Manual Transmission

22D-0-1
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-1
TRANSMISSION MODEL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-3
ADJUSTMENT SNAP RINGS AND SPACERS . . . . . . . . . . . . . . . . . 22D-1-5
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-8
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-1-9
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-2-1
3. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-3-1
4. EXTENSION HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-4-1
5. COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-5-1
6. MAINSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-6-1
7. SPEEDOMETER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-7-1
8. TRANSFER <V5M21-9> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-8-1
9. TRANSFER <V5M21-A> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-9-1
10. REAR OUTPUT SHAFT <V5M21-9> . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-10-1
11. REAR OUTPUT SHAFT <V5M21-A> . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-11-1
12. INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-12-1
13. FRONT OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-13-1
14. H-L SHIFT FORK <V5M21-9> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D-14-1
15. 2WD/4WD SHIFT FORK AND RAIL <V5M21-A> . . . . . . . . . . . . . . 22D-15-1
16. 2WD/4WD SYNCHRONIZER <V5M21-A> . . . . . . . . . . . . . . . . . . . . . 22D-16-1
17. TRANSFER CASE PLATE <V5M21-A> . . . . . . . . . . . . . . . . . . . . . . . . 22D-17-1
E Mitsubishi Motors Corporation
Aug. 2000
PWEE8914-J
Added
22D-0-2
NOTES
Aug. 2000
PWEE8914-J
Added
MANUAL TRANSMISSION - General Information
22D-0-3
GENERAL INFORMATION
R5M21-5-D
Aug. 2000
PWEE8914-J
Added
22D-0-4
R5M21-5-G
Aug. 2000
PWEE8914-J
Added
22D-0-5
R5M21-5-P
Aug. 2000
PWEE8914-J
Added
22D-0-6
R5M21-5-T
Aug. 2000
PWEE8914-J
Added
22D-0-7
V5M21-9-D
Aug. 2000
PWEE8914-J
Added
22D-0-8
V5M21-9-G
Aug. 2000
PWEE8914-J
Added
22D-0-9
V5M21-9-P
Aug. 2000
PWEE8914-J
Added
22D-0-10
V5M21-9-T
Aug. 2000
PWEE8914-J
Added
MANUAL TRANSMISSION - Specifications
22D-1-1
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE - MODEL 2001
Transmission Model
Gear ratio
Speedometer
gear ratio
Vehicle Model
Engine Model
EUR
R5M21-5-DIF4
29/8
L200-2WD
4G63
R5M21-5-PF4
26/8
L200-2WD
4D56
R5M21-5-PF5
26/8
L200-2WD
4D56
V5M21-9-GGG4
27/8
L200-4WD
4G64
V5M21-9-GEG4
27/8
L200-4WD
4G64
V5M21-A-MG
PAJERO-Pinin / MONTERO-iO
4G94
R5M21-5-DI4
29/8
L200-2WD
4G63
R5M21-5-DI5
29/8
L200-2WD
4G63
R5M21-5-DIF4
29/8
L200-2WD
4G63
R5M21-5-PF4
26/8
L200-2WD
4D56
R5M21-5-PF5
26/8
L200-2WD
4D56
R5M21-5-GF5
26/8
L200-2WD
4G64
R5M21-5-GF4
26/8
L200-2WD
4G64
R5M21-5-TF5
26/8
L200-2WD
4M40
V5M21-9-DI4
29/8
L200-4WD
4G63
V5M21-9-DI5
29/8
L200-4WD
4G63
V5M21-9-PG4
27/8
L200-4WD
4D56
V5M21-9-PG5
27/8
L200-4WD
4D56
V5M21-9-GG4
27/8
L200-4WD
4G64
V5M21-9-TF4
26/8
L200-4WD
4M40
V5M21-A-LJA
PAJERO-iO / MONTERO-iO
4G18
V5M21-A-LHA
4G93
V5M21-A-MI
4G93
R5M21-5-GF5
26/8
L200-2WD
4G64
V5M21-9-TE5
25/8
L200-4WD
4M40
V5M21-A-LJA
PAJERO-iO
4G18
V5M21-A-LHA
PAJERO-iO
4G93
EXP
AUS
Aug. 2000
PWEE8914-J
Added
22D-1-2
GENERAL SPECIFICATIONS
R5M21 TRANSMISSION MODEL
Gear ratio
1st
4.330
3.967
2nd
2.355
2.136
3rd
1.509
1.360
4th
1.000
1.000
5th
0.827
0.856
Reverse
4.142
3.578
V5M21 TRANSMISSION MODEL

Gear ratio
1st
4.330
3.967
3.967
2nd
2.355
2.136
2.136
3rd
1.509
1.360
1.360
4th
1.000
1.000
1.000
5th
0.827
0.856
0.822
Reverse
4.142
3.578
3.578
Transfer High
1.000
1.000
1.000
Transfer Low
1.925
1.925
1.548
Aug. 2000
PWEE8914-J
Added
22D-1-3
SERVICE SPECIFICATIONS
Items
Standard mm
Transmission
Main drive gear bearing end play
0 - 0.06
Front bearing retainer to bearing
0 - 0.1
3rd-4th speed synchronizer hub end play
0 - 0.08
Main shaft rear bearing end play <R5M21, V5M21-A>
0 - 0.13
Countershaft preload <Countershaft taper roller bearing type>
0 - 0.05
Overdrive gear end play <Overdrive gear snap ring hold type>
0.15 - 0.40
Transfer
Input gear end play
0 - 0.06
Input gear bearing end play
0 - 0.06
H-L clutch hub end play
0 - 0.08
Rear output shaft end play <except V5M21-A>
0 - 0.1
Front output shaft end play <except V5M21-A>
2 or less
2WD/4WD clutch hub end play <V5M21-A>
0 - 0.08
Differential lock hub end play <V5M21-A>
0 - 0.08
Rear output shaft rear bearing end play <V5M21-A>
0 - 0.08
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
91
Control lever assembly bolt
19 3
Aug. 2000
PWEE8914-J
Added
22D-1-4
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)
91
Plunger boss bolt (except V5M21-A)
92
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
Aug. 2000
PWEE8914-J
Added
22D-1-5
ADJUSTMENT SNAP RINGS AND SPACERS

Part name
Thickness mm
Identification symbol
Part No.
0.84
Black
MD701845
0.93
MD701839
1.02
Red
MD701840
1.11
White
MD701841
1.20
Yellow
MD701842
1.29
Blue
MD701843
1.38
Green
MD701844
*1.47
Brown
MB896942
*1.56
Purple
MB896943
2.30
White
MD701729
2.35
Brown
MD701730
2.40
MD701731
2.45
Blue
MD701732
2.50
Yellow
MD701733
2.15
Blue
MD701761
2.22
MD701762
2.29
Brown
MD701763
2.36
White
MD701764
2.60
White
MD723092
2.79
Blue
MD723093
2.98
MD723094
3.17
Black
MD723095
3.36
Red
MD723096
3.55
Yellow
MD723099
Transmission
Spacer
(For adjustment of front bearing retainer)
*: except R5M21-5-D, V5M21-9-D
Snap ring
(For adjustment of main drive gear bearing)
Snap ring
(For adjustment of 3rd-4th speed synchronizer
hub)
Snap ring: except R5M21-5-G, V5M21-9-G

(For adjustment of main shaft overdrive gear)
Aug. 2000
PWEE8914-J
Added
22D-1-6
Part name
Thickness mm
Part No.
Snap ring: except R5M21-5-D, V5M21-9-D

(For adjustment of countershaft)
1.84
84
MD706580
1.87
87
MD706581
1.90
90
MD706582
1.93
93
MD706583
1.96
96
MD706584
1.99
99
MD706585
2.02
02
MD706586
2.05
05
MD706587
2.08
08
MD706588
2.11
11
MD706589
2.14
14
MD706590
2.17
17
MD706591
2.20
20
MD706592
2.23
23
MD706593
2.26
26
MD706594
2.29
29
MD706595
2.32
32
MD706596
2.35
35
MD706597
2.38
38
MD706598
2.41
41
MD706599
2.44
44
MD706600
2.47
47
MD706601
2.50
50
MD706602
2.53
53
MD706603
2.56
56
MD706604
2.59
59
MD706605
2.62
62
MD706606
2.65
65
MD706607
2.68
68
MD706608
1.4
MD703779
1.5
Brown
MD703780
Snap ring: R5M21

(For adjustment of main shaft rear bearing)
Aug. 2000
PWEE8914-J
Added

Part name
22D-1-7
Thickness mm
Part No.
2.30
MD704199
2.35
Red
MD704200
2.40
White
MD704201
2.45
Blue
MD704202
2.50
Green
MD704203
2.70
Purple
MD704204
2.75
Pink
MD704205
2.80
Yellow
MD704206
2.85
White
MD704207
2.90
Blue
MD704208
2.14
MD704212
2.21
Yellow
MD704213
2.28
White
MD704214
2.35
Blue
MD704215
2.42
Red
MD704216
0.84
84
MD734326
0.93
93
MD734327
1.02
02
MD734328
1.11
11
MD734329
1.20
20
MD734330
1.29
29
MD734331
1.38
38
MD734332
1.47
47
MD734333
1.56
56
MD734334
1.65
65
MD734335
1.74
74
MD734336
1.83
83
MD734337
1.92
92
MD734338
2.01
01
MD734339
Transfer V5M21
Snap ring
(For adjustment of input gear bearing)
Snap ring
(For adjustment of input gear assembly)
Snap ring
(For adjustment of H-L clutch hub)
Spacer: except V5M21-A

(For adjustment of rear output shaft bearing)
Aug. 2000
PWEE8914-J
Added
22D-1-8
Part name
Thickness mm
Part No.
Snap ring: V5M21-A

(For adjustment of differential lock hub)
2.56
MD738386
2.63
Red
MD738387
2.70
White
MD738388
2.77
Blue
MD738389
2.84
Yellow
MD738390
2.91
Green
MD738391
2.98
Purple
MD738392
2.18
Blue
MR388669
2.25
MR388670
2.32
Brown
MR388671
2.39
White
MR388672
Snap ring: V5M21-A

(For adjustment of rear output shaft bearing)
SEALANTS
Item
Specified sealants
Transmission
Adapter gasket
Mitsubishi genuine sealant Part No. MD997740 or

equivalent
Extension housing gasket

equivalent
Front bearing retainer gasket

equivalent
Air breather
3M super Weatherstrip No. 8001 or equivalent
Rear bearing retainer mounting bolt
3M STUD Locking No. 4170 or equivalent
Reverse idler gear shaft mounting bolt
Poppet plug
3M ATD Part No. 8660 or equivalent
Seal plug
Transfer
Rear cover

equivalent
Chain cover

equivalent
Transfer case plate

equivalent
Control housing

equivalent
Aug. 2000
PWEE8914-J
Added
22D-1-9
Item
Specified sealants
Cover

equivalent
Air breather
Return spring plug
Cover mounting bolt
Center bearing retainer seal bolt
Poppet plug
Plug
Poppet seal bolt
H-L shift fork

Select plunger seal plug
Transfer case plate

Interlock plunger seal bolt
Extension housing
Control shaft cap
LUBRICANTS
Item
Specified grease
Transmission
Neutral plunger
Mitsubishi genuine grease Part No. 0101011 or

equivalent
Friction damper

equivalent
Oil seal lip

equivalent
Transfer
Wave spring

equivalent
Oil seal lip

equivalent
Extension housing
Oil seal lip

equivalent
Aug. 2000
PWEE8914-J
Added
NOTES
MANUAL TRANSMISSION - Special Tools
22D-2-1
2. SPECIAL TOOLS
Tool
Number
Name
Use
MD998020
Bearing puller
Removal of the bearing and bearing sleeve
MD998028
Bearing puller
adapter
Use with MD998020
MD998067
Bearing installer
Installation of the bearing
MD998192
Counter gear bearing puller
Removal of the countershaft front bearing and

center bearing
MD998199
Countershaft bearing installer
Installation of the countershaft front bearing
MD998200
Front bearing retainer oil seal installer
Installation of front bearing retainer oil seal
MD998800
Oil seal installer
Installation of the oil seal
MD998801
Bearing puller
Removal and installation of the clutch hub and

bearing
MD998803
Oil seal installer
Aug. 2000
PWEE8914-J
Added
22D-2-2
Tool

Number
Name
Use
MD998809
Lock nut wrench

(41)
Removal of the mainshaft lock nut
MD998812
Installer cap
MD998813
Installer (100)
MD998814
Installer (200)
MD998815
MD998816
MD998817
MD998818
MD998819
MD998820
MD998821
MD998822
MD998823
MD998824
MD998825
MD998826
MD998827
MD998828
MD998829
MD998830
Installer adapter
MD998835
Lock nut wrench

(46)
Removal of the transfer rear output shaft lock

nut
Aug. 2000
PWEE8914-J
Added

Tool
22D-2-3
Number
Name
Use
MD998917
Bearing puller
Removal of the countershaft bearing
MB990925
Bearing and oil

seal installer set
Aug. 2000
PWEE8914-J
Added
22D-2-4
CONTENTS OF BEARING AND OIL SEAL INSTALLER SET MB990925

Set
Contents
Tool
Bearing and oil seal installer set MB990925
Aug. 2000
Name
Tool No.
Diameter mm
Installer adapter
MB990926
39
MB990927
45
MB990928
49.5
MB990929
51
MB990930
54
MB990931
57
MB990932
61
MB990933
63.5
MB990934
67.5
MB990935
71.5
MB990936
75.5
MB990937
79
Installer bar
MB990938
Brass bar
MB990939
PWEE8914-J
Added
22D-3-1
MANUAL TRANSMISSION - Transmission
3. TRANSMISSION
R5M21-5-D
8
Apply gear oil to all
moving parts before
installation.
11
12
19 3 Nm
19 3 Nm
13
10
9
8
2
12 1 Nm
5
4
3
29 2 Nm
"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
Aug. 2000
"ZA
"ZA
AA" "YA
"XA
PWEE8914-J
10.
11.
12.
13.
Neutral plunger A
Neutral plunger B
Extension housing
Added
22D-3-2
R5M21-5-D
25
24
23
26
18
19
18
20
31
19
20
27
17
16
16
172 14 Nm
28
30
29
22

moving parts before
installation.
21
15
14
9 1 Nm
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
Aug. 2000
"TA 23.
24.
25.
26.
27.
"SA 28.
"RA 29.
30.
31.
PWEE8914-J
Spring pin for OD-R shift fork

OD-R shift rail
3rd-4th speed shift rail
OD-R shift fork
Interlock plunger
Countershaft lock nut
Countershaft rear bearing
Counter overdrive gear
1st-2nd speed shift rail
Added
22D-3-3

R5M21-5-D
38
255 10 Nm
50
48
37
20 2 Nm
43
59
40
57
Aug. 2000
42
54
52
53
55
"MA 46.
47.
48.
"LA 49.
50.
51.
52.
53.
54.
55.
"JA 56.
AD" "KA 57.
"JA 58.
59.
PWEE8914-J
33
40 19 Nm
39
20 2 Nm
Disassembly steps
"QA 32. Snap ring
33. Spacer
34. Steel ball
35. Overdrive gear
36. Needle bearing
37. Bearing spacer
AB" "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
35
44 46
49 47
58
41
32
44
45

moving parts before
installation.
36
34
51
56
OD-R synchronizer hub

Reverse gear
Needle bearing
Bearing sleeve
Spacer
Split pin
Slotted nut
Thrust washer
Reverse idler gear
Needle bearing
Bolt
Reverse idler gear shaft
Bolt
Rear bearing retainer
Added
22D-3-4
R5M21-5-D
61
62
78
moving parts before
installation.
71
60
70
67
69
64
63
66
77
68
65
76
75
74
12 1 Nm
73
72
AE" "HA
AF" "GA
"FA
"EA
AG" "DA
"CA
"BA
Disassembly steps
60. Countershaft center bearing
61. Mainshaft center bearing
62. Bearing spacer
63. Front bearing retainer
64. Front bearing retainer gasket
65. Oil seal
66. Countershaft front bearing
67. Spacer
68. Snap ring
69. Snap ring
Aug. 2000
AH" "AA 70.

71.
72.
73.
74.
75.
76.
77.
78.
PWEE8914-J
Maindrive gear bearing

Maindrive gear
3rd-4th speed shift fork
1st-2nd speed shift fork
Countershaft
Mainshaft front bearing
3rd-4th synchronizer ring
Mainshaft assembly
Transmission case
Added
22D-3-5

R5M21-5-G
8
moving parts before
installation.
11
12
19 3 Nm
19 3 Nm
13
10
9
8
2
12 1 Nm
5
4
3
29 2 Nm
"bA
"aA
Disassembly steps
1. Sleeve clamp
2. Speedometer gear
4. Gasket
5. Steel ball
7. Steel ball
8. Seal plug
9. Spring
Aug. 2000
"ZA
"ZA
AA" "YA
"XA
PWEE8914-J
10.
11.
12.
13.
Neutral plunger A
Neutral plunger B
Extension housing
Added
22D-3-6
R5M21-5-G
25
24
23
26
18
19
18
20
31
19
20
27
17
16
16
172 14 Nm
28
30
29
22

moving parts before
installation.
21
15
14
9 1 Nm
Disassembly steps
14. Under cover
"WA 16. Snap ring
"VA 18. Poppet plug
"VA 20. Steel ball
fork
fork
Aug. 2000
"TA 23.
24.
25.
26.
27.
"SA 28.
"RA 29.
30.
31.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-7

R5M21-5-G
255 10 Nm
32
40
39
moving parts before
installation.
44
45
48
56
43
20 2 Nm
57
35
34
47
Aug. 2000
50
51
55
37
46
44
40 19 Nm
52
33
20 2 Nm
Disassembly steps
33. Spacer
35. Spacer
36. Spacer
37. Steel ball
38. Overdrive gear
39. Needle bearing
AC" "OA 40. Bearing sleeve
41. Bearing spacer
"MA 42. Overdrive synchronizer ring
41
42
38
36
53
49
54

"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
AD" "KA 55. Reverse idler gear shaft
"JA 56. Bolt
57. Rear bearing retainer
PWEE8914-J
Added
22D-3-8
R5M21-5-G
61
60
78

moving parts before
installation.
71
58
59
70
67
63
69
62
68
65
77
66
76
64
75
74
12 1 Nm
73
72
"IA
AF" "LA
AF" "GA
"FA
"EA
"CA
Disassembly steps
58. Spacer
59. Countershaft center bearing outer
race
60. Bearing sleeve
64. Oil seal
65. Spacer
66. Countershaft front bearing outer
race
67. Spacer
Aug. 2000
"BA 68.
69.
AH" "AA 70.
71.
72.
73.
74.
75.
76.
77.
78.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Countershaft assembly
Mainshaft assembly
Transmission case
Added
22D-3-9

R5M21-5-P
11

moving parts before
installation.
12
19 3 Nm
19 3 Nm
13
10
9
8
2
5
4
3
12 1 Nm
29 2 Nm
"bA
"aA
Disassembly steps
1. Sleeve clamp
2. Speedometer gear
4. Gasket
5. Steel ball
7. Steel ball
8. Seal plug
9. Spring
Aug. 2000
"ZA
"ZA
AA" "YA
"XA
PWEE8914-J
10.
11.
12.
13.
Neutral plunger A
Neutral plunger B
Extension housing
Added
22D-3-10
R5M21-5-P
25
24
23
26
18
19
18
20
31
19
20
27
16
17
16
172 14 Nm
28
30
22
29

moving parts before
installation.
21
15
14
9 1 Nm
Disassembly steps
14. Under cover
"WA 16. Snap ring
"VA 18. Poppet plug
"VA 20. Steel ball
fork
fork
Aug. 2000
"TA 23.
24.
25.
26.
27.
"SA 28.
"RA 29.
30.
31.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-11

R5M21-5-P
38
255 10 Nm
50
48
37
20 2 Nm
43
49
58
59
41
40
57
Aug. 2000
33
42
54
52
53
40 19 Nm
39
55
"MA 46.
47.
48.
"LA 49.
50.
51.
52.
53.
54.
55.
"JA 56.
AD" "KA 57.
"JA 58.
59.
PWEE8914-J
35
44 46
47
20 2 Nm
Disassembly steps
"QA 32. Snap ring
33. Spacer
34. Steel ball
35. Overdrive gear
36. Needle bearing
37. Bearing spacer
39. Spacer
41. Spacer
32
44
45

moving parts before
installation.
36
34
51
56

Reverse gear
Needle bearing
Bearing sleeve
Spacer
Split pin
Slotted nut
Thrust washer
Reverse idler gear
Needle bearing
Bolt
Bolt
Added
22D-3-12
R5M21-5-P
62
60
63
80
moving parts before
installation.
61
73
72
65
69
71
64
70
67
68
79
78
66
77
76
12 1 Nm
75
74
"IA
AE" "HA
AF" "GA
"FA
"EA
AG" "DA
"CA
Disassembly steps
60. Spacer
race
63. Bearing spacer
66. Oil seal
67. Spacer
race
69. Spacer
Aug. 2000
"BA 70.
71.
AH" "AA 72.
73.
74.
75.
76.
77.
78.
79.
80.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Mainshaft assembly
Transmission case
Added
22D-3-13

R5M21-5-T
8
moving parts before
installation.
11
12
19 3 Nm
19 3 Nm
13
10
9
8
2
5
4
3
12 1 Nm
29 2 Nm
"bA
"aA
Disassembly steps
1. Sleeve clamp
2. Speedometer gear
4. Gasket
5. Steel ball
7. Steel ball
8. Seal plug
9. Spring
Aug. 2000
"ZA
"ZA
AA" "YA
"XA
PWEE8914-J
10.
11.
12.
13.
Neutral plunger A
Neutral plunger B
Extension housing
Added
22D-3-14
R5M21-5-T
25
24
23
26
18
19
18
20
31
19
20
27
17
16
16
172 14 Nm
28
30
29
22

moving parts before
installation.
21
15
14
9 1 Nm
Disassembly steps
14. Under cover
"WA 16. Snap ring
"VA 18. Poppet plug
"VA 20. Steel ball
fork
fork
Aug. 2000
"TA 23.
24.
25.
26.
27.
"SA 28.
"RA 29.
30.
31.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-15

R5M21-5-T
255 10 Nm

moving parts before
installation.
20 2 Nm
48
47
45
38
34
36
44
37
43
50
57
55
52
39
51
41
20 2 Nm
Aug. 2000
33
40 19 Nm
56
Disassembly steps
"QA 32. Snap ring
33. Spacer
34. Steel ball
35. Overdrive gear
36. Needle bearing
37. Bearing spacer
39. Spacer
41. Spacer
35
42
44 46
40
32
53
49
54

47. Reverse gear
48. Needle bearing
49. Split pin
50. Slotted nut
51. Thrust washer
53. Needle bearing
"JA 54. Bolt
"JA 56. Bolt
PWEE8914-J
Added
22D-3-16
R5M21-5-T
61
60
78

moving parts before
installation.
71
59
70
67
63
58
68
62
69
65
77
66
76
64
75
74
12 1 Nm
73
72
"IA
AF" "LA
AF" "GA
"FA
"EA
"CA
Disassembly steps
58. Spacer
race
60. Bearing sleeve
64. Oil seal
65. Spacer
race
67. Spacer
Aug. 2000
"BA 68.
69.
AH" "AA 70.
71.
72.
73.
74.
75.
76.
77.
78.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Mainshaft assembly
Transmission case
Added
22D-3-17

V5M21-9-D
1
19 3 Nm

moving parts before
installation.
8
9
35 6 Nm
7
35 6 Nm
10
11
13
12
11
10
35 6 Nm
35 6 Nm
"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
Aug. 2000
"aA 10.
11.
"ZA 12.
"ZA 13.
PWEE8914-J
Seal plug
Neutral return spring
Neutral return plunger (B)
Neutral return plunger (A)
Added
22D-3-18
V5M21-9-D
17

moving parts before
installation.
23
18
20
19 3 Nm
19
19 3 Nm
21
19 3 Nm
22
16
15
14
29 2 Nm
Disassembly steps
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.
Aug. 2000
PWEE8914-J
Added
22D-3-19

V5M21-9-D
32
33
31
26
27
26
28
34
27
28
39
35
172 14 Nm
36
38
37

moving parts before
installation.
30
29
25
24
9 1 Nm
"VA
"VA
"VA
"UA
"UA
Disassembly steps
24. Under cover
26. Poppet plug
27. Poppet spring
28. Steel ball
29. Spring pin for 3rd-4th speed shift
fork
30. Spring pin for 1st-2nd speed shift
fork
Aug. 2000
"TA 31.
32.
33.
34.
35.
"SA 36.
"RA 37.
38.
39.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-20
V5M21-9-D

moving parts before
installation.
255 10 Nm
52
53
66
44
46
40
42
56
58
20 2 Nm
45
43
41
50
51
57
55
52
54
62
48
47
63
20 2 Nm
Disassembly steps
"QA 40. Snap ring
41. Spacer
42. Steel ball
43. Overdrive gear
44. Needle bearing
45. Bearing spacer
47. Spacer
49. Spacer
Aug. 2000
"MA 54.
55.
56.
"LA 57.
58.
59.
60.
61.
62.
63.
"JA 64.
AD" "KA 65.
"JA 66.
67.
PWEE8914-J
40 19 Nm
65
67
49
61 60
59
64

Reverse gear
Needle bearing
Bearing sleeve
Spacer
Split pin
Slotted nut
Thrust washer
Reverse idler gear
Needle bearing
Bolt
Bolt
Added
22D-3-21

V5M21-9-D
69
moving parts before
installation.
70
86
79
68
78
75
72
77
74
85
76
84
73
83
71
82
12 1 Nm
81
80
Disassembly steps
AE" "HA 68. Countershaft center bearing
AF" "GA 69. Mainshaft center bearing
70. Bearing spacer
"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
Aug. 2000
AH" "AA 78.

79.
80.
81.
82.
83.
84.
85.
86.
PWEE8914-J

Maindrive gear
Countershaft
Mainshaft assembly
Transmission case
Added
22D-3-22
V5M21-9-G
1
19 3 Nm

moving parts before
installation.
8
9
35 6 Nm
7
35 6 Nm
10
11
13
12
11
10
35 6 Nm
35 6 Nm
"eA
"dA
Disassembly steps
2. Bracket
3. Spring pin
4. Change shifter
6. Adapter gasket
7. Plug
8. Spring
9. Steel ball
Aug. 2000
"aA 10.
11.
"ZA 12.
"ZA 13.
PWEE8914-J
Seal plug
Added
22D-3-23

V5M21-9-G
17

moving parts before
installation.
23
18
20
19 3 Nm
19
19 3 Nm
21
19 3 Nm
22
16
15
14
29 2 Nm
Disassembly steps
15. Gasket
16. Steel ball
"cA 17. Breather
18. Plug

"XA 20. Case gasket
21. Lock pin*
22. Control finger*
23. Control shaft*
Caution
Aug. 2000
PWEE8914-J
Added
22D-3-24
V5M21-9-G
32
33
31
26
27
26
28
34
27
28
39
35
172 14 Nm
36
38
37

moving parts before
installation.
30
29
25
24
9 1 Nm
"VA
"VA
"VA
"UA
"UA
Disassembly steps
24. Under cover
26. Poppet plug
27. Poppet spring
28. Steel ball
fork
fork
Aug. 2000
"TA 31.
32.
33.
34.
35.
"SA 36.
"RA 37.
38.
39.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-25

V5M21-9-G
255 10 Nm

moving parts before
installation.
47
53
64
48
40
52
44
56
49
45
46
50
51
20 2 Nm
65
43
52
55
54
60
40 19 Nm
59
58
63
42
41
61
57
62
20 2 Nm
Disassembly steps
41. Spacer
43. Spacer
44. Spacer
45. Steel ball
46. Overdrive gear
47. Needle bearing
AC" "OA 48. Bearing sleeve
49. Bearing spacer
"MA 50. Overdrive synchronizer ring
Aug. 2000

55. Reverse gear
56. Needle bearing
57. Split pin
58. Slotted nut
59. Thrust washer
61. Needle bearing
"JA 62. Bolt
"JA 64. Bolt
PWEE8914-J
Added
22D-3-26
V5M21-9-G
69
moving parts before
installation.
78
68
86
66
79
67
77
75
70
76
73
85
74
72
84
83
12 1 Nm
82
71
81
80
Disassembly steps
"IA 66. Spacer
race
AF" "LA 68. Bearing sleeve
"EA 72. Oil seal
73. Spacer
race
"CA 75. Spacer
Aug. 2000
"BA 76.
77.
AH" "AA 78.
79.
80.
81.
82.
83.
84.
85.
86.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Mainshaft assembly
Transmission case
Added
22D-3-27

V5M21-9-P
1
19 3 Nm

moving parts before
installation.
8
9
35 6 Nm
7
35 6 Nm
10
11
13
12
11
10
35 6 Nm
35 6 Nm
"eA
"dA
Disassembly steps
2. Bracket
3. Spring pin
4. Change shifter
6. Adapter gasket
7. Plug
8. Spring
9. Steel ball
Aug. 2000
"aA 10.
11.
"ZA 12.
"ZA 13.
PWEE8914-J
Seal plug
Added
22D-3-28
V5M21-9-P
17

moving parts before
installation.
23
18
20
19 3 Nm
19
19 3 Nm
21
19 3 Nm
22
16
15
14
29 2 Nm
Disassembly steps
15. Gasket
16. Steel ball
"cA 17. Breather
18. Plug

"XA 20. Case gasket
21. Lock pin*
22. Control finger*
23. Control shaft*
Caution
Aug. 2000
PWEE8914-J
Added
22D-3-29

V5M21-9-P
32
33
31
26
27
26
28
34
27
28
39
35
172 14 Nm
36
38
30
37

moving parts before
installation.
29
25
24
9 1 Nm
"VA
"VA
"VA
"UA
"UA
Disassembly steps
24. Under cover
26. Poppet plug
27. Poppet spring
28. Steel ball
fork
fork
Aug. 2000
"TA 31.
32.
33.
34.
35.
"SA 36.
"RA 37.
38.
39.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-30
V5M21-9-P

moving parts before
installation.
255 10 Nm
52
53
66
44
46
40
42
56
58
20 2 Nm
45
43
41
50
51
57
55
52
54
62
48
47
63
20 2 Nm
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
AB" "PA 48. Counter reverse gear
49. Spacer
Aug. 2000
"MA 54.
55.
56.
"LA 57.
58.
59.
60.
61.
62.
63.
"JA 64.
AD" "KA 65.
"JA 66.
67.
PWEE8914-J
40 19 Nm
65
67
49
61 60
59
64

Reverse gear
Needle bearing
Bearing sleeve
Spacer
Split pin
Slotted nut
Thrust washer
Reverse idler gear
Needle bearing
Bolt
Bolt
Added
22D-3-31

V5M21-9-P
70
71
88

moving parts before
installation.
69
68
81
80
77
79
72
86
78
74
75
76
87
85
84
12 1 Nm
73
83
82
Disassembly steps
"IA 68. Spacer
AE" "HA 69. Countershaft center bearing outer
race
71. Bearing spacer
"EA 74. Oil seal
75. Spacer
AG" "DA 76. Countershaft front bearing outer
race
"CA 77. Spacer
Aug. 2000
"BA 78.
79.
AH" "AA 80.
81.
82.
83.
84.
85.
86.
87.
88.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Mainshaft assembly
Transmission case
Added
22D-3-32
V5M21-9-T
1
19 3 Nm

moving parts before
installation.
8
9
35 6 Nm
7
35 6 Nm
10
11
13
12
11
10
35 6 Nm
35 6 Nm
"eA
"dA
Disassembly steps
2. Bracket
3. Spring pin
4. Change shifter
6. Adapter gasket
7. Plug
8. Spring
9. Steel ball
Aug. 2000
"aA 10.
11.
"ZA 12.
"ZA 13.
PWEE8914-J
Seal plug
Added
22D-3-33

V5M21-9-T
17

moving parts before
installation.
23
18
20
19 3 Nm
19
19 3 Nm
21
19 3 Nm
22
16
15
14
29 2 Nm
Disassembly steps
15. Gasket
16. Steel ball
"cA 17. Breather
18. Plug

"XA 20. Case gasket
21. Lock pin*
22. Control finger*
23. Control shaft*
Caution
Aug. 2000
PWEE8914-J
Added
22D-3-34
V5M21-9-T
32
33
31
26
27
26
28
34
27
28
39
35
172 14 Nm
36
38
37

moving parts before
installation.
30
29
25
24
9 1 Nm
"VA
"VA
"VA
"UA
"UA
Disassembly steps
24. Under cover
26. Poppet plug
27. Poppet spring
28. Steel ball
fork
fork
Aug. 2000
"TA 31.
32.
33.
34.
35.
"SA 36.
"RA 37.
38.
39.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Added
22D-3-35

V5M21-9-T

moving parts before
installation.
255 10 Nm
44
52
53
20 2 Nm
46
40
42
56
45
43
41
50
51
55
64
63
65
49
52
48
54
60
59
40 19 Nm
58
47
61
57
62
20 2 Nm
Disassembly steps
"QA 40. Snap ring
41. Spacer
42. Steel ball
43. Overdrive gear
44. Needle bearing
45. Bearing spacer
47. Spacer
49. Spacer
Aug. 2000

55. Reverse gear
56. Needle bearing
57. Split pin
58. Slotted nut
59. Thrust washer
61. Needle bearing
"JA 62. Bolt
"JA 64. Bolt
PWEE8914-J
Added
22D-3-36
V5M21-9-T
69
moving parts before
installation.
78
86
68
66
79
67
77
75
70
76
85
73 74
84
72
83
12 1 Nm
82
71
81
80
Disassembly steps
"IA 66. Spacer
race
AF" "LA 68. Bearing sleeve
"EA 72. Oil seal
73. Spacer
race
"CA 75. Spacer
Aug. 2000
"BA 76.
77.
AH" "AA 78.
79.
80.
81.
82.
83.
84.
85.
86.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Mainshaft assembly
Transmission case
Added
22D-3-37

V5M21-A

moving parts before
installation.
1
2
3
35 6 Nm
7
8
5
6
10
8
7
35 6 Nm
35 6 Nm
"eA
"hA
"aA
"ZA
Disassembly steps
1. Spring pin
2. Change shifter
4. Plug
5. Spring
6. Steel ball
7. Seal plug
8. Neutral return spring
9. Neutral return plunger B
Aug. 2000
"ZA 10. Neutral return plunger A
PWEE8914-J
Added
22D-3-38
V5M21-A

moving parts before
installation.
22
15
17
19
16
19 3 Nm
11
18
20
24
21
14
13
23
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
12
19 3 Nm
29 2 Nm
18.
AA" "YA 19.
20.
21.
22.
"WA 23.
"WA 24.
Baffle plate
Transfer case adapter*
Lock pin*
Control finger*
Control shaft*
Snap ring
Mainshaft rear bearing
Caution
Aug. 2000
PWEE8914-J
Added
22D-3-39

V5M21-A
33

moving parts before
installation.
34
27
32
28
27
35
29
28
29
36
40
37
38
172 14 Nm
39
31
30
26
25
9 1 Nm
"VA
"VA
"VA
"UA
"UA
Disassembly steps
25. Oil pan
26. Oil pan gasket
27. Poppet plug
28. Poppet spring
29. Steel ball
fork
fork
Aug. 2000
"TA 32.
33.
34.
35.
36.
"SA 37.
"RA 38.
39.
40.
PWEE8914-J

OD-R shift rail
OD-R shift fork
Interlock plunger
Countershaft overdrive gear
Added
22D-3-40
V5M21-A

moving parts before
installation.
255 10 Nm
45
49
48
47
44
43
42
51
46
50
66
67
57
55
54
53
52
50
40 19 Nm
59
20 2 Nm
60
58
56
62
63
61
64
65
20 2 Nm
41
AB" "PA
AC" "OA
"MA
"MA
"NA
"NA
"MA
Disassembly steps
41. 1st-2nd speed shift fork
42. Mainshaft lock nut
43. Spacer
44. Steel ball
45. Overdrive gear
46. Needle bearing
47. Bearing sleeve
48. Overdrive synchronizer ring
49. OD-R synchronizer sleeve
50. OD-R synchronizer spring
51. OD-R synchronizer key
52. OD-R synchronizer hub
53. Reverse synchronizer ring
54. Reverse gear
Aug. 2000
"fA
"JA
AD" "KA
"JA
PWEE8914-J
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
Needle bearing
Counter reverse gear
Spacer
Split pin
Reverse idler gear shaft nut
Thrust washer
Reverse idler gear
Friction damper
Needle bearing
Reverse idler gear shaft seal bolt
Rear bearing retainer seal bolt
Added
22D-3-41

V5M21-A

moving parts before
installation.
70
88
71
68
80
69
81
74
82
12 1 Nm
76
78 79
75
77
87
83
73
84
72
85
86
Disassembly steps
"IA 68. Spacer
race
"LA 70. Reverse gear bearing sleeve
71. Mainshaft center bearing outer race
"EA 74. Oil seal
"CA 75. Spacer
76. Spacer
race
Aug. 2000
"BA 78.
79.
AH" "AA 80.
81.
82.
83.
84.
85.
86.
87.
88.
PWEE8914-J
Snap ring
Snap ring
Maindrive gear
Oil guide
Synchronizer ring
Countershaft
Mainshaft
Transmission case
Added
22D-3-42
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.
AB" MAINSHAFT LOCK NUT REMOVAL

(1) Use the special tool to remove the lock nut.
MD998809
AC" BEARING SLEEVE REMOVAL

(1) Use the special tools to remove the bearing sleeve.
MD998020
MD998028
(V5M21)
Bearing sleeve
MD998192
Aug. 2000
AD" REVERSE IDLER GEAR SHAFT REMOVAL

(1) Use the special tool to remove the reverse idler gear
shaft.
AE" COUNTERSHAFT CENTER BEARING REMOVAL

(1) Use the special tool to remove the countershaft center
bearing.
PWEE8914-J
Added
22D-3-43
AF" MAINSHAFT CENTER BEARING REMOVAL

(1) Use the special tools to remove the mainshaft center
bearing and bearing sleeve.
Mainshaft center
bearing
MD998020
Bearing sleeve
MD998028
AG" COUNTERSHAFT FRONT BEARING REMOVAL

(1) Use the special tool to remove the countershaft front
bearing.
MD998192
MD998020
Aug. 2000
AH" MAINDRIVE GEAR BEARING REMOVAL

(1) Use the special tool to remove the maindrive gear bearing.
PWEE8914-J
Added
22D-3-44

REASSEMBLY SERVICE POINTS
MD998813
MD998819
MD998812
"AA MAINDRIVE GEAR BEARING INSTALLATION

(1) Use the special tool to install the maindrive gear bearing.
TRM0033
"BA SNAP RING INSTALLATION

(1) Select and install snap ring so that maindrive gear bearing
end play reaches the standard value.
Standard value: 0 - 0.06 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.
"DA COUNTERSHAFT FRONT BEARING

INSTALLATION
(1) Use the special tool to install the countershaft front
bearing.
MD998819
Aug. 2000
PWEE8914-J
Added
MD998200
22D-3-45
"EA OIL SEAL INSTALLATION

(1) After applying grease to the oil seal lips, use the special
tool to install the oil seal.
Specified grease:
equivalent
"FA FRONT BEARING RETAINER GASKET

INSTALLATION
(1) After applying sealant to the front bearing retainer gasket.
(Both sides)
Specified sealant:
Mitsubishi genuine sealant Part No. 997740 or
equivalent
"GA MAINSHAFT CENTER BEARING INSTALLATION

(1) Use the special tools to install the mainshaft center
bearing.
MD998812
MD998814
MD998813
MD998819
TRM0036
MD998812
"HA COUNTERSHAFT CENTER BEARING

INSTALLATION
(1) Use the special tools to install the countershaft center
bearing.
MD998813
MD998816
TRM0037
"IA SPACER INSTALLATION

(1) Press the outer race and counter gear in positively.
Aug. 2000
PWEE8914-J
Added
22D-3-46

(2) Install the selective spacer and use a straight edge.
(3) Select an appropriate, spacer to obtain the standard value.
Straight edge
Thickness gauge
"JA BOLT INSTALLATION

(1) Apply sealant to the bolt beforehand.
Specified sealant:
equivalent
6 mm
2 mm
"KA REVERSE IDLER GEAR SHAFT INSTALLATION

(1) Use the bolt (M8 50 mm) as a guide to install the reverse
idler gear shaft.
Reverse idler
gear
Bolt
"LA BEARING SLEEVE INSTALLATION

(1) Use the special tools to install the bearing sleeve.
MD998812
MD998814
MD998813
MD998819
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
Aug. 2000
PWEE8914-J
Added
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
"OA BEARING SLEEVE INSTALLATION

MD998812
MD998813
MD998814
MD998818
TRM0039
MD998809
"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
Aug. 2000
PWEE8914-J
Added
22D-3-48

"QA SNAP RING INSTALLATION
(1) Select and install snap ring so that overdrive gear end
play reaches the standard value.
Snap ring
Standard value: 0.15 - 0.40 mm
MD998812
MD998816
"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.
Aug. 2000
PWEE8914-J
Added
22D-3-49
"UA SPRING PIN INSTALLATION

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.
(2) Apply sealant to the poppet plug.
5.5 - 6.0 mm
Specified sealant:
Apply
sealant
5.5 - 6.0 mm
5.5 - 6.0 mm
Snap ring
Mainshaft
"WASNAP RING INSTALLATION

(1) Install a snap ring of the same size as having been used.
(2) Use the special tools to install the mainshaft rear bearing.
MD998812
MD998814
MD998817
Mainshaft
rear bearing
Aug. 2000
PWEE8914-J
Added
22D-3-50
Standard value
Snap ring
(3) Select and install a snap ring with which the mainshaft
rear bearing clearance can be adjusted to standard value.
(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:
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:
equivalent
"aA SEAL PLUG INSTALLATION

(1) Apply sealant to the threaded area of the seal plug before
tightening to specified torque.
Specified sealant:
NOTE
Ensure that any old sealant still adhering to the seal
plug is fully removed.
Aug. 2000
PWEE8914-J
Added

Mating marks
Identification mark
22D-3-51
"bA SPEEDOMETER GEAR INSTALLATION

(1) Match the mating marks to the number of teeth.
"cA AIR BREATHER INSTALLATION

(1) Apply sealant to the air breather.
Specified sealant:
3M Super Weatherstrip No. 8001 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:
equivalent
(Both sides)
"eA SPRING PIN INSTALLATION

as shown.
Change shifter
Change shifter
3 - 3.5 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:
equivalent
Friction damper
Aug. 2000
PWEE8914-J
Added
22D-3-52
MD998803
"gA OIL SEAL INSTALLATION

(1) After applying grease to the oil seal lips, use the special
tool to install the oil seal.
Specified grease:
equivalent
Plug
Aug. 2000
"hA PLUG INSTALLATION

(1) Screw in the plug until end is flush with the end face
of the transfer case adapter.
PWEE8914-J
Added
MANUAL TRANSMISSION - Extension Housing
22D-4-1
4. EXTENSION HOUSING

moving parts before
installation.
6
8
2
3
9
Disassembly steps
1. Lock pin
2. Lock pin
3. Control finger and control shaft
4. Neutral return finger
5. Change shifter
Aug. 2000
6. Dust seal guard

"BA 7. Control shaft cap
"AA 8. Oil seal
9. Extension housing
PWEE8914-J
Added
22D-4-2
MANUAL TRANSMISSION - Extension Housing

Oil seal

"AA OIL SEAL INSTALLATION
(1) After installation, pack grease between the lips of the
oil seal.
Specified grease:
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:
Aug. 2000
PWEE8914-J
Added
22D-5-1
MANUAL TRANSMISSION - Countershaft
5. COUNTERSHAFT
Disassembly steps
AA" "BA 1. Countershaft front bearing inner
race
AB" "AA 2. Countershaft center bearing inner
race
Aug. 2000
3. Countershaft gear
PWEE8914-J
Added
22D-5-2
Bearing inner race
Bearing inner race
MANUAL TRANSMISSION - Countershaft

MD998817
MD998817
MD998812
MD998813

AA" COUNTERSHAFT FRONT BEARING INNER RACE
REMOVAL
(1) Use the special tool to remove the Countershaft front
bearing inner race.
AB" COUNTERSHAFT CENTER BEARING INNER

RACE REMOVAL
(1) Use the special tool to remove the Countershaft center
bearing inner race.

"AA COUNTERSHAFT CENTER BEARING INNER
RACE INSTALLATION
(1) Use the special tools to install the Countershaft center
bearing inner race.
MD998816
TRM0046
MD998816
MD998812
"BA COUTERSHAFT FRONT BEARING INNER RACE

REMOVAL
(1) Use the special tools to install the Countershaft front
bearing inner race.
TRM0045
Aug. 2000
PWEE8914-J
Added
22D-6-1
MANUAL TRANSMISSION - Mainshaft
6. MAINSHAFT
R5M21
19
18 20
17
16 14 15
15
13
21
1
2
9
5
6
11
7
AB" "EA
"DA
"BA
"BA
10
Disassembly steps
1. Ball bearing inner race (double row
ball bearing)
2. Spacer (single raw ball bearing)
3. 1st speed gear
4. Needle bearing
5. Bearing sleeve
6. Synchronizer ring
7. 1st-2nd speed synchronizer sleeve
8. Synchronizer spring
9. Synchronizer key
10. 1st-2nd speed synchronizer hub
12
AA" "FA
Aug. 2000
PWEE8914-J
"CA
"AA
"BA
"BA
"AA
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2nd speed gear

Needle bearing
Snap ring
3rd-4th speed synchronizer sleeve
Synchronizer spring
Synchronizer key
3rd-4th speed synchronizer hub
Synchronizer ring
3rd speed gear
Needle bearing
Mainshaft
Added
22D-6-2
V5M21 (1ST-2ND SINGLE SYNCHRONIZER RING TYPE)
19
18 20
17
16 14 15
15
13
21
1
2
9
5
6
12
7
6
AB" "EA
"DA
"BA
"BA
10
Disassembly steps
1. Ball bearing inner race (double row
ball bearing)
2. Spacer (single raw ball bearing)
3. 1st speed gear
4. Needle bearing
5. Bearing sleeve
6. Synchronizer ring
9. Synchronizer key
11
AA" "FA
Aug. 2000
PWEE8914-J
"CA
"AA
"BA
"BA
"AA
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2nd speed gear

Needle bearing
Snap ring
Synchronizer spring
Synchronizer key
Synchronizer ring
3rd speed gear
Needle bearing
Mainshaft
Added
22D-6-3

V5M21 (1ST-2ND DOUBLE SYNCHRONIZER RING TYPE)
21
20
17 16
18
15
19
16
5
14
12
13
22
1
3
4
5
10
6
7
8
9
11
9
AA" "FA
AB" "EA
"DA
"BA
"BA
Disassembly steps
1. Ball bearing inner race
2. 1st speed gear
3. Needle bearing
4. Bearing sleeve
5. Synchronizer inner ring
6. Synchronizer cone
7. Synchronizer outer ring
10. Synchronizer key
Aug. 2000
PWEE8914-J
"CA
"AA
"BA
"BA
"AA
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
2nd speed gear

Needle bearing
Snap ring
Synchronizer spring
Synchronizer key
Synchronizer ring
3rd speed gear
Needle bearing
Mainshaft
Added
22D-6-4
1st speed gear

Bearing inner race
MD998917
2nd speed gear
Bearing inner race

MD998917
AA" BALL BEARING INNER RACE REMOVAL

(1) Support the 1st speed gear on the special tool as
illustrated.
(2) Remove the ball bearing inner race using a press.
AB" BEARING SLEEVE REMOVAL

(1) Support the 2nd speed gear on the special tool as
illustrated.
(2) Remove the bearing sleeve using a press.
INSPECTION
A
Gear
Synchronizer
ring
SYNCHRONIZER RING
(1) Check the synchronizer ring for worn and damaged
internal threads.
(2) With synchronizer assembled to cone of each gear, check
dimension A. If dimension A exceeds the limit, replace
the synchronizer ring and/or gear.
Limit: 0.5 mm
OUTER SYNCHRONIZER RING / INNER

SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surfaces and
cone surfaces are not damaged and broken.
Gear
Outer ring
(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance A. If A is less
than the limit, replace.
Limit: 0.3 mm
Cone
Caution
When any of the outer ring, inner ring or cone has
to be replaced, replace them as a set.
Inner ring
Aug. 2000
PWEE8914-J
Added

45
22D-6-5
30
"AA 3RD-4TH SPEED SYNCHRONIZER SLEEVE /

3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
(1) Assemble the synchronizer hub and sleeve. Make sure
that the hub and sleeve slide smoothly.
Front
Hub
Sleeve
Key
Step of spring
"BA SYNCHRONIZER KEY / SYNCHRONIZER SPRING

INSTALLATION
(1) Install two synchronizer springs. When installing springs,
make sure that steps of front and rear springs are
positioned on a synchronizer key, but not on the same
key.
Step of spring
"CA SNAP RING INSTALLATION

(1) Select and install the snap ring so that the synchronizer
hub end play may reach the standard value.
End play
Snap ring
Identification
groove
"DA 1ST-2ND SPEED SYNCHRONIZER SLEEVE

INSTALLATION
(1) Install the synchronizer sleeve in the illustrated direction.
Installation
direction
MD998812
MD998813
"EA BALL BEARING INNER RACE INSTALLATION

MD998814
MD998819
TRM0098
Aug. 2000
PWEE8914-J
Added
22D-6-6
MD998067
Bearing
sleeve
Aug. 2000
"FA BEARING SLEEVE INSTALLATION

(1) Use the special tool to install the bearing sleeve.
PWEE8914-J
Added
MANUAL TRANSMISSION - Speedometer Gear
22D-7-1
7. SPEEDOMETER GEAR
1

moving parts before
installation.
2
5
3
4
Disassembly Steps
"AA 1. Spring pin
2. Driven gear
3. Sleeve
Spring pin
4. O-ring
5. O-ring
REASSEMBLY SERVICE POINT
Slit
"AA SPRING PIN INSTALLATION

(1) Drive the spring pin in, while making sure that slit does
not face gear shaft.
O-ring
Aug. 2000
PWEE8914-J
Added
NOTES
22D-8-1
MANUAL TRANSMISSION - Transfer
8. TRANSFER <V5M21-9>
<LHD>
1
3
2

moving parts before
installation.
34 5 Nm
12
35 6 Nm
6
34 5 Nm
35 6 Nm
35 6 Nm
7
1
3
13
10
35 6 Nm
32 2 Nm
5
6
17
18
15
11
14
16
19 3 Nm
19 3 Nm
Disassembly steps
"QA 1. Detection switch
2. Steel ball
3. Gasket
"PA 4. Plug
"OA 5. Poppet plug
6. Poppet spring
7. Steel ball
8. Sleeve clamp
"NA 9. Speedometer gear
Aug. 2000
"MA 10. Rear cover

"MA 11. Spacer
12. Dust seal guard
"LA 13. Oil seal
14. Snap ring
"KA 15. Cover
"KA 16. Wave spring
17. H-L shift rail plug
"JA 18. Spring pin for H-L shift fork
PWEE8914-J
Added
22D-8-2
<LHD>
moving parts before
installation.
35
32
41
36
33
31
21
32
34
38
37
43
19
42
19 3 Nm
27
28
9 1 Nm
44
29
28
20
30
35 6 Nm
39
24
29
22
23
40
25
26
Disassembly steps
AA" "JA 19. H-L shift rail
AA" "IA 20. Chain cover
"IA 21. Interlock plunger
22. Side cover
23. Side cover gasket
24. Lock plate
AB" "HA 25. Counter gear shaft
26. O-ring
27. Counter gear
"GA 28. Thrust washer
29. Needle bearing
30. Bearing spacer
31. Snap ring for 2-4WD shift rail
Aug. 2000
"FA
AC" "EA
AC" "EA
AC" "EA
PWEE8914-J
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Spring retainer
Spring
Spring pin for 2-4WD shift lug
2-4WD shift rail
Distance piece
2-4WD shift lug
Rear output shaft
Chain
Front output shaft
2-4WD shift fork
H-L shift fork
H-L clutch sleeve
Needle bearing
Added
22D-8-3

<LHD>

moving parts before
installation.
45
46
52
51
48
47
50
49
Disassembly steps
"DA 45. Snap ring
46. Input gear
"CA 47. Oil seal (Input gear)
48. Baffle plate
Aug. 2000
49. Dust seal guide

"BA 50. Oil seal (Front output shaft)
"AA 51. Oil seal
52. Transfer case
PWEE8914-J
Added
22D-8-4
<RHD>

moving parts before
installation.
1
3
2
34 5 Nm
12
35 6 Nm
13
6
7
35 6 Nm
35 6 Nm
1
3
10
34 5 Nm
11
14
18
15
17
19 3 Nm
32 2 Nm
35 6 Nm
19 3 Nm
6 5
Disassembly steps
"QA 1. Detection switch
2. Steel ball
3. Gasket
"PA 4. Plug
"OA 5. Poppet plug
6. Poppet spring
7. Steel ball
8. Sleeve clamp
"NA 9. Speedometer gear
Aug. 2000
16
"MA 10. Rear cover

"MA 11. Spacer
12. Dust seal guard
"LA 13. Oil seal
14. Snap ring
"KA 15. Cover
"KA 16. Wave spring
17. H-L shift rail plug
"JA 18. Spring pin for H-L shift fork
PWEE8914-J
Added
22D-8-5

<RHD>
35
21
41
32
33
31
32
34
42
38
43 44
19
36
37
27
28
9 1 Nm
19 3 Nm
28
20
30
29
35 6 Nm
39
24
22
29
23
40
26

moving parts before
installation.
25
Disassembly steps
AA" "JA 19. H-L shift rail
AA" "IA 20. Chain cover
"IA 21. Interlock plunger
22. Side cover
23. Side cover gasket
24. Lock plate
AB" "HA 25. Counter gear shaft
26. O-ring
27. Counter gear
"GA 28. Thrust washer
29. Needle bearing
30. Bearing spacer
31. Snap ring for 2-4WD shift rail
Aug. 2000
"FA
AC" "EA
AC" "EA
AC" "EA
PWEE8914-J
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Spring retainer
Spring
Spring pin for 2-4WD shift lug
2-4WD shift rail
Distance piece
2-4WD shift lug
Rear output shaft
Chain
Front output shaft
2-4WD shift fork
H-L shift fork
H-L clutch sleeve
Needle bearing
Added
22D-8-6
<RHD>

moving parts before
installation.
45
46
52
51
48
47
50
49
Disassembly steps
"DA 45. Snap ring
46. Input gear
"CA 47. Oil seal (Input gear)
48. Baffle plate
Aug. 2000
49. Dust seal guide

"BA 50. Oil seal (Front output shaft)
"AA 51. Oil seal
52. Transfer case
PWEE8914-J
Added
22D-8-7

SERVICE POINTS OF DISASSEMBLY
<RHD>
AA" H-L SHIFT RAIL / CHAIN COVER REMOVAL

(1) Lock the H-L shift rail at the high side, using the poppet
spring.
(2) Place the 2-4WD shift rail at the 4WD position.
TRM0272
NOTE
If the 2-4WD shift rail is left at the 2WD position, the
chain cover cannot be removed because interlock is
actuated.
(3) Remove the chain cover and remove the H-L shift rail.
<LHD>
2-4WD
shift rail
TRM0281
AB" COUNTER GEAR SHAFT REMOVAL

(1) Remove the counter gear shaft toward the transmission
case side.
TRA0277
AC" REAR OUTPUT SHAFT / CHAIN / FRONT

OUTPUT SHAFT REMOVAL
(1) Remove the front output shaft, rear output shaft and chain
together.
INSPECTION
Detection Switch Inspection
(1) Check for continuity between the connector terminal and
switch body.
Switch state
Continuity
Switch end pressed
No
Switch end released
Exists
TRA0280
Aug. 2000
PWEE8914-J
Added
22D-8-8

(1) Using a socket wrench, install the oil seal. After installation,
pack the lips with grease.
TRM0220
"BA OIL SEAL (FRONT OUTPUT SHAFT)

INSTALLATION
(1) Apply transmission oil to the lip of the oil seal before
press-fitting.
MB990929
MB990938
Transfer case
"CA OIL SEAL (INPUT GEAR) INSTALLATION

press-fitting.
MB990934
MB990938
Transfer case
Input gear
"DA SNAP RING INSTALLATION

(1) Select the thickest snap ring that will fit into the groove
and install it.
Strandard value: 0 - 0.06 mm
"EA REAR OUTPUT SHAFT / CHAIN / FRONT

OUTPUT SHAFT INSTALLATION
(1) Engage the chain precisely with the sprockets of the rear
output shaft and the front output shaft.
(2) Install the 2-4WD shift fork on the 2-4WD clutch sleeve.
While passing them along the 2-4WD shift rail, install
the rear and front output shafts and chain.
Aug. 2000
PWEE8914-J
Added
22D-8-9
"FA SPRING PIN INSTALLATION

as shown.
TRM0210
Thrust washer
Groove
Tab
Counter gear
"GA THRUST WASHER INSTALLATION

(1) Install the thrust washer in such a way that the tab will
fit into the case groove.
Groove
"HA COUNTER GEAR SHAFT INSTALLATION

(1) Insert the counter gear shaft from the transmission case
side, while taking into account the lock plate groove
position.
TRA0285
"IA CHAIN COVER / INTERLOCK PLUNGER

INSTALLATION
(1) Insert the interlock plunger into a position where it does
not interfere with the 2-4WD shift rail.
(2) Apply a sealant to the chain cover before installing it.
Specified sealant:
equivalent
TRA0289
Aug. 2000
Caution
Squeeze the sealant out evenly to apply it in an
unbroken, non-excessive quantity.
PWEE8914-J
Added
22D-8-10
RHD

"JA H-L SHIFT RAIL / SPRING PIN FOR H-L SHIFT
FORK INSTALLATION
(1) Insert the H-L shift rail from the H-L shift rail plug hole,
while taking into account its direction.
(2) Line up the shift rail and shift fork spring pin holes and
install the spring pin so that the slit of the spring pin
will face the axial center of the shift rail.
RHD
LHD
LHD
"KA COVER / WAVE SPRING (SPACER)

INSTALLATION
(1) Measure projection A of the front output shaft rear
bearing and depth B of the cover.
If B is more than 2 mm greater than A, add a spacer
between the wave spring and cover.
If the difference is 2 mm or less, using only the wave
spring is enough.
(2) Apply a sealant to the cover.
Specified sealant:
equivalent
Wave spring
Caution
Squeeze out the sealant evenly to apply it in an
unbroken, non-excessive quantity.
Spacer
"LA OIL SEAL INSTALLATION

press-fitting.
MB990938
MB990929
Aug. 2000
PWEE8914-J
Added
"MASPACER / REAR COVER INSTALLATION

(1) Measure projection A of the rear output shaft bearing
and depth B of the second stage of the rear cover.
Subtract A from B and let the answer be C. Subtract
the thickness of the spacer from C, and select a snap
ring so that the subtracted value will be the standard
value shown below.
Rear cover
22D-8-11

(2) Apply sealant to the rear cover.
Specified sealant:
equivalent
Snap ring
Spacer
TRA0293
"NA SPEEDOMETER GEAR INSTALLATION

(1) Match the matching marks to the number of teeth.
Matching
marks
TRA0295
"OA SEALANT TO POPPET PLUG INSTALLATION

(1) Apply sealant to the poppet plug before installation.
Specified sealant:
TRA0296
"PA SEALANT TO PLUG INSTALLATION

(1) The plug is a precoated one. When it is to be reused,
apply sealant to the plug beforehand.
Specified sealant:
TRA0297
Aug. 2000
PWEE8914-J
Added
22D-8-12
"QA DETECTION SWITCH INSTALLATION

(1) Mount detection switches in the right position, while being
careful not to confuse anything.
LHD
A: Ball built in
B: Ball separate
A
TRA0300
RHD
A: Ball built in
B: Ball separate
A
TRM0229
Aug. 2000
PWEE8914-J
Added
22D-9-1
9. TRANSFER <V5M21-A>
34 5 Nm
5
3
10
1
19 3 Nm
26
32 2 Nm
25
24
7
8
27
34 5 Nm
35 6 Nm
23
20
22
21
28
19
12
11 1 Nm
14
18
11
17
34 5 Nm
13

moving parts before
installation.
16
34 5 Nm
35 6 Nm
15
34 5 Nm
"cA
"bA
"bA
"aA
"ZA
Disassembly steps
1. Dust seal guard
2. Dust seal guard
3. Select plunger seal plug
4. Return spring
5. Return spring
6. Select plunger
7. Hi-Lo detector switch
8. Gasket
9. 4WD operation detector switch
10. Gasket
11. Lock operation detector switch
12. Gasket
13. 4WD detector switch
14. Gasket
Aug. 2000
"ZA 15.
16.
"YA 17.
"XA 18.
19.
"YA 20.
"XA 21.
22.
AA" "WA 23.
"VA 24.
"UA 25.
26.
"TA 27.
28.
PWEE8914-J
Lock detector switch

Gasket
Poppet seal bolt
Spring
Steel ball
Poppet seal bolt
Spring
Steel ball
Transfer control housing
Spring pin
Spring pin
Hi-Lo shift lug
2WD/4WD shift lug
Vehicle speed sensor
Added
22D-9-2

35 6 Nm

moving parts before
installation.
32
40
30
33
41
38
36
31
46
29
34
44
35
37
39
43
42
45
AB" "SA
"RA
"QA
"PA
"OA
AC" "NA
"MA
"LA
Disassembly steps
29. Transfer rear cover
30. Oil seal
31. Oil guide
32. Wave spring
33. Snap ring
34. Ball bearing
35. Viscous coupling
36. Snap ring
37. Spacer
Aug. 2000
38. Steel ball

AD" "KA 39. 2WD/4WD synchronizer
AD" "KA 40. Chain
AD" "KA 41. Front output shaft
42. Needle bearings
"JA 43. Spacer
44. Steel ball
"IA 45. Synchronizer sleeve
"IA 46. 2WD/4WD shift fork and rail
PWEE8914-J
Added
22D-9-3

moving parts before
installation.
54
53
52
47
51
49
56
57
58
55
50
48
35 6 Nm
AE" "HA
"GA
"FA
"EA
Disassembly steps
47. Transfer case plate
48. Thrust washer
49. Needle bearing
50. Counter gear
51. Hi-Lo clutch sleeve
52. Spring pin
Aug. 2000
"EA 53. Hi-Lo shift fork

"EA 54. Hi-Lo shift rail
55. Needle bearings
56. Bearing spacer
"DA 57. Counter gear shaft
"DA 58. Thrust washer
PWEE8914-J
Added
22D-9-4
19 3 Nm

moving parts before
installation.
61
59
60
65
62
63
64
Disassembly steps
"CA 59. Snap ring
60. Differential lock hub
"BA 61. Center bearing retainer seal bolt
62. Center bearing retainer
63. Rear output shaft
"AA 64. Oil seal
65. Transfer case
Aug. 2000
PWEE8914-J
Added
22D-9-5

AA" TRANSFER CONTROL HOUSING REMOVAL
(1) Remove the transfer control housing by tapping lightly
with a plastic hammer or some other similar tool.
Transfer
control
housing
AB" TRANSFER REAR COVER REMOVAL

(1) Tap the transfer rear cover at the two locations indicated
in the illustration to remove it.
AC" BALL BEARING REMOVAL

(1) Remove the ball bearing using the indicated special tool.
MD998020
Ball
bearing
AD" 2WD/4WD SYNCHRONIZER / CHAIN / FRONT

OUTPUT SHAFT REMOVAL
(1) Remove the 2WD/4WD synchronizer, chain, and front
output shaft at the same time.
AE" TRANSFER CASE PLATE REMOVAL

(1) Tap the transfer case plate at the two locations indicated
in the illustration to remove it.
Caution
The counter gear and ancillary parts will be freed
together; take care to avoid letting them fall.
Aug. 2000
PWEE8914-J
Added
22D-9-6

(1) Apply grease to the lip of the oil seal; then assemble
the seal using the indicated special tool.
Apply
grease
Specified grease:
Mitsubishi genuine grease Part No. MD0101011
or equivalent
MD998800
"BA CENTER BEARING RETAINER SEAL BOLT

INSTALLATION (when reused)
(1) Apply sealant to the threaded area of the bolt indicated
in the illustration; following this, tighten to the specified
torque.
Apply
sealant
Specified sealant:
NOTE
Ensure that any old sealant still adhering to the seal
bolt is fully removed.
6 mm
2 mm
Differential lock hub

Standard value

(1) Select and install a suitable snap ring to ensure that
the end play of the differential lock hub is at the standard
value.
Snap ring
"DA THRUST WASHER / COUNTER GEAR SHAFT

INSTALLATION
(1) Install the thrust washer on the counter gear shaft as
shown with the oil grooves in the washer oriented in the
indicated direction.
Thrust washer
Aug. 2000
PWEE8914-J
Added
22D-9-7
(2) Install the counter gear shaft with its notch toward the
center bearing retainer so that it can be prevented from
turning by the retainer.
Center bearing
retainer
Counter gear shaft
"EA HI-LO SHIFT RAIL / HI-LO SHIFT FORK /

SPRING PIN INSTALLATION
(1) Assemble the Hi-Lo shift rail and Hi-Lo shift fork in such
a way that they are oriented as shown.
Notch
(2) Drive in the spring pin with its slit oriented as shown.
Spring pin
"FA HI-LO CLUTCH SLEEVE INSTALLATION

(1) Install the Hi-Lo clutch sleeve in the indicated orientation.
Installation direction
"GA THRUST WASHER INSTALLATION

(1) Align the flat of the thrust washer with that of the counter
gear shaft, then install the thrust washer with its
oil-grooved surface facing the counter gear.
Thrust washer
Counter gear
shaft
Aug. 2000
PWEE8914-J
Added
22D-9-8

Notched sector
"HA TRANSFER CASE PLATE INSTALLATION

(1) Align the teeth of the input gear which are located at
the notched section with those of the sub-gear.
Teeth of input gear Teeth of sub-gear
(2) Apply sealant to the illustrated position of the transfer

case plate.
Specified sealant:
Mitsubishi genuine sealant Part No. MD997740
or equivalent
Caution
Squeeze the sealant out evenly to ensure that the
bead is not broken and that over-application is not
performed.
Apply
sealant
(3) Direct the notch in the input gear toward the counter
gear, then install the transfer case plate while using care
that the teeth alignment attained in step (1) may be
maintained.
NOTE
The transfer case plate must be installed smoothly without
hitching.
"IA 2WD/4WD SHIFT FORK, SHIFT RAIL /

SYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve in the indicated direction.
Installation
direction
(2) Shift the Hi-Lo shift rail in the illustrated position, then
assemble the synchronizer sleeve, the 2WD/4WD shift
fork, and the shift rail.
Aug. 2000
PWEE8914-J
Added

Oil grooves
22D-9-9
"JA SPACER INSTALLATION

(1) Install the spacer with its oil grooves oriented as indicated.
"KA FRONT OUTPUT SHAFT / CHAIN / 2WD/4WD

SYNCHRONIZER INSTALLATION
(1) Apply white paint or something similar to the three deep
tooth grooves in the 2WD/4WD synchronizer sprocket.
(2) Apply white paint or something similar to the three spline

projections on the synchronizer sleeve.
(3) Mesh the chain with the 2WD/4WD synchronizer sprocket

and the front output shaft sprocket.
(4) With the sprockets distanced as far from each other as
possible, install the assembly in the case while aligning
the markings made in steps (1) and (2) above.
"LA SPACER INSTALLATION

(1) Install the spacer with its oil grooves facing the 2WD/4WD
synchronizer.
Spacer
Aug. 2000
PWEE8914-J
Added
22D-9-10

"MAVISCOUS COUPLING INSTALLATION
(1) If the grooves in the viscous coupling and the 2WD/4WD
synchronizer are not aligned, slowly rotate either the rear
output shaft or the viscous coupling itself to bring each
into alignment.
MD998812
MD998814
"NA BALL BEARING INSTALLATION

(1) Assemble the ball bearing using the indicated special
tools.
MD998819
"OA SNAP RING INSTALLATION

(1) Select and install a suitable snap ring to ensure that
the rear output shaft rear bearing clearance is at the
standard value.
Bearing
Standard value
Snap ring
"PA WAVE SPRING INSTALLATION

(1) Apply grease to the wave spring and secure it to the
transfer rear cover.
Specified grease:
or equivalent
Wave spring
MD998812
"QA OIL GUIDE INSTALLATION

(1) Install the oil guide using the indicated special tools.
MD998814
Oil guide
MD998830
Aug. 2000
PWEE8914-J
Added
22D-9-11
"RA OIL SEAL INSTALLATION

(1) Apply grease to the lip of the oil seal; then assemble
the seal using the indicated special tool.
Apply
grease
Specified grease:
or equivalent
MD998800
"SA TRANSFER REAR COVER INSTALLATION

(1) Apply sealant to the illustrated position of the transfer
rear cover.
Specified sealant:
or equivalent
Caution
performed.
Apply sealant
"TA 2WD/4WD SHIFT LUG INSTALLATION

(1) Rotate the 2WD/4WD shift rail to line up the spring pin
hole in the 2WD/4WD shift lug with that in the shift rail.
Shift lug
Spring pin hole
Spring pin
Aug. 2000
"UA SPRING PIN INSTALLATION

as shown.
PWEE8914-J
Added
22D-9-12

"VA SPRING PIN INSTALLATION
as shown.
Spring pin
"WA TRANSFER CONTROL HOUSING INSTALLATION

(1) Apply sealant to the transfer control housing at the
indicated position.
Specified sealant:
or equivalent
Caution
performed.
Apply
sealant
"XA SPRING INSTALLATION

(1) Install the spring with the tapered end facing the ball
side.
"YA POPPET SEAL BOLT INSTALLATION (when

reused)
(1) Apply sealant to the threaded area of the poppet seal
bolt before tightening to the specified torque.
Apply
sealant
Specified sealant:
Aug. 2000
PWEE8914-J
Added
22D-9-13
"ZA LOCK DETECTOR SWITCH / 4WD DETECTOR

SWITCH INSTALLATION
(1) Install each of the detector switches at the correct position.
4WD detector
switch
Lock detector
switch
4WD detector
switch
connector
Name
Connector
color
Harness tube
color
Brown
Black
4WD detector switch
White
Black
Lock detector
switch
connector
"aA LOCK OPERATION DETECTOR SWITCH

INSTALLATION
(1) Install the detector switch as illustrated.
Name
Connector
color
Harness tube
color
Lock operation detector

switch
Brown
Yellow
Lock operation
detector switch
Lock operation detector

switch connector
4WD operation
detector switch
connector
Aug. 2000
"bA 4WD OPERATION DETECTOR SWITCH / HI-LO

DETECTOR SWITCH INSTALLATION
(1) Install each of these detector switches as illustrated.
Name
Connector
color
Harness tube
color
4WD operation detector

switch
White
Blue
Hi-Lo detector switch
Black
Black
PWEE8914-J
Added
22D-9-14
Hi-Lo detector
switch connector
"cA SELECT PLUNGER SEAL PLUG INSTALLATION

