

4. Insert the counter gear sub-assembly into the

Installtion 5th gear

12.Install the synchromesh shifting key spring No.3

9. Check the installation direction of 5th gear thrust

10.Install the needle roller bearing.

14.Install the shaft snap ring to the counter shaft gear

11.Install the synchromesh shifting key No.3 to the

15.Install the counter shaft gear No.5.

CAUTION 18.Check the installation direction of the

16.Install the synchronizer outer race No.3.

19.Select a snap ring to secure the thrust clearance.

Reverse shift arm

17.Using special tools to install the gear spline piece

x Installer adapter (56) (MD998827)

Transmission 21.Install the E ring.

22.Install the reverse shift fork and the reverse shift

23.Install the compression spring into the reverse

25.Install the gear shift fork shaft No.4 into the

24.Install the ball into the reverse shift fork.

Gear shift fork No.3

34.Install the straight pin to the gear shift fork shaft

30.Install the slotted spring pin to the gear shift fork

35.Install the gear shift fork shaft No.1 to the

Special sealant: Mitsubishi genuine sealant

48.Install the snap ring to the cylindrical roller

44.Install the transmission magnet to the

49.Install the snap ring to the radial ball bearing.

45.Completely degrease the FIPG-applied surface

57.Apply sealant to the threads. Tighten the straight

58.Install the oil receiver pipe into the transfer

59.Completely degrease the FIPG-applied surface AK501350AB

63.Install the control shaft assembly to the transfer

61.Install the transfer adaptor sub-assembly. Install

64.Tighten the flange bolt to the specified torque of

68.Tighten the reverse restrict pin assembly to the

65.Completely degrease the FIPG-applied surface

67.Install the cover to the transfer adaptor sub-

INSPECTION 2. Check that the sleeve is free from damage at its

NEEDLE ROLLER BEARING

SYNCHRONIZER SLEEVE AND HUB A 37.984 38.000 37.984