Page 122 of 396
MANUAL TRANSMISSION – Lubricant / Special Tools22A-2
LUBRICANT
ItemSpecified lubricantQuantity dm3 ()
Transmission oilMITSUBISHI genuine “Dia-Queen” multi gear oil <75W/85W>2.8 (2.8)
Transfer oilMITSUBISHI genuine “Dia-Queen Super” hypoid gear oil (GL-5)0.62 (0.62)
SPECIAL TOOLS
ToolNumberNameUse
MB990635 or
MB991113Steering linkage
pullerTie rod end and lower arm disconnection
Recommended
tool MZ203826
by Anzen
Jidosha or
MZ203827 by
BanzaiEngine lifterSupporting the engine assembly during
removal and installation of the transmission
MB991453Engine hanger
MB991612AdapterRemoving output shaft
MB990211Slide hammer
MB991193PlugPreventing oil flowing out from and foreign
matter entry into transfer.
Page 123 of 396
MANUAL TRANSMISSION – On-vehicle Service22A-3
ON-VEHICLE SERVICE
1. TRANSMISSION OIL CHECK
(1) Remove the oil filler plug.
(2) Oil level should be at the lower portion of the filler plug
hole.
(3) Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
2. TRANSMISSION OIL REPLACEMENT
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transmission oil
Specified oil:
MITSUBISHI genuine “Dia-Queen” multi gear oil
<75W/85W>
Quantity: 2.8 dm
3 (2.8 )
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
3. TRANSFER OIL CHECK
(1) Remove the oil filler plug.
(2) Oil level should be at the lower portion of the filler plug
hole.
(3) Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
4. TRANSFER OIL REPLACEMENT
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transfer oil
Specified oil:
MITSUBISHI genuine “Dia-Queen Super” hypoid
gear oil (GL-5)
Quantity: 0.62 dm
3 (0.62 )
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
Transmission oilFiller plug hole
Filler plug
Drain plug
Filler plug
Drain plug
Transfer oil
Page 127 of 396
MANUAL TRANSMISSION – Transmission Assembly22A-7
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Transmission Oil Draining (Refer to P.22A-3.)
(2) Transfer Oil Draining (Refer to P.22A-3.)
(3) Under Cover Removal
(4) Front Exhaust Pipe Removal (Refer to GROUP 15.)
(5) Battery and Battery Tray Removal
(6) Air Cleaner Assembly RemovalPost-installation Operation
(1) Air Cleaner Assembly Installation
(2) Battery and Battery Tray Installation
(3) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(4) Under Cover Installation
(5) Transfer Oil Supplying (Refer to P.22A-3.)
(6) Transmission Oil Supplying (Refer to P.22A-3.)
(7) Shift Lever Operation Check
(8) Speedometer Operation Check
1
2
34 5
6
7
8 8
Unit: Nm {kgfm}
49 {5.0} 98 {10.0}*
88 {9.0}19 {1.9}
48 {4.9}19 {1.9}
Removal steps
1. Shift cable and select cable con-
nection
2. Backup lamp switch connector
3. Vehicle speed sensor connector
A4. Starter motor
5. Clutch release cylinder connection
6. Transmission assembly upper part
coupling bolts7. Transmission mount bracket
8. Transmission mount stopper
Engine assembly supporting
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.
Page 130 of 396
MANUAL TRANSMISSION – Transfer Assembly22A-10
TRANSFER ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Transmission Oil Draining and Supplying
(Refer to P.22A-3.)
Transfer Oil Draining and Supplying
(Refer to P.22A-3.)Front Exhaust Pipe Removal and Installation
(Refer to GROUP 15.)
Gear oil:
MITSUBISHI genuine “Dia-Queen
Super” hypoid gear oil (GL-5)
Unit: Nm {kgfm}
2
69 {7.0}
1
Removal steps
Drive shaft (Refer to P.22A-9.)
Output shaft (Refer to P.22A-9.)
1. Front propeller shaft
(Refer to GROUP 25)
A2. Transfer assembly
REMOVAL SERVICE POINT
ATRANSFER ASSEMBLY REMOVAL
Caution
(1) Use care not to damage the lip of the oil seal in the
transfer case.
(2) Use the special tool to cover the opening in the transfer
case to prevent oil from flowing out or foreign materi-
als from entering the case.
Oil seal lip MB991193
Page 135 of 396
MANUAL TRANSMISSION OVERHAUL – Sealants and Adhesives22B-5
SEALANTS AND ADHESIVES
TRANSMISSION
ItemsSpecified sealants and adhesives
Clutch housing-transmission case mating surfaceTHREEBOND 1216
Control housing-transmission case mating surface
Under cover-transmission case mating surface
Air breatherTHREEBOND 1501
Center differential drive gear boltTHREEBOND 1303 or LOKTITE 648
TRANSFER
ItemsSpecified sealants and adhesives
Air breatherTHREEBOND 1501
FORM-IN-PLACE GASKET
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that
the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
SURFACE PREPARATION
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 10 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
Page 136 of 396
Lubricants / Snap Rings, Spacers
and Thrust Plates for Adjustment MANUAL TRANSMISSION
OVERHAUL –22B-6
LUBRICANTS
TRANSMISSION
ItemsSpecified lubricants
Drive shaft oil seal lip areaDIA QUEEN MULTI-GEAR OIL 75W/85W
(Transmission oil)
Input shaft oil seal lip area
(Transmission oil)
Control shaft oil seal lip area
Select lever shoeMOLYWHITE TA No.1 or No.2
TRANSFER
ItemsSpecified lubricants
Drive shaft oil seal lip areaDIA QUEEN MULTI-GEAR OIL 75W/85W
(Transmission oil)
Front differential oil seal lip area
(Transmission oil)
O-rings
SNAP RINGS, SPACERS AND THRUST PLATES FOR
ADJUSTMENT
Part nameThickness mmIdentification symbolPart No.
Spacer
(For adj stment of inp t shaft end pla )
1.3434MD723600
(For adjustment of input shaft end play)1.4343MD723603
1.5252MD723606
1.6161MD723609
1.7070MD756760
1.7979MD756763
Snap ring
(For adj stment of inp t shaft front bearing
1.43Green (2)MD746708
(For adjustment of input shaft front bearing
clearance)1.51White (2)MD746709
1.59Yellow (2)MD746710
Snap ring
(For adj stment of inp t shaft rear bearing
1.44NoneMD746602
(For adjustment of input shaft rear bearing
clearance)1.51BlueMD746603
1.58BrownMD746604
Page 140 of 396
Torque Specifications /
Special toolsMANUAL TRANSMISSION OVERHAUL – 22B-10
TRANSFER
ItemsNm {kgfm}
Transfer cover mounting bolt23 {2.4}
Transmission-transfer mounting bolt69 {7.0}
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bushing
remover & installer
ringInstallation of transfer oil seal
MB990891Bushing remover &
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller bearing
MB990933Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing outer race
MB990937Installer adapterInstallation of differential case taper roller
bearing
Page 141 of 396
MANUAL TRANSMISSION OVERHAUL – Special Tools22B-11
Tool UseName Number
MB990938HandleUse with Installer adapter
MB991445Bushing remover
and installer baseInstallation of differential case taper roller
bearing outer race
MD998304Oil seal installerInstallation of transfer extension housing oil
seal
MD998364Camshaft oil seal
installerInstallation of gear, bearing and sleeve
MD998800Oil seal installerInstallation of differential oil seal and transfer
cover oil seal
MD998801Bearing removerInstallation and removal of gear, bearing and
sleeve
MD998812Installer capUse with Installer and installer adapter
MD998813Installer-100Use with Installer cap and installer adapter
MD998814Installer-200Use with Installer cap and installer adapter