(when reused)
(1) Apply sealant to the threaded area of the seal plug before
tightening to the specified torque.
Apply
sealant
Specified sealant:
INSPECTION
DETECTOR SWITCHES
(1) Check each detector switch for continuity between the
connector terminal and the switch body.
(2) Replace the switch if the test results shown below are
not obtained.
Names
Connector color
Harness tube color
Switch pressed
Switch released
Hi-Lo detector switch
Black
Black
No continuity
Continuity exists
4WD detector switch
White
Black
No continuity
Continuity exists
Brown
Black
No continuity
Continuity exists
4WD operation detector switch
White
Blue
Continuity exists
No continuity
Lock operation detector switch
Brown
Yellow
Continuity exists
No continuity
Aug. 2000
PWEE8914-J
Added
22D-10-1
MANUAL TRANSMISSION - Rear Output Shaft
10. REAR OUTPUT SHAFT <V5M21-9>
19
7
5
2
4
10
113 14 Nm
14
18
17
12
11
13
15
16
"FA
AA" "EA
AB" "DA
AC" "CA
Disassembly steps
1. Snap ring
2. Clutch hub (H-L)
3. Low speed gear
4. Bearing spacer
5. Needle bearing
6. Lock nut
7. Radial ball bearing
8. Oil guide
9. Sprocket spacer
10. Steel ball
Aug. 2000
11.
12.
13.
14.
15.
AD" "BA 16.
"AA 17.
"AA 18.
19.
PWEE8914-J
Drive sprocket
Needle bearing
Sprocket sleeve
Steel ball
Clutch sleeve
Clutch hub (2-4WD)
Stopper plate
Ball bearing
Rear output shaft
Added
22D-10-2

AA" CLUTCH HUB (H-L) REMOVAL
NOTE
Some of the clutch hubs may be removed without using a
press.
MD998801
(1) Set the special tool so that load may be received by

the low speed gear.
(2) Use a press to push the front end of the rear output
shaft and remove the hub and gear.
AB" LOCK NUT REMOVAL
(1) Use a chisel and hammer to set the lock nut free.
(2) Using the special tool, remove the lock nut.

MD998835
TRA0316
AC" RADIAL BALL BEARING REMOVAL

NOTE
Some of the bearings are loosely fitted on the shaft and
may be removed without using a press.
MD998801
AD" CLUTCH HUB (2-4WD) / BALL BEARING

REMOVAL
NOTE
Some of the 2-4WD clutch hubs may be removed without
using a press.
MD998801
(1) Set the special tool so that load may be received by

the bearing.
(2) Use a press to push the rear end of the rear output shaft
and remove the hub and bearing.
Aug. 2000
PWEE8914-J
Added
22D-10-3
MD998812
MD998813
"AA BALL BEARING / STOPPER PLATE

INSTALLATION
(1) Place the stopper plate on the bearing.
(2) Using a special tool, install the ball bearing on the rear
output shaft.
MD998814
MD998801
MD998829
TRM0050
"BA CLUTCH HUB (2-4WD) INSTALLATION

(1) Direct the clutch hub as shown in the illustration to install
it to the rear output shaft.
MD998812
MD998813
MD998814
MD998821
MD998801
"CA RADIAL BALL BEARING INSTALLATION
MD998812
MD998814
MD998819
MD998801
TRA0317
"DA LOCK NUT INSTALLATION

(1) Use the special tool to tighten the rear output shaft lock
nut to the specified torque.
MD998835
TRA0318
(2) Use a punch and hammer to secure the lock nut in

alignment with the groove in the output shaft.
Aug. 2000
PWEE8914-J
Added
22D-10-4

"EA CLUTCH HUB (H-L) INSTALLATION
(1) Use the special tools to install the H-L clutch hub to the
rear output shaft.
MD998812
MD998821
NOTE
Some of the hubs may be installed without using a press.
MD998801
"FA SNAP RING INSTALLATION

(1) Select the thickest snap ring that will fit into the groove
in the front end of the rear output shaft and install it.
Sanp ring
Aug. 2000
PWEE8914-J
Added
22D-11-1
11. REAR OUTPUT SHAFT <V5M21-A>
6
5
3
4
7
2
1
Disassembly steps
"CA 1. Snap ring
"BA 2. Hi-Lo clutch hub
3. Low speed gear
4. Bearing spacer
5. Needle bearing
AA" "AA 6. Center bearing
7. Rear output shaft
DISASSEMBLY SERVICE POINT
Ball bearing
MD998917
Aug. 2000
AA" CENTER BEARING REMOVAL

(1) Remove the center bearing using the indicated special
tool.
PWEE8914-J
Added
22D-11-2

MD998812
MD998813

"AA CENTER BEARING INSTALLATION
(1) Install the center bearing using the indicated special tool.
MD998814
MD998192
MD998830
Installation
direction
"BA HI-LO CLUTCH HUB INSTALLATION

(1) Install the Hi-Lo clutch hub in the direction indicated by
arrow.

(1) Choose and assemble a suitable snap ring to ensure
that the Hi-Lo clutch hub clearance is at the standard
value.
Hi-Lo clutch hub
Standard value
Snap ring
Aug. 2000
PWEE8914-J
Added
22D-12-1
MANUAL TRANSMISSION - Input Shaft
12. INPUT SHAFT
3
2
6
5
4
Disassembly steps
"DA 1. Snap ring
AA" "CA 2. Bearing
"BA 3. Snap ring <V5M21-A>
4. Spacer
MD998917
5.
6.
7.
8.
Snap ring
Cone spring
Sub gear
Input gear

AA" BEARING REMOVAL
(1) Remove the bearing using the indicated special tool.
Caution
Do not allow the special tool to contact the spacer.

"AA CONE SPRING INSTALLATION
(1) Install the cone spring in the indicated orientation.
Cone spring
Sub gear
Aug. 2000
PWEE8914-J
Added
22D-12-2
MANUAL TRANSMISSION - Input Shaft

Transfer
case plate
Snap ring
Standard value
"BA SNAP RING SELECTION

(1) Install the bearing in the transfer case plate.
that the input gear end play is at the standard value.
Bearing
"CA BEARING INSTALLATION

(1) Install the bearing using the indicated special tool.
MD998812
MD998825
Bearing
"DA SNAP RING INSTALLATION

that the input gear bearing clearance is at the standard
value.
Bearing
Standard value
Snap ring
Aug. 2000
PWEE8914-J
Added
22D-13-1
MANUAL TRANSMISSION - Front Output Shaft
13. FRONT OUTPUT SHAFT

moving parts before
installation.
1
2
Disassembly steps
AA" "AA 1. Ball bearing
AA" "AA 2. Ball bearing
3. Front output shaft

MD998801
MD998812
MD998801
MD998812
MD998818
MD998813
Ball
bearing
MD998818
AA" BALL BEARING REMOVAL

(1) Remove the bearing using the indicated special tool.

"AA BALL BEARING INSTALLATION
(1) Install the bearing using the indicated special tools.
Ball
bearing
Aug. 2000
PWEE8914-J
Added
NOTES
MANUAL TRANSMISSION - H-L Shift Fork
22D-14-1
14. H-L SHIFT FORK <V5M21-9>

1
2
3
4
5
6
9 2 Nm
TRM0226
Disassembly steps
"AA 1. Return spring plug
2. Return spring
3. Return spring
4. Select plunger
5. Plunger boss
6. H-L shift fork

"AA RETURN SPRING PLUG INSTALLATION
(1) Apply sealant to the return spring plug and thread the
plug in until it is flush with the plunger boss end.
Specified sealant:
3M Super Weatherstrip No. 8001 or equivalent
TRM0227
Aug. 2000
PWEE8914-J
Added
NOTES
MANUAL TRANSMISSION - 2WD/4WD Shift Fork and Rail
22D-15-1
15. 2WD/4WD SHIFT FORK AND RAIL <V5M21-A>
7
4
Disassembly steps
1. Snap ring
2. Spring retainers
3. Return spring
4. 2WD/4WD shift fork
Aug. 2000
5.
6.
7.
8.
PWEE8914-J
Spring retainers
Return spring
Snap ring
2WD/4WD shift rail
Added
NOTES
22D-16-1
MANUAL TRANSMISSION - 2WD/4WD Synchronizer
16. 2WD/4WD SYNCHRONIZER <V5M21-A>
3
4
2
7
Disassembly steps
"CA 1. Snap ring
"BA 2. 2WD/4WD clutch hub
3. Outer synchronizer ring
"AA 4. Synchronizer spring
5. Synchronizer cone
6. Inner synchronizer ring
7. Drive sprocket
8. Needle bearing
9. Front input sleeve

"AA SYNCHRONIZER SPRING INSTALLATION
(1) Securely mount the synchronizer spring on the outer
synchronizer ring.
Synchronizer
spring
Aug. 2000
PWEE8914-J
Added
22D-16-2
MANUAL TRANSMISSION - 2WD/4WD Synchronizer

"BA 2WD/4WD CLUTCH HUB INSTALLATION
(1) Install the 2WD/4WD clutch hub in the arrowed direction.
Installation
direction

that the 2WD/4WD clutch hub end play is at the standard
value.
2WD/4WD clutch hub
Standard value
Snap ring
Aug. 2000
PWEE8914-J
Added
22D-17-1
MANUAL TRANSMISSION - Transfer Case Plate
17. TRANSFER CASE PLATE <V5M21-A>
6
5
35 Nm
Disassembly steps
1. Input shaft
"CA 2. Oil seal
3. Baffle plate
"BA 4. Oil seal
"AA 5. Interlock plunger seal bolt
6. Interlock plunger
7. Transfer case plate
Apply
sealant
"AA INTERLOCK PLUNGER SEAL BOLT

INSTALLATION (when reused)
(1) Apply sealant to the threaded area of the seal bolt before
tightening to the specified torque.
Specified sealant:
TRM1271
Aug. 2000
PWEE8914-J
Added
22D-17-2
MANUAL TRANSMISSION - Transfer Case Plate
Socket
wrench
"BA OIL SEAL INSTALLATION

(1) Install the oil seal using a socket wrench or some other
similar tool. After installation, apply grease to the lip of
the oil seal.
Specified grease:
or equivalent
MD998803
"CA OIL SEAL INSTALLATION

(1) Install the oil seal using the indicated special tool.
Following this, apply grease to the lip of the oil seal.
Specified grease:
or equivalent
Aug. 2000
PWEE8914-J
Added

Manual Transmission

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Manual Transmission

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22D-0-1

E Mitsubishi Motors Corporation

E Mitsubishi Motors Corporation