Manual Transmission (FR)

22-1
GROUP 22
MANUAL
TRANSMISSION
(FR)
CONTENTS
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MANUAL TRANSMISSION (FR). . . . . . . . . . . . . . . . . . . . . . . . . 22A
MANUAL TRANSMISSION OVERHAUL <R5MB1> . . . . . . . . . 22B
MANUAL TRANSMISSION OVERHAUL <V5MB1> . . . . . . . . . 22C

22A-1
GROUP 22A
MANUAL
TRANSMISSION
(FR)
CONTENTS
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GENERAL INFORMATION . . . . . . . . 22A-2 4WD OPERATION DETECTION SWITCH
CONTINUITY CHECK <SUPER SELECT 4WD>
...................................... 22A-6
LUBRICANT(S) . . . . . . . . . . . . . . . . . 22A-2
HIGH/LOW DETECTION SWITCH CONTINUITY
CHECK <SUPER SELECT 4WD> . . . . . . . 22A-6
SEALANT AND ADHESIVE. . . . . . . . 22A-2
4LLc DETECTION SWITCH CONTINUITY CHECK
<HIGH POWER ENGINE> . . . . . . . . . . . . . 22A-6
ON-VEHICLE SERVICE. . . . . . . . . . . 22A-3
TRANSMISSION OIL LEVEL CHECK . . . . 22A-3 TRANSMISSION CONTROL . . . . . . . 22A-7
TRANSMISSION OIL CHANGE . . . . . . . . . 22A-3 TRANSMISSION CONTROL REMOVAL AND
TRANSFER OIL LEVEL CHECK . . . . . . . . 22A-4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 22A-7
TRANSFER OIL CHANGE . . . . . . . . . . . . . 22A-4
4WD DETECTION SWITCH CONTINUITY CHECK TRANSMISSION ASSEMBLY . . . . . . 22A-9
<EASY SELECT 4WD> . . . . . . . . . . . . . . . 22A-4 TRANSMISSION ASSEMBLY REMOVAL AND
HIGH/LOW DETECTION SWITCH CONTINUITY INSTALLATION <2WD> . . . . . . . . . . . . . . . 22A-9
CHECK <EASY SELECT 4WD>. . . . . . . . . 22A-5 TRANSMISSION ASSEMBLY REMOVAL AND
CENTRE DIFFERENTIAL LOCK DETECTION INSTALLATION <4WD> . . . . . . . . . . . . . . . 22A-10
SWITCH CONTINUITY CHECK <SUPER SELECT
4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A-5 4WD INDICATOR-ECU. . . . . . . . . . . . 22A-11
2WD/4WD DETECTION SWITCH CONTINUITY 4WD INDICATOR-ECU REMOVAL AND
CHECK <SUPER SELECT 4WD> . . . . . . . 22A-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 22A-11
CENTRE DIFFERENTIAL LOCK OPERATION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22A-11
DETECTION SWITCH CONTINUITY CHECK <SUPER
SELECT 4WD> . . . . . . . . . . . . . . . . . . . . . . 22A-5
22A-2 MANUAL TRANSMISSION (FR)
GENERAL INFORMATION
GENERAL INFORMATION
M1221100100403
The R5MB1 and V5MB1 type manual transmission
has been adopted.
SPECIFICATIONS
Item Specification
Transmission mode R5MB1 V5MB1-J- V5MB1-J- V5MB1-J- V5MB1-J- V5MB1-J-
NEG PCG NE PD2 NEZ
Engine model 4D56
Transmission type 5 forward speed, one reverse, constant mesh
Gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
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Reverse 4.220
Drive system 2WD Easy select 4WD Super select 4WD
Centre differential - Not provided Provided
Transfer type - 2speeds, constant mesh
Transfer gear ratio High - 1.000
Low - 1.900
LUBRICANT
M1221100200154
Item Specified lubricant Quantity L

Transmission oil 2WD Gear oil API classification GL-3 SAE 75W-85 2.3
4WD 3.4
Transfer oil <4WD> Gear oil API classification GL-3 SAE 75W-85 or API 2.5
classification GL-4 SAE 75W-85
SEALANTS
M1221102000060
Item Specified sealant

Transmission control lever assembly and 3M ATD Part No.8660 or equivalent
transfer control lever assembly
MANUAL TRANSMISSION (FR)
ON-VEHICLE SERVICE
22A-3
ON-VEHICLE SERVICE
TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL REPLACEMENT
M1221100600259 M1221100700342
Filler plug hole Filler plug

Gasket
Drain plug
Filler plug
Transmission oil
AC700330AL AC502641AD
Filler plug Filler plug hole
Gasket
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Drain plug
Filler plug
Transmission oil
AC502641AD AC700330AL
1. Remove the filler plug and gasket. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and drain the oil.
the filler plug hole. 3. Tighten the drain plug to the specified torque.
3. Check that the oil is not noticeably dirty. Tightening torque: 37 ± 11 N⋅m
4. Install the filler plug and new gasket, then tighten 4. Fill with gear oil API classification GