Mitsubishi F5M41 Manual do Utilizador

22B-1GROUP 22BMANUAL TRANSMISSION OVERHAULCONTENTSGENERAL INFORMATION . . . . . . . . 22B-3GENERAL SPECIFICATIONS . . . . . . 22B-6SERVICE SPECIFICATI

SEALANTS AND ADHESIVESMANUAL TRANSMISSION OVERHAUL22B-10SEALANTS AND ADHESIVESM1222000500139FORM-IN-PLACE GASKET (FIPG)This transmission has several a

SPECIAL TOOLSMANUAL TRANSMISSION OVERHAUL22B-11SPECIAL TOOLSM1222000600158Tool Number Name ApplicationMB990935 Installer adapter Installation of diffe

SPECIAL TOOLSMANUAL TRANSMISSION OVERHAUL22B-12MD998825 Installer adapter (52) Installation of 1st-2nd speed synchronizer hub <F5M42>, 3rd-4th s

SPECIAL TOOLSMANUAL TRANSMISSION OVERHAUL22B-13MD999566 Claw Removal of taper roller bearing outer raceMD998772 Valve spring compressorRemoval of outp

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-14TRANSMISSIONDISASSEMBLY AND REASSEMBLYM1222001000159<F5M41>AK30021570 ± 10 N·m70 ± 10 N·m3.9 ± 1.0

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-15AK300214Apply gear oil to allmoving parts beforeinstallation.18 ± 3 N·m30 ± 3 N·m44 ± 5 N·m48 ± 6 N·m18

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-16AK300216302931453534383946433718 ± 3 N·m36324133424044ABApply gear oil to allmoving parts beforeinstalla

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-17 <F5M42>AK20315132 ± 2 N·m3.9 ± 1.0 N·m70 ± 10 N·m18 ± 3 N·m438697101152170 ± 10 N·m18 ± 3 N·m3.9

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-18AK204218Apply gear oil to allmoving parts beforeinstallation.18 ± 3 N·m30 ± 3 N·m44 ± 5 N·m48 ± 6 N·m6.9

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-19DISASSEMBLY SERVICE POINTS<<A>> SEALING CAP REMOVAL1. Drive a screwdriver into the center of

22B-2CONTROL HOUSING . . . . . . . . . . . . 22B-48CONTROL HOUSING DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 22B-48CLU

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-20<<B>> TRANSAXLE CASE REMOVAL1. Remove all sixteen bolts securing the transaxle case to the c

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-212. Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hol

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-22REASSEMBLY SERVICE POINTS>>A<< OUTPUT SHAFT/INPUT SHAFT INSTALLATIONInstall the input and ou

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-233. While sliding the reverse shift lug in the direction shown, install the 5th speed shift fork, 5th spe

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-242. Using special tools, press the outer race into the transaxle case.• Installer adapter (MB990935)• Han

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-25>>K<< SEALING CAP INSTALLATION1. Using special tools, press install the sealing cap onto the

TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-26Tightening torque: 18 ± 3 N⋅mNOTE: After installation, keep the sealed area away from the oil for approx

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-27INPUT SHAFTDISASSEMBLY AND REASSEMBLYM1222001600140<F5M41>AK300291910111214131516182194206718317596

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-28<F5M42>DISASSEMBLY SERVICE POINTS<<A>> BALL BEARING REMOVAL1. Using special tool Bearin

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-29<<B>> 5TH SPEED-REVERSE SYNCHRONIZER HUB REMOVAL1. Using special tool Bearing remover (MD9989

GENERAL INFORMATIONMANUAL TRANSMISSION OVERHAUL22B-3GENERAL INFORMATIONM1222000100120MANUAL TRANSMISSION MODELSTransmission model Combined engine Vehi

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-30REASSEMBLY SERVICE POINTS>>A<< OIL SEAL INSTALLATIONInstall the oil seal into the end of the

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-311. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft,

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-32>>J<< 5TH SPEED GEAR INSTALLATION1. Using special tool Bearing remover (MD998801), support th

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-334. Make sure that the synchronizer ring on the 5th speed gear side can rotate freely.>>N<< SY

INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-341. Install the thickest snap ring that can be fitted in the groove of the input shaft.2. Make sure that t

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-353. Check that the gear inside diameter and front and rear surfaces are not damaged and worn.OUTPUT SHAFT

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-36<F5M42><<G>> >>A<<25. Roller bearing inner race26. Output shaftDisassembly

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-37DISASSEMBLY SERVICE POINTS<<A>> BALL BEARING REMOVAL1. Using special tools, support the ball

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-38<<E>> 2ND SPEED GEAR SLEEVE REMOVAL1. Using special tool Bearing remover (MD998917), support

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-39>>B<< SNAP RING INSTALLATION1. Install the thickest snap ring that can be fitted in the groo

GENERAL INFORMATIONMANUAL TRANSMISSION OVERHAUL22B-4SECTIONAL VIEW<F5M41>AK300634

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-40• Installer cap (MD998812)• Installer-200 (MD998814)• Installer adapter (MD998822) <F5M41>• Instal

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-41>>I<< SNAP RING INSTALLATION1. Install the thickest snap ring that can be fitted in the groo

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-423. Check that the 5th speed-reverse synchronizer hub is oriented correctly for installation, and fit it

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-431. Install the thickest snap ring that can be fitted in the groove of output shaft.2. Make sure that the

OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-44SYNCHRONIZER SLEEVE AND HUB1. Combine the synchronizer sleeve and hub, and check that they slide smoothl

REVERSE IDLER GEARMANUAL TRANSMISSION OVERHAUL22B-45REVERSE IDLER GEARDISASSEMBLY AND REASSEMBLYM1222012500103<F5M42>AK2043964561237ABApply gear

SPEEDOMETER GEARMANUAL TRANSMISSION OVERHAUL22B-46SPEEDOMETER GEARDISASSEMBLY AND REASSEMBLYM1222003400108AK2043974231ABApply gear oil to allmoving pa

SELECT LEVERMANUAL TRANSMISSION OVERHAUL22B-47SELECT LEVERDISASSEMBLY AND REASSEMBLYM1222012800096REASSEMBLY SERVICE POINT>>A<< DUST COVER

CONTROL HOUSINGMANUAL TRANSMISSION OVERHAUL22B-48CONTROL HOUSINGDISASSEMBLY AND REASSEMBLYM1222013100131DISASSEMBLY SERVICE POINT<<A>> LOC

CONTROL HOUSINGMANUAL TRANSMISSION OVERHAUL22B-49REASSEMBLY SERVICE POINTS>>A<< NEEDLE BEARING INSTALLATIONPress fit the needle bearing in

GENERAL INFORMATIONMANUAL TRANSMISSION OVERHAUL22B-5<F5M42>AK300023

CLUTCH HOUSINGMANUAL TRANSMISSION OVERHAUL22B-50CLUTCH HOUSINGDISASSEMBLY AND REASSEMBLYM1222003700132DISASSEMBLY SERVICE POINT<<A>> OUTER

CLUTCH HOUSINGMANUAL TRANSMISSION OVERHAUL22B-51<<B>> OUTER RACE REMOVAL1. Set special tools as indicated in the figure.• Valve spring com

CLUTCH HOUSINGMANUAL TRANSMISSION OVERHAUL22B-52>>D<<OIL SEAL INSTALLATION1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W conform

TRANSMISSION CASEMANUAL TRANSMISSION OVERHAUL22B-53TRANSMISSION CASEDISASSEMBLY AND REASSEMBLYM1222013400109REASSEMBLY SERVICE POINTS>>A<<

TRANSMISSION CASEMANUAL TRANSMISSION OVERHAUL22B-542. Be sure the bushing is fully seated as shown. It must be 3 mm below the housing surface.>>

DIFFERENTIALMANUAL TRANSMISSION OVERHAUL22B-55DIFFERENTIALDISASSEMBLY AND REASSEMBLYM1222002500124DISASSEMBLY SERVICE POINT<<A>> BALL BEAR

DIFFERENTIALMANUAL TRANSMISSION OVERHAUL22B-56<<B>> TAPER ROLLER BEARING REMOVAL1. Using special tool Bearing remover (MD998801), support

DIFFERENTIALMANUAL TRANSMISSION OVERHAUL22B-57>>C<< TAPER ROLLER BEARING INSTALLATIONUsing special tools, install the taper roller bearing

127(6

GENERAL SPECIFICATIONSMANUAL TRANSMISSION OVERHAUL22B-6GENERAL SPECIFICATIONSM1222000200161TRANSMISSION MODEL TABLEGEAR RATIO TABLESERVICE SPECIFICATI

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENTMANUAL TRANSMISSION OVERHAUL22B-7SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENTM1222012000153SPACE

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENTMANUAL TRANSMISSION OVERHAUL22B-8SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY) <

TORQUE SPECIFICATIONSMANUAL TRANSMISSION OVERHAUL22B-9SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION) <F5M42>TORQU