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1 22D-0-1 MANUAL TRANSMISSION CONTENTS GENERAL INFORMATION... 22D SPECIFICATIONS... 22D-1-1 TRANSMISSION MODEL TABLE GENERAL SPECIFICATIONS SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS ADJUSTMENT SNAP RINGS AND SPACERS SEALANTS LUBRICANTS D D D D D D D SPECIAL TOOLS... 22D TRANSMISSION... 22D EXTENSION HOUSING... 22D COUNTERSHAFT... 22D MAINSHAFT... 22D SPEEDOMETER GEAR... 22D TRANSFER <V5M21-9>... 22D TRANSFER <V5M21-A>... 22D REAR OUTPUT SHAFT <V5M21-9>... 22D REAR OUTPUT SHAFT <V5M21-A>... 22D INPUT SHAFT... 22D FRONT OUTPUT SHAFT... 22D H-L SHIFT FORK <V5M21-9>... 22D WD/4WD SHIFT FORK AND RAIL <V5M21-A>... 22D WD/4WD SYNCHRONIZER <V5M21-A>... 22D TRANSFER CASE PLATE <V5M21-A>... 22D-17-1

2 22D-0-2 NOTES

3 MANUAL TRANSMISSION - General Information 22D-0-3 GENERAL INFORMATION R5M21-5-D

4 22D-0-4 MANUAL TRANSMISSION - General Information R5M21-5-G

5 MANUAL TRANSMISSION - General Information 22D-0-5 R5M21-5-P

6 22D-0-6 MANUAL TRANSMISSION - General Information R5M21-5-T

7 MANUAL TRANSMISSION - General Information 22D-0-7 V5M21-9-D

8 22D-0-8 MANUAL TRANSMISSION - General Information V5M21-9-G

9 MANUAL TRANSMISSION - General Information 22D-0-9 V5M21-9-P

10 22D-0-10 MANUAL TRANSMISSION - General Information V5M21-9-T

11 MANUAL TRANSMISSION - Specifications 22D SPECIFICATIONS TRANSMISSION MODEL TABLE - MODEL 2001 Transmission Model Gear ratio Speedometer gear ratio Vehicle Model Engine Model EUR R5M21-5-DIF4 A 29/8 L200-2WD 4G63 R5M21-5-PF4 A 26/8 L200-2WD 4D56 R5M21-5-PF5 A 26/8 L200-2WD 4D56 V5M21-9-GGG4 B 27/8 L200-4WD 4G64 V5M21-9-GEG4 B 27/8 L200-4WD 4G64 V5M21-A-MG C - PAJERO-Pinin / MONTERO-iO 4G94 EXP R5M21-5-DI4 A 29/8 L200-2WD 4G63 R5M21-5-DI5 A 29/8 L200-2WD 4G63 R5M21-5-DIF4 A 29/8 L200-2WD 4G63 R5M21-5-PF4 A 26/8 L200-2WD 4D56 R5M21-5-PF5 A 26/8 L200-2WD 4D56 R5M21-5-GF5 B 26/8 L200-2WD 4G64 R5M21-5-GF4 B 26/8 L200-2WD 4G64 R5M21-5-TF5 A 26/8 L200-2WD 4M40 V5M21-9-DI4 A 29/8 L200-4WD 4G63 V5M21-9-DI5 A 29/8 L200-4WD 4G63 V5M21-9-PG4 A 27/8 L200-4WD 4D56 V5M21-9-PG5 A 27/8 L200-4WD 4D56 V5M21-9-GG4 B 27/8 L200-4WD 4G64 V5M21-9-TF4 A 26/8 L200-4WD 4M40 V5M21-A-LJA C - PAJERO-iO / MONTERO-iO 4G18 V5M21-A-LHA C - PAJERO-iO / MONTERO-iO 4G93 V5M21-A-MI C - PAJERO-iO / MONTERO-iO 4G93 AUS R5M21-5-GF5 A 26/8 L200-2WD 4G64 V5M21-9-TE5 A 25/8 L200-4WD 4M40 V5M21-A-LJA C - PAJERO-iO 4G18 V5M21-A-LHA C - PAJERO-iO 4G93

12 22D-1-2 MANUAL TRANSMISSION - Specifications GENERAL SPECIFICATIONS R5M21 TRANSMISSION MODEL Gear ratio A B 1st nd rd th th Reverse V5M21 TRANSMISSION MODEL Gear ratio A B C 1st nd rd th th Reverse Transfer High Transfer Low

13 MANUAL TRANSMISSION - Specifications 22D-1-3 SERVICE SPECIFICATIONS Items Standard mm Transmission Main drive gear bearing end play Front bearing retainer to bearing rd-4th speed synchronizer hub end play Main shaft rear bearing end play <R5M21, V5M21-A> Countershaft preload <Countershaft taper roller bearing type> Overdrive gear end play <Overdrive gear snap ring hold type> Transfer Input gear end play Input gear bearing end play H-L clutch hub end play Rear output shaft end play <except V5M21-A> Front output shaft end play <except V5M21-A> 2 or less 2WD/4WD clutch hub end play <V5M21-A> Differential lock hub end play <V5M21-A> Rear output shaft rear bearing end play <V5M21-A> TORQUE SPECIFICATIONS Items Torque Nm Transmission Backup lamp switch 29 ± 2 Extension housing mounting bolt 19 ± 3 Mainshaft lock nut 255 ± 10 Coutershaft lock nut 172 ± 14 Front bearing retainer mounting nut 12 ± 1 Bearing retainer mounting nut 20 ± 2 Reverse idler gear shaft mounting bolt 20 ± 2 Reverse idler gear shaft lock nut 40 ± 19 Speedometer sleeve clamp bolt 12 ± 1 Transmission case to adapter bolt 19 ± 3 Under cover bolt 9 ± 1 Control lever assembly bolt 19 ± 3

14 22D-1-4 MANUAL TRANSMISSION - Specifications Items Torque Nm Adapter to transfer case mounting bolt and nut 35 ± 6 Transfer Detection switch 34 ± 5 Poppet plug 35 ± 6 Chain cover bolt (except V5M21-A) 35 ± 6 Cover bolt (except V5M21-A) 19 ± 3 Rear cover bolt (except V5M21-A) 35 ± 6 Sleeve clamp bolt (except V5M21-A) 19 ± 3 H-L shift rail plug (except V5M21-A) 32 ± 2 Rear output shaft lock nut (except V5M21-A) 113 ± 14 Lock plate bolt (except V5M21-A) 19 ± 3 Side cover bolt (except V5M21-A) 9 ± 1 Plunger boss bolt (except V5M21-A) 9 ± 2 Select plunger seal plug (V5M21-A) 32 ± 2 Transfer rear cover bolt (V5M21-A) 35 ± 6 Transfer control housing bolt (V5M21-A) 19 ± 3 Vehicle speed sensor bolt (V5M21-A) 11 ± 1 Transfer case plate bolt (V5M21-A) 35 ± 6 Center bearing retainer bolt (V5M21-A) 19 ± 3 Interlock plunger seal bolt (V5M21-A) 35 ± 6

15 MANUAL TRANSMISSION - Specifications 22D-1-5 ADJUSTMENT SNAP RINGS AND SPACERS Part name Thickness mm Identification symbol Part No. Transmission Spacer 0.84 Black MD (For adjustment of front bearing retainer) *: except R5M21-5-D, V5M21-9-D MD Red MD White MD Yellow MD Blue MD Green MD *1.47 Brown MB *1.56 Purple MB Snap ring 2.30 White MD (For adjustment of main drive gear bearing) 2.35 Brown MD MD Blue MD Yellow MD Snap ring 2.15 Blue MD (For adjustment of 3rd-4th speed synchronizer hub) MD Brown MD White MD Snap ring: except R5M21-5-G, V5M21-9-G 2.60 White MD (For adjustment of main shaft overdrive gear) 2.79 Blue MD MD Black MD Red MD Yellow MD723099

16 22D-1-6 MANUAL TRANSMISSION - Specifications Part name Thickness mm Identification symbol Part No. Snap ring: except R5M21-5-D, V5M21-9-D MD (For adjustment of countershaft) MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD Snap ring: R5M MD (For adjustment of main shaft rear bearing) 1.5 Brown MD703780

17 MANUAL TRANSMISSION - Specifications 22D-1-7 Part name Thickness mm Identification symbol Part No. Transfer V5M21 Snap ring MD (For adjustment of input gear bearing) 2.35 Red MD White MD Blue MD Green MD Snap ring 2.70 Purple MD (For adjustment of input gear assembly) 2.75 Pink MD Yellow MD White MD Blue MD Snap ring MD (For adjustment of H-L clutch hub) 2.21 Yellow MD White MD Blue MD Red MD Spacer: except V5M21-A MD (For adjustment of rear output shaft bearing) MD MD MD MD MD MD MD MD MD MD MD MD MD734339

18 22D-1-8 MANUAL TRANSMISSION - Specifications Part name Thickness mm Identification symbol Part No. Snap ring: V5M21-A MD (For adjustment of differential lock hub) 2.63 Red MD White MD Blue MD Yellow MD Green MD Purple MD Snap ring: V5M21-A 2.18 Blue MR (For adjustment of rear output shaft bearing) MR Brown MR White MR SEALANTS Item Specified sealants Transmission Adapter gasket Extension housing gasket Front bearing retainer gasket Air breather Rear bearing retainer mounting bolt Reverse idler gear shaft mounting bolt Poppet plug Seal plug Mitsubishi genuine sealant Part No. MD or equivalent Mitsubishi genuine sealant Part No. MD or equivalent Mitsubishi genuine sealant Part No. MD or equivalent 3M super Weatherstrip No or equivalent 3M STUD Locking No or equivalent 3M STUD Locking No or equivalent 3M ATD Part No or equivalent 3M ATD Part No or equivalent Transfer Rear cover Chain cover Transfer case plate Control housing Mitsubishi genuine sealant Part No. MD or equivalent Mitsubishi genuine sealant Part No. MD or equivalent Mitsubishi genuine sealant Part No. MD or equivalent Mitsubishi genuine sealant Part No. MD or equivalent

19 MANUAL TRANSMISSION - Specifications 22D-1-9 Item Cover Air breather Return spring plug Cover mounting bolt Center bearing retainer seal bolt Poppet plug Plug Poppet seal bolt Specified sealants Mitsubishi genuine sealant Part No. MD or equivalent 3M super Weatherstrip No or equivalent 3M super Weatherstrip No or equivalent 3M STUD Locking No or equivalent 3M STUD Locking No or equivalent 3M ATD Part No or equivalent 3M ATD Part No or equivalent 3M ATD Part No or equivalent H-L shift fork Select plunger seal plug 3M ATD Part No or equivalent Transfer case plate Interlock plunger seal bolt 3M ATD Part No or equivalent Extension housing Control shaft cap 3M ATD Part No or equivalent LUBRICANTS Item Specified grease Transmission Neutral plunger Friction damper Oil seal lip Mitsubishi genuine grease Part No or equivalent Mitsubishi genuine grease Part No or equivalent Mitsubishi genuine grease Part No or equivalent Transfer Wave spring Oil seal lip Mitsubishi genuine grease Part No or equivalent Mitsubishi genuine grease Part No or equivalent Extension housing Oil seal lip Mitsubishi genuine grease Part No or equivalent

20 NOTES

21 MANUAL TRANSMISSION - Special Tools 22D SPECIAL TOOLS Tool Number Name Use MD Bearing puller Removal of the bearing and bearing sleeve MD Bearing puller adapter Use with MD MD Bearing installer Installation of the bearing MD Counter gear bearing puller Removal of the countershaft front bearing and center bearing MD Countershaft bearing installer Installation of the countershaft front bearing MD Front bearing retainer oil seal installer Installation of front bearing retainer oil seal MD Oil seal installer Installation of the oil seal MD Bearing puller Removal and installation of the clutch hub and bearing MD Oil seal installer Installation of the oil seal

22 22D-2-2 MANUAL TRANSMISSION - Special Tools Tool Number Name MD Lock nut wrench (41) Use Removal of the mainshaft lock nut MD Installer cap Installation of the bearing MD Installer (100) Installation of the bearing MD Installer (200) Installation of the bearing MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD MD Installer adapter Installation of the bearing MD Lock nut wrench (46) Removal of the transfer rear output shaft lock nut

23 MANUAL TRANSMISSION - Special Tools 22D-2-3 Tool Number Name Use MD Bearing puller Removal of the countershaft bearing MB Bearing and oil seal installer set Installation of the oil seal

24 22D-2-4 MANUAL TRANSMISSION - Special Tools CONTENTS OF BEARING AND OIL SEAL INSTALLER SET MB Set Contents Tool Name Tool No. Diameter mm Bearing and oil seal installer set MB Installer adapter MB MB MB MB MB MB MB MB MB MB MB MB Installer bar MB Brass bar MB

25 MANUAL TRANSMISSION - Transmission 22D TRANSMISSION R5M21-5-D Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 3Nm ± 1Nm ± 2Nm "ba "aa Disassembly steps 1. Sleeve clamp 2. Speedometer gear 3. Backup lamp switch 4. Gasket 5. Steel ball 6. Resistance spring 7. Steel ball 8. Seal plug 9. Spring AA" "ZA 10. Neutral plunger A "ZA 11. Neutral plunger B "YA 12. Extension housing "XA 13. Extension housing gasket

26 22D-3-2 MANUAL TRANSMISSION - Transmission R5M21-5-D ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 14. Under cover 15. Under cover gasket "WA 16. Snap ring "WA 17. Mainshaft rear bearing "VA 18. Poppet plug "VA 19. Poppet spring "VA 20. Steel ball "UA 21. Spring pin for 3rd-4th speed shift fork "UA 22. Spring pin for 1st-2nd speed shift fork "TA 23. Spring pin for OD-R shift fork 24. OD-R shift rail 25. 3rd-4th speed shift rail 26. OD-R shift fork 27. Interlock plunger "SA 28. Countershaft lock nut "RA 29. Countershaft rear bearing 30. Counter overdrive gear 31. 1st-2nd speed shift rail

27 MANUAL TRANSMISSION - Transmission 22D-3-3 R5M21-5-D 255 ± 10 Nm Apply gear oil to all moving parts before installation. 20 ± 2Nm ± 19 Nm ± 2Nm 56 AB" Disassembly steps "QA 32. Snap ring 33. Spacer 34. Steel ball 35. Overdrive gear 36. Needle bearing 37. Bearing spacer "PA 38. Mainshaft lock nut 39. Spacer 40. Counter reverse gear 41. Spacer "MA 42. OD-R synchronizer ring "MA 43. OD-R synchronizer sleeve "NA 44. OD-R synchronizer spring "NA 45. OD-R synchronizer key AD" "MA 46. OD-R synchronizer hub 47. Reverse gear 48. Needle bearing "LA 49. Bearing sleeve 50. Spacer 51. Split pin 52. Slotted nut 53. Thrust washer 54. Reverse idler gear 55. Needle bearing "JA 56. Bolt "KA 57. Reverse idler gear shaft "JA 58. Bolt 59. Rear bearing retainer

28 22D-3-4 MANUAL TRANSMISSION - Transmission R5M21-5-D Apply gear oil to all moving parts before installation ± 1Nm AE" AF" Disassembly steps "HA 60. Countershaft center bearing "GA 61. Mainshaft center bearing 62. Bearing spacer 63. Front bearing retainer "FA 64. Front bearing retainer gasket "EA 65. Oil seal AG" "DA 66. Countershaft front bearing "CA 67. Spacer "BA 68. Snap ring 69. Snap ring AH" "AA 70. Maindrive gear bearing 71. Maindrive gear 72. 3rd-4th speed shift fork 73. 1st-2nd speed shift fork 74. Countershaft 75. Mainshaft front bearing 76. 3rd-4th synchronizer ring 77. Mainshaft assembly 78. Transmission case

29 MANUAL TRANSMISSION - Transmission 22D-3-5 R5M21-5-G Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 3Nm ± 1Nm ± 2Nm "ba "aa Disassembly steps 1. Sleeve clamp 2. Speedometer gear 3. Backup lamp switch 4. Gasket 5. Steel ball 6. Resistance spring 7. Steel ball 8. Seal plug 9. Spring AA" "ZA 10. Neutral plunger A "ZA 11. Neutral plunger B "YA 12. Extension housing "XA 13. Extension housing gasket

30 22D-3-6 MANUAL TRANSMISSION - Transmission R5M21-5-G ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 14. Under cover 15. Under cover gasket "WA 16. Snap ring "WA 17. Mainshaft rear bearing "VA 18. Poppet plug "VA 19. Poppet spring "VA 20. Steel ball "UA 21. Spring pin for 3rd-4th speed shift fork "UA 22. Spring pin for 1st-2nd speed shift fork "TA 23. Spring pin for OD-R shift fork 24. OD-R shift rail 25. 3rd-4th speed shift rail 26. OD-R shift fork 27. Interlock plunger "SA 28. Countershaft lock nut "RA 29. Countershaft rear bearing 30. Counter overdrive gear 31. 1st-2nd speed shift rail

31 MANUAL TRANSMISSION - Transmission 22D-3-7 R5M21-5-G ± 10 Nm Apply gear oil to all moving parts before installation ± 2Nm ± 19 Nm ± 2Nm AB" AC" Disassembly steps "PA 32. Mainshaft lock nut 33. Spacer 34. Counter reverse gear 35. Spacer 36. Spacer 37. Steel ball 38. Overdrive gear 39. Needle bearing "OA 40. Bearing sleeve 41. Bearing spacer "MA 42. Overdrive synchronizer ring "MA 43. OD-R synchronizer sleeve "NA 44. OD-R synchronizer spring AD" "NA 45. OD-R synchronizer key "MA 46. OD-R synchronizer hub 47. Reverse gear 48. Needle bearing 49. Split pin 50. Slotted nut 51. Thrust washer 52. Reverse idler gear 53. Needle bearing "JA 54. Bolt "KA 55. Reverse idler gear shaft "JA 56. Bolt 57. Rear bearing retainer

32 22D-3-8 MANUAL TRANSMISSION - Transmission R5M21-5-G Apply gear oil to all moving parts before installation ± 1Nm AF" AF" Disassembly steps "IA 58. Spacer 59. Countershaft center bearing outer race "LA 60. Bearing sleeve "GA 61. Mainshaft center bearing 62. Front bearing retainer "FA 63. Front bearing retainer gasket "EA 64. Oil seal 65. Spacer 66. Countershaft front bearing outer race "CA 67. Spacer AH" "BA 68. Snap ring 69. Snap ring "AA 70. Maindrive gear bearing 71. Maindrive gear 72. 3rd-4th speed shift fork 73. 1st-2nd speed shift fork 74. Countershaft assembly 75. Mainshaft front bearing 76. 3rd-4th synchronizer ring 77. Mainshaft assembly 78. Transmission case

33 MANUAL TRANSMISSION - Transmission 22D-3-9 R5M21-5-P Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 3Nm ± 1Nm ± 2Nm "ba "aa Disassembly steps 1. Sleeve clamp 2. Speedometer gear 3. Backup lamp switch 4. Gasket 5. Steel ball 6. Resistance spring 7. Steel ball 8. Seal plug 9. Spring AA" "ZA 10. Neutral plunger A "ZA 11. Neutral plunger B "YA 12. Extension housing "XA 13. Extension housing gasket

34 22D-3-10 MANUAL TRANSMISSION - Transmission R5M21-5-P ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 14. Under cover 15. Under cover gasket "WA 16. Snap ring "WA 17. Mainshaft rear bearing "VA 18. Poppet plug "VA 19. Poppet spring "VA 20. Steel ball "UA 21. Spring pin for 3rd-4th speed shift fork "UA 22. Spring pin for 1st-2nd speed shift fork "TA 23. Spring pin for OD-R shift fork 24. OD-R shift rail 25. 3rd-4th speed shift rail 26. OD-R shift fork 27. Interlock plunger "SA 28. Countershaft lock nut "RA 29. Countershaft rear bearing 30. Counter overdrive gear 31. 1st-2nd speed shift rail

35 MANUAL TRANSMISSION - Transmission 22D-3-11 R5M21-5-P 255 ± 10 Nm Apply gear oil to all moving parts before installation. 20 ± 2Nm ± 19 Nm ± 2Nm 56 AB" Disassembly steps "QA 32. Snap ring 33. Spacer 34. Steel ball 35. Overdrive gear 36. Needle bearing 37. Bearing spacer "PA 38. Mainshaft lock nut 39. Spacer 40. Counter reverse gear 41. Spacer "MA 42. OD-R synchronizer ring "MA 43. OD-R synchronizer sleeve "NA 44. OD-R synchronizer spring "NA 45. OD-R synchronizer key AD" "MA 46. OD-R synchronizer hub 47. Reverse gear 48. Needle bearing "LA 49. Bearing sleeve 50. Spacer 51. Split pin 52. Slotted nut 53. Thrust washer 54. Reverse idler gear 55. Needle bearing "JA 56. Bolt "KA 57. Reverse idler gear shaft "JA 58. Bolt 59. Rear bearing retainer

36 22D-3-12 MANUAL TRANSMISSION - Transmission R5M21-5-P Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps "IA 60. Spacer AE" "HA 61. Countershaft center bearing outer race AF" "GA 62. Mainshaft center bearing 63. Bearing spacer 64. Front bearing retainer "FA 65. Front bearing retainer gasket "EA 66. Oil seal 67. Spacer AG" "DA 68. Countershaft front bearing outer race "CA 69. Spacer AH" "BA 70. Snap ring 71. Snap ring "AA 72. Maindrive gear bearing 73. Maindrive gear 74. 3rd-4th speed shift fork 75. 1st-2nd speed shift fork 76. Countershaft assembly 77. Mainshaft front bearing 78. 3rd-4th synchronizer ring 79. Mainshaft assembly 80. Transmission case

37 MANUAL TRANSMISSION - Transmission 22D-3-13 R5M21-5-T Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 3Nm ± 1Nm ± 2Nm "ba "aa Disassembly steps 1. Sleeve clamp 2. Speedometer gear 3. Backup lamp switch 4. Gasket 5. Steel ball 6. Resistance spring 7. Steel ball 8. Seal plug 9. Spring AA" "ZA 10. Neutral plunger A "ZA 11. Neutral plunger B "YA 12. Extension housing "XA 13. Extension housing gasket

38 22D-3-14 MANUAL TRANSMISSION - Transmission R5M21-5-T ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 14. Under cover 15. Under cover gasket "WA 16. Snap ring "WA 17. Mainshaft rear bearing "VA 18. Poppet plug "VA 19. Poppet spring "VA 20. Steel ball "UA 21. Spring pin for 3rd-4th speed shift fork "UA 22. Spring pin for 1st-2nd speed shift fork "TA 23. Spring pin for OD-R shift fork 24. OD-R shift rail 25. 3rd-4th speed shift rail 26. OD-R shift fork 27. Interlock plunger "SA 28. Countershaft lock nut "RA 29. Countershaft rear bearing 30. Counter overdrive gear 31. 1st-2nd speed shift rail

39 MANUAL TRANSMISSION - Transmission 22D-3-15 R5M21-5-T 255 ± 10 Nm Apply gear oil to all moving parts before installation. 20 ± 2Nm ± 19 Nm ± 2Nm AB" Disassembly steps "QA 32. Snap ring 33. Spacer 34. Steel ball 35. Overdrive gear 36. Needle bearing 37. Bearing spacer "PA 38. Mainshaft lock nut 39. Spacer 40. Counter reverse gear 41. Spacer "MA 42. OD-R synchronizer ring "MA 43. OD-R synchronizer sleeve "NA 44. OD-R synchronizer spring AD" "NA 45. OD-R synchronizer key "MA 46. OD-R synchronizer hub 47. Reverse gear 48. Needle bearing 49. Split pin 50. Slotted nut 51. Thrust washer 52. Reverse idler gear 53. Needle bearing "JA 54. Bolt "KA 55. Reverse idler gear shaft "JA 56. Bolt 57. Rear bearing retainer

40 22D-3-16 MANUAL TRANSMISSION - Transmission R5M21-5-T Apply gear oil to all moving parts before installation ± 1Nm AF" AF" Disassembly steps "IA 58. Spacer 59. Countershaft center bearing outer race "LA 60. Bearing sleeve "GA 61. Mainshaft center bearing 62. Front bearing retainer "FA 63. Front bearing retainer gasket "EA 64. Oil seal 65. Spacer 66. Countershaft front bearing outer race "CA 67. Spacer AH" "BA 68. Snap ring 69. Snap ring "AA 70. Maindrive gear bearing 71. Maindrive gear 72. 3rd-4th speed shift fork 73. 1st-2nd speed shift fork 74. Countershaft assembly 75. Mainshaft front bearing 76. 3rd-4th synchronizer ring 77. Mainshaft assembly 78. Transmission case

41 MANUAL TRANSMISSION - Transmission 22D-3-17 V5M21-9-D 1 Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 6Nm ± 6Nm ± 6Nm 35 ± 6Nm "ea "da Disassembly steps 1. Control lever assembly 2. Bracket 3. Spring pin 4. Change shifter 5. Transfer assembly 6. Adapter gasket 7. Plug 8. Spring 9. Steel ball "aa 10. Seal plug 11. Neutral return spring "ZA 12. Neutral return plunger (B) "ZA 13. Neutral return plunger (A)

42 22D-3-18 MANUAL TRANSMISSION - Transmission V5M21-9-D Apply gear oil to all moving parts before installation ± 3Nm ± 3Nm ± 3Nm ± 2Nm Disassembly steps 14. Backup lamp switch 15. Gasket 16. Steel ball "ca 17. Breather 18. Plug AA" "YA 19. Transfer adapter* "XA 20. Case gasket 21. Lock pin* 22. Control finger* 23. Control shaft* Caution *: The control finger and control shaft should be left installed in the transfer adapter as the lock pin cannot be removed. If any of these four parts requires replacement, order them all and replace them as a unit.

43 MANUAL TRANSMISSION - Transmission 22D-3-19 V5M21-9-D ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 24. Under cover 25. Under cover gasket "VA 26. Poppet plug "VA 27. Poppet spring "VA 28. Steel ball "UA 29. Spring pin for 3rd-4th speed shift fork "UA 30. Spring pin for 1st-2nd speed shift fork "TA 31. Spring pin for OD-R shift fork 32. OD-R shift rail 33. 3rd-4th speed shift rail 34. OD-R shift fork 35. Interlock plunger "SA 36. Countershaft lock nut "RA 37. Countershaft rear bearing 38. Counter overdrive gear 39. 1st-2nd speed shift rail

44 22D-3-20 MANUAL TRANSMISSION - Transmission V5M21-9-D Apply gear oil to all moving parts before installation ± 10 Nm ± 2Nm ± 19 Nm ± 2Nm 64 AB" Disassembly steps "QA 40. Snap ring 41. Spacer 42. Steel ball 43. Overdrive gear 44. Needle bearing 45. Bearing spacer "PA 46. Mainshaft lock nut 47. Spacer 48. Counter reverse gear 49. Spacer "MA 50. OD-R synchronizer ring "MA 51. OD-R synchronizer sleeve "NA 52. OD-R synchronizer spring "NA 53. OD-R synchronizer key AD" "MA 54. OD-R synchronizer hub 55. Reverse gear 56. Needle bearing "LA 57. Bearing sleeve 58. Spacer 59. Split pin 60. Slotted nut 61. Thrust washer 62. Reverse idler gear 63. Needle bearing "JA 64. Bolt "KA 65. Reverse idler gear shaft "JA 66. Bolt 67. Rear bearing retainer

45 MANUAL TRANSMISSION - Transmission 22D-3-21 V5M21-9-D 69 Apply gear oil to all moving parts before installation ± 1Nm AE" AF" Disassembly steps "HA 68. Countershaft center bearing "GA 69. Mainshaft center bearing 70. Bearing spacer 71. Front bearing retainer "FA 72. Front bearing retainer gasket "EA 73. Oil seal AG" "DA 74. Countershaft front bearing "CA 75. Spacer "BA 76. Snap ring 77. Snap ring AH" "AA 78. Maindrive gear bearing 79. Maindrive gear 80. 3rd-4th speed shift fork 81. 1st-2nd speed shift fork 82. Countershaft 83. Mainshaft front bearing 84. 3rd-4th synchronizer ring 85. Mainshaft assembly 86. Transmission case

46 22D-3-22 MANUAL TRANSMISSION - Transmission V5M21-9-G 1 Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 6Nm ± 6Nm ± 6Nm 35 ± 6Nm "ea "da Disassembly steps 1. Control lever assembly 2. Bracket 3. Spring pin 4. Change shifter 5. Transfer assembly 6. Adapter gasket 7. Plug 8. Spring 9. Steel ball "aa 10. Seal plug 11. Neutral return spring "ZA 12. Neutral return plunger (B) "ZA 13. Neutral return plunger (A)

47 MANUAL TRANSMISSION - Transmission 22D-3-23 V5M21-9-G Apply gear oil to all moving parts before installation ± 3Nm ± 3Nm ± 3Nm ± 2Nm Disassembly steps 14. Backup lamp switch 15. Gasket 16. Steel ball "ca 17. Breather 18. Plug AA" "YA 19. Transfer adapter* "XA 20. Case gasket 21. Lock pin* 22. Control finger* 23. Control shaft* Caution *: The control finger and control shaft should be left installed in the transfer adapter as the lock pin cannot be removed. If any of these four parts requires replacement, order them all and replace them as a unit.

48 22D-3-24 MANUAL TRANSMISSION - Transmission V5M21-9-G ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 24. Under cover 25. Under cover gasket "VA 26. Poppet plug "VA 27. Poppet spring "VA 28. Steel ball "UA 29. Spring pin for 3rd-4th speed shift fork "UA 30. Spring pin for 1st-2nd speed shift fork "TA 31. Spring pin for OD-R shift fork 32. OD-R shift rail 33. 3rd-4th speed shift rail 34. OD-R shift fork 35. Interlock plunger "SA 36. Countershaft lock nut "RA 37. Countershaft rear bearing 38. Counter overdrive gear 39. 1st-2nd speed shift rail

49 MANUAL TRANSMISSION - Transmission 22D-3-25 V5M21-9-G Apply gear oil to all moving parts before installation ± 10 Nm ± 2Nm ± 19 Nm ± 2Nm AB" AC" Disassembly steps "PA 40. Mainshaft lock nut 41. Spacer 42. Counter reverse gear 43. Spacer 44. Spacer 45. Steel ball 46. Overdrive gear 47. Needle bearing "OA 48. Bearing sleeve 49. Bearing spacer "MA 50. Overdrive synchronizer ring "MA 51. OD-R synchronizer sleeve "NA 52. OD-R synchronizer spring AD" "NA 53. OD-R synchronizer key "MA 54. OD-R synchronizer hub 55. Reverse gear 56. Needle bearing 57. Split pin 58. Slotted nut 59. Thrust washer 60. Reverse idler gear 61. Needle bearing "JA 62. Bolt "KA 63. Reverse idler gear shaft "JA 64. Bolt 65. Rear bearing retainer

50 22D-3-26 MANUAL TRANSMISSION - Transmission V5M21-9-G 69 Apply gear oil to all moving parts before installation ± 1Nm AF" AF" Disassembly steps "IA 66. Spacer 67. Countershaft center bearing outer race "LA 68. Bearing sleeve "GA 69. Mainshaft center bearing 70. Front bearing retainer "FA 71. Front bearing retainer gasket "EA 72. Oil seal 73. Spacer 74. Countershaft front bearing outer race "CA 75. Spacer AH" "BA 76. Snap ring 77. Snap ring "AA 78. Maindrive gear bearing 79. Maindrive gear 80. 3rd-4th speed shift fork 81. 1st-2nd speed shift fork 82. Countershaft assembly 83. Mainshaft front bearing 84. 3rd-4th synchronizer ring 85. Mainshaft assembly 86. Transmission case

51 MANUAL TRANSMISSION - Transmission 22D-3-27 V5M21-9-P 1 Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 6Nm ± 6Nm ± 6Nm 35 ± 6Nm "ea "da Disassembly steps 1. Control lever assembly 2. Bracket 3. Spring pin 4. Change shifter 5. Transfer assembly 6. Adapter gasket 7. Plug 8. Spring 9. Steel ball "aa 10. Seal plug 11. Neutral return spring "ZA 12. Neutral return plunger (B) "ZA 13. Neutral return plunger (A)

52 22D-3-28 MANUAL TRANSMISSION - Transmission V5M21-9-P Apply gear oil to all moving parts before installation ± 3Nm ± 3Nm ± 3Nm ± 2Nm Disassembly steps 14. Backup lamp switch 15. Gasket 16. Steel ball "ca 17. Breather 18. Plug AA" "YA 19. Transfer adapter* "XA 20. Case gasket 21. Lock pin* 22. Control finger* 23. Control shaft* Caution *: The control finger and control shaft should be left installed in the transfer adapter as the lock pin cannot be removed. If any of these four parts requires replacement, order them all and replace them as a unit.

53 MANUAL TRANSMISSION - Transmission 22D-3-29 V5M21-9-P ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 24. Under cover 25. Under cover gasket "VA 26. Poppet plug "VA 27. Poppet spring "VA 28. Steel ball "UA 29. Spring pin for 3rd-4th speed shift fork "UA 30. Spring pin for 1st-2nd speed shift fork "TA 31. Spring pin for OD-R shift fork 32. OD-R shift rail 33. 3rd-4th speed shift rail 34. OD-R shift fork 35. Interlock plunger "SA 36. Countershaft lock nut "RA 37. Countershaft rear bearing 38. Counter overdrive gear 39. 1st-2nd speed shift rail

54 22D-3-30 MANUAL TRANSMISSION - Transmission V5M21-9-P Apply gear oil to all moving parts before installation ± 10 Nm ± 2Nm ± 19 Nm ± 2Nm 64 AB" Disassembly steps "QA 40. Snap ring 41. Spacer 42. Steel ball 43. Overdrive gear 44. Needle bearing 45. Bearing spacer 46. Mainshaft lock nut 47. Spacer "PA 48. Counter reverse gear 49. Spacer "MA 50. OD-R synchronizer ring "MA 51. OD-R synchronizer sleeve "NA 52. OD-R synchronizer spring "NA 53. OD-R synchronizer key AD" "MA 54. OD-R synchronizer hub 55. Reverse gear 56. Needle bearing "LA 57. Bearing sleeve 58. Spacer 59. Split pin 60. Slotted nut 61. Thrust washer 62. Reverse idler gear 63. Needle bearing "JA 64. Bolt "KA 65. Reverse idler gear shaft "JA 66. Bolt 67. Rear bearing retainer

55 MANUAL TRANSMISSION - Transmission 22D-3-31 V5M21-9-P 70 Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps "IA 68. Spacer AE" "HA 69. Countershaft center bearing outer race AF" "GA 70. Mainshaft center bearing 71. Bearing spacer 72. Front bearing retainer "FA 73. Front bearing retainer gasket "EA 74. Oil seal 75. Spacer AG" "DA 76. Countershaft front bearing outer race "CA 77. Spacer AH" "BA 78. Snap ring 79. Snap ring "AA 80. Maindrive gear bearing 81. Maindrive gear 82. 3rd-4th speed shift fork 83. 1st-2nd speed shift fork 84. Countershaft assembly 85. Mainshaft front bearing 86. 3rd-4th synchronizer ring 87. Mainshaft assembly 88. Transmission case

56 22D-3-32 MANUAL TRANSMISSION - Transmission V5M21-9-T 1 Apply gear oil to all moving parts before installation. 19 ± 3Nm ± 6Nm ± 6Nm ± 6Nm 35 ± 6Nm "ea "da Disassembly steps 1. Control lever assembly 2. Bracket 3. Spring pin 4. Change shifter 5. Transfer assembly 6. Adapter gasket 7. Plug 8. Spring 9. Steel ball "aa 10. Seal plug 11. Neutral return spring "ZA 12. Neutral return plunger (B) "ZA 13. Neutral return plunger (A)

57 MANUAL TRANSMISSION - Transmission 22D-3-33 V5M21-9-T Apply gear oil to all moving parts before installation ± 3Nm ± 3Nm ± 3Nm ± 2Nm Disassembly steps 14. Backup lamp switch 15. Gasket 16. Steel ball "ca 17. Breather 18. Plug AA" "YA 19. Transfer adapter* "XA 20. Case gasket 21. Lock pin* 22. Control finger* 23. Control shaft* Caution *: The control finger and control shaft should be left installed in the transfer adapter as the lock pin cannot be removed. If any of these four parts requires replacement, order them all and replace them as a unit.

58 22D-3-34 MANUAL TRANSMISSION - Transmission V5M21-9-T ± 14 Nm Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps 24. Under cover 25. Under cover gasket "VA 26. Poppet plug "VA 27. Poppet spring "VA 28. Steel ball "UA 29. Spring pin for 3rd-4th speed shift fork "UA 30. Spring pin for 1st-2nd speed shift fork "TA 31. Spring pin for OD-R shift fork 32. OD-R shift rail 33. 3rd-4th speed shift rail 34. OD-R shift fork 35. Interlock plunger "SA 36. Countershaft lock nut "RA 37. Countershaft rear bearing 38. Counter overdrive gear 39. 1st-2nd speed shift rail

59 MANUAL TRANSMISSION - Transmission 22D-3-35 V5M21-9-T Apply gear oil to all moving parts before installation ± 10 Nm ± 2Nm ± 19 Nm ± 2Nm 62 AB" Disassembly steps "QA 40. Snap ring 41. Spacer 42. Steel ball 43. Overdrive gear 44. Needle bearing 45. Bearing spacer "PA 46. Mainshaft lock nut 47. Spacer 48. Counter reverse gear 49. Spacer "MA 50. OD-R synchronizer ring "MA 51. OD-R synchronizer sleeve "NA 52. OD-R synchronizer spring AD" "NA 53. OD-R synchronizer key "MA 54. OD-R synchronizer hub 55. Reverse gear 56. Needle bearing 57. Split pin 58. Slotted nut 59. Thrust washer 60. Reverse idler gear 61. Needle bearing "JA 62. Bolt "KA 63. Reverse idler gear shaft "JA 64. Bolt 65. Rear bearing retainer

60 22D-3-36 MANUAL TRANSMISSION - Transmission V5M21-9-T Apply gear oil to all moving parts before installation ± 1Nm AF" AF" Disassembly steps "IA 66. Spacer 67. Countershaft center bearing outer race "LA 68. Bearing sleeve "GA 69. Mainshaft center bearing 70. Front bearing retainer "FA 71. Front bearing retainer gasket "EA 72. Oil seal 73. Spacer 74. Countershaft front bearing outer race "CA 75. Spacer AH" "BA 76. Snap ring 77. Snap ring "AA 78. Maindrive gear bearing 79. Maindrive gear 80. 3rd-4th speed shift fork 81. 1st-2nd speed shift fork 82. Countershaft assembly 83. Mainshaft front bearing 84. 3rd-4th synchronizer ring 85. Mainshaft assembly 86. Transmission case

61 MANUAL TRANSMISSION - Transmission 22D-3-37 V5M21-A Apply gear oil to all moving parts before installation ± 6Nm ± 6Nm 35 ± 6Nm "ea "ha "aa "ZA Disassembly steps 1. Spring pin 2. Change shifter 3. Transfer assembly 4. Plug 5. Spring 6. Steel ball 7. Seal plug 8. Neutral return spring 9. Neutral return plunger B "ZA 10. Neutral return plunger A

62 22D-3-38 MANUAL TRANSMISSION - Transmission V5M21-A Apply gear oil to all moving parts before installation ± 3Nm ± 3Nm ± 2Nm Disassembly steps "XA 11. Transfer case adapter gasket 12. Back light switch 13. Gasket 14. Steel ball "da 15. Air breather 16. Plug "ga 17. Oil seal 18. Baffle plate AA" "YA 19. Transfer case adapter* 20. Lock pin* 21. Control finger* 22. Control shaft* "WA 23. Snap ring "WA 24. Mainshaft rear bearing Caution *: The control finger and control shaft should be left installed in the transfer adapter as the lock pin cannot be removed. If any of these four parts requires replacement, order them all and replace them as a unit.

63 MANUAL TRANSMISSION - Transmission 22D-3-39 V5M21-A Apply gear oil to all moving parts before installation ± 14 Nm ± 1Nm Disassembly steps 25. Oil pan 26. Oil pan gasket "VA 27. Poppet plug "VA 28. Poppet spring "VA 29. Steel ball "UA 30. Spring pin for 3rd-4th speed shift fork "UA 31. Spring pin for 1st-2nd speed shift fork "TA 32. Spring pin for OD-R shift fork 33. OD-R shift rail 34. 3rd-4th speed shift rail 35. OD-R shift fork 36. Interlock plunger "SA 37. Countershaft lock nut "RA 38. Countershaft rear bearing 39. Countershaft overdrive gear 40. 1st-2nd speed shift rail

64 22D-3-40 MANUAL TRANSMISSION - Transmission V5M21-A Apply gear oil to all moving parts before installation ± 10 Nm ± 2Nm ± 19 Nm ± 2Nm 41 Disassembly steps 41. 1st-2nd speed shift fork AB" "PA 42. Mainshaft lock nut 43. Spacer 44. Steel ball 45. Overdrive gear 46. Needle bearing AC" "OA 47. Bearing sleeve 48. Overdrive synchronizer ring "MA 49. OD-R synchronizer sleeve "MA 50. OD-R synchronizer spring "NA 51. OD-R synchronizer key "NA 52. OD-R synchronizer hub "MA 53. Reverse synchronizer ring 54. Reverse gear AD" 55. Needle bearing 56. Counter reverse gear 57. Spacer 58. Split pin 59. Reverse idler gear shaft nut 60. Thrust washer 61. Reverse idler gear "fa 62. Friction damper 63. Needle bearing "JA 64. Reverse idler gear shaft seal bolt "KA 65. Reverse idler gear shaft "JA 66. Rear bearing retainer seal bolt 67. Rear bearing retainer

65 MANUAL TRANSMISSION - Transmission 22D-3-41 V5M21-A Apply gear oil to all moving parts before installation ± 1Nm Disassembly steps "IA 68. Spacer 69. Countershaft center bearing outer race "LA 70. Reverse gear bearing sleeve 71. Mainshaft center bearing outer race 72. Front bearing retainer "FA 73. Front bearing retainer gasket "EA 74. Oil seal "CA 75. Spacer 76. Spacer 77. Countershaft front bearing outer race AH" "BA 78. Snap ring 79. Snap ring "AA 80. Maindrive gear bearing 81. Maindrive gear 82. Oil guide 83. Mainshaft front bearing 84. Synchronizer ring 85. Countershaft 86. 3rd-4th speed shift fork 87. Mainshaft 88. Transmission case

66 22D-3-42 MANUAL TRANSMISSION - Transmission Control shaft Control finger Shift lug DISASSEMBLY SERVICE POINTS AA" EXTENSION HOUSING OR TRANSFER ADAPTER REMOVAL (1) Turn the control shaft to the counterclockwise and remove the control finger from the groove in the shift lug, then remover the extension housing or the transfer adapter from the transmission case. MD AB" MAINSHAFT LOCK NUT REMOVAL (1) Use the special tool to remove the lock nut. MD Bearingsleeve MD (V5M21) AC" BEARING SLEEVE REMOVAL (1) Use the special tools to remove the bearing sleeve. Reverse idler gear shaft AD" REVERSE IDLER GEAR SHAFT REMOVAL (1) Use the special tool to remove the reverse idler gear shaft. MD AE" COUNTERSHAFT CENTER BEARING REMOVAL (1) Use the special tool to remove the countershaft center bearing.

67 MANUAL TRANSMISSION - Transmission 22D-3-43 MD Mainshaft bearing center AF" MAINSHAFT CENTER BEARING REMOVAL (1) Use the special tools to remove the mainshaft center bearing and bearing sleeve. Bearingsleeve MD MD AG" COUNTERSHAFT FRONT BEARING REMOVAL (1) Use the special tool to remove the countershaft front bearing. MD AH" MAINDRIVE GEAR BEARING REMOVAL (1) Use the special tool to remove the maindrive gear bearing.

68 22D-3-44 MANUAL TRANSMISSION - Transmission MD REASSEMBLY SERVICE POINTS "AA MAINDRIVE GEAR BEARING INSTALLATION (1) Use the special tool to install the maindrive gear bearing. MD MD TRM0033 "BA SNAP RING INSTALLATION (1) Select and install snap ring so that maindrive gear bearing end play reaches the standard value. Standard value: mm Solder "CA SPACER INSTALLATION (1) Place two pieces of solder measuring about 10 mm in length and 1.6 mm in diameter on the bearing outer race as shown in the illustration. (2) Install the front bearing retainer and tighten the nuts to the specified torque. (3) Remove the front bearing retainer and solder. NOTE If the solder wire 1.6 mm diameter have not crushed, use the one with 3 mm diameter. (4) Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play. Standard value: mm MD "DA COUNTERSHAFT FRONT BEARING INSTALLATION (1) Use the special tool to install the countershaft front bearing.

69 MANUAL TRANSMISSION - Transmission 22D-3-45 MD "EA OIL SEAL INSTALLATION (1) After applying grease to the oil seal lips, use the special tool to install the oil seal. Specified grease: Mitsubishi genuine grease Part No or equivalent (Both sides) "FA FRONT BEARING RETAINER GASKET INSTALLATION (1) After applying sealant to the front bearing retainer gasket. Specified sealant: Mitsubishi genuine sealant Part No or equivalent MD MD "GA MAINSHAFT CENTER BEARING INSTALLATION (1) Use the special tools to install the mainshaft center bearing. MD MD TRM0036 MD MD "HA COUNTERSHAFT CENTER BEARING INSTALLATION (1) Use the special tools to install the countershaft center bearing. MD TRM0037 "IA SPACER INSTALLATION (1) Press the outer race and counter gear in positively.

70 22D-3-46 Straight edge MANUAL TRANSMISSION - Transmission (2) Install the selective spacer and use a straight edge. (3) Select an appropriate, spacer to obtain the standard value. Standard value: mm Thickness gauge "JA BOLT INSTALLATION (1) Apply sealant to the bolt beforehand. Specified sealant: Mitsubishi genuine sealant Part No or equivalent 6mm 2mm Reverse idler gear Bolt "KA REVERSE IDLER GEAR SHAFT INSTALLATION (1) Use the bolt (M8 50 mm) as a guide to install the reverse idler gear shaft. MD MD "LA BEARING SLEEVE INSTALLATION (1) Use the special tools to install the bearing sleeve. MD MD TRM0038 Lock nut fixed type Synchronizer hub "MAOD-R SYNCHRONIZER HUB / OD-R SYNCHRONIZER SLEEVE INSTALLATION (1) Install the OD-R synchronizer hub and OD-R synchronizer sleeve in the indicated direction. Front Synchronizer sleeve

71 MANUAL TRANSMISSION - Transmission 22D-3-47 Except lock nut fixed type Synchronizer hub Front Synchronizer sleeve Key Step of spring "NA SYNCHRONIZER KEY / SYNCHRONIZER SPRING INSTALLATION (1) When installing spring, make sure that steps of front and rear spring are positioned on synchronizer key, but not on the same key. Step of spring MD MD "OA BEARING SLEEVE INSTALLATION (1) Use the special tools to install the bearing sleeve. MD MD TRM0039 MD "PA MAINSHAFT LOCK NUT INSTALLATION (1) Use the special tool to tighten the mainshaft lock nut. (2) Stake the lock nut as shown in the illustration. Lock nut

72 22D-3-48 MANUAL TRANSMISSION - Transmission Snap ring "QA SNAP RING INSTALLATION (1) Select and install snap ring so that overdrive gear end play reaches the standard value. Standard value: mm MD MD "RA COUNTERSHAFT REAR BEARING INSTALLATION (1) Use the special tools to install the countershaft rear bearing. Bearing "SA COUNTERSHAFT LOCK NUT INSTALLATION (1) Tighten the countershaft lock nut. (2) Stake the lock nut as shown in the illustration. "TA SPRING PIN INSTALLATION (1) Drive in the spring pin in such a way that its slit is oriented as shown.

73 MANUAL TRANSMISSION - Transmission 22D-3-49 "UA SPRING PIN INSTALLATION (1) Drive in the spring pin in such a way that its slit is oriented as shown. "VA STEEL BALL / POPPET SPRING INSTALLATION (1) Insert the poppet spring with small end on ball side. Three springs are identical to one another mm mm Apply sealant (2) Apply sealant to the poppet plug. Specified sealant: 3M ATD Part No or equivalent mm Snap ring Mainshaft "WASNAP RING INSTALLATION (1) Install a snap ring of the same size as having been used. MD (2) Use the special tools to install the mainshaft rear bearing. MD MD Mainshaft rear bearing

74 22D-3-50 MANUAL TRANSMISSION - Transmission Standard value Snap ring (3) Select and install a snap ring with which the mainshaft rear bearing clearance can be adjusted to standard value. Standard value: mm (4) If neither of snap rings can adjusted the mainshaft rear bearing clearance to the standard value, repeat the steps (2) and (3) after replacing the snap ring installed in step (1) with one having a different size. "XA EXTENSION HOUSING GASKET INSTALLATION (1) After applying sealant to the extension housing gasket. Specified sealant: Mitsubishi genuine sealant Part No or equivalent Control shaft Control finger Shift lug "YA EXTENSION HOUSING OR TRANSFER ADAPTER INSTALLATION (1) Turn the control shaft to the counterclockwise and install the extension housing or transfer adapter. (2) Turn the control shaft to the clockwise and insert the control finger in the groove of the shift lug. "ZA NEUTRAL PLUNGER A AND B INSTALLATION (1) Apply grease to the sliding surfaces of the neutral plungers before installation. Specified grease: Mitsubishi genuine grease Part No or equivalent "aa SEAL PLUG INSTALLATION (1) Apply sealant to the threaded area of the seal plug before tightening to specified torque. Specified sealant: 3M ATD Part No or equivalent NOTE Ensure that any old sealant still adhering to the seal plug is fully removed.

75 MANUAL TRANSMISSION - Transmission 22D-3-51 Mating marks "ba SPEEDOMETER GEAR INSTALLATION (1) Match the mating marks to the number of teeth. Identification mark "ca AIR BREATHER INSTALLATION (1) Apply sealant to the air breather. Specified sealant: 3M Super Weatherstrip No or equivalent (2) Install the breather with the identification mark toward the rear. "da ADAPTER GASKET INSTALLATION (1) After applying sealant to the adapter gasket. Specified sealant: Mitsubishi genuine sealant Part No or equivalent (Both sides) Change shifter "ea SPRING PIN INSTALLATION (1) Drive in the spring pin in such a way that its slit is oriented as shown. Change shifter mm Friction damper Reverse idler gear shaft "fa FRICTION DAMPER INSTALLATION (1) Install the friction damper in the illustrated direction. After installation, apply grease to the surfaces brought into contact with the reverse idler gear. Specified grease: Mitsubishi genuine grease Part No or equivalent Friction damper

76 22D-3-52 MANUAL TRANSMISSION - Transmission MD "ga OIL SEAL INSTALLATION (1) After applying grease to the oil seal lips, use the special tool to install the oil seal. Specified grease: Mitsubishi genuine grease Part No or equivalent Plug "ha PLUG INSTALLATION (1) Screw in the plug until end is flush with the end face of the transfer case adapter.

77 MANUAL TRANSMISSION - Extension Housing 22D EXTENSION HOUSING Apply gear oil to all moving parts before installation Disassembly steps 1. Lock pin 2. Lock pin 3. Control finger and control shaft 4. Neutral return finger 5. Change shifter "BA "AA 6. Dust seal guard 7. Control shaft cap 8. Oil seal 9. Extension housing

78 22D-4-2 MANUAL TRANSMISSION - Extension Housing Oil seal REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION (1) After installation, pack grease between the lips of the oil seal. Specified grease: Mitsubishi genuine grease Part No or equivalent Control shaft cap "BA CONTROL SHAFT CAP INSTALLATION (1) Apply sealant the entire circumference of the control shaft cap end press in the cap until it becomes flat with the extension housing. Specified sealant: 3M ATD Part No or equivalent

79 MANUAL TRANSMISSION - Countershaft 22D COUNTERSHAFT Disassembly steps AA" "BA 1. Countershaft front bearing inner race AB" "AA 2. Countershaft center bearing inner race 3. Countershaft gear

80 22D-5-2 MANUAL TRANSMISSION - Countershaft Bearing inner race MD DISASSEMBLY SERVICE POINTS AA" COUNTERSHAFT FRONT BEARING INNER RACE REMOVAL (1) Use the special tool to remove the Countershaft front bearing inner race. Bearing inner race MD AB" COUNTERSHAFT CENTER BEARING INNER RACE REMOVAL (1) Use the special tool to remove the Countershaft center bearing inner race. MD MD REASSEMBLY SERVICE POINTS "AA COUNTERSHAFT CENTER BEARING INNER RACE INSTALLATION (1) Use the special tools to install the Countershaft center bearing inner race. MD TRM0046 MD MD "BA COUTERSHAFT FRONT BEARING INNER RACE REMOVAL (1) Use the special tools to install the Countershaft front bearing inner race. TRM0045

81 MANUAL TRANSMISSION - Mainshaft 22D MAINSHAFT R5M Disassembly steps AA" "FA 1. Ball bearing inner race (double row ball bearing) 2. Spacer (single raw ball bearing) 3. 1st speed gear 4. Needle bearing AB" "EA 5. Bearing sleeve 6. Synchronizer ring "DA 7. 1st-2nd speed synchronizer sleeve "BA "BA 8. Synchronizer spring 9. Synchronizer key 10. 1st-2nd speed synchronizer hub 11. 2nd speed gear 12. Needle bearing "CA 13. Snap ring "AA 14. 3rd-4th speed synchronizer sleeve "BA 15. Synchronizer spring "BA 16. Synchronizer key "AA 17. 3rd-4th speed synchronizer hub 18. Synchronizer ring 19. 3rd speed gear 20. Needle bearing 21. Mainshaft

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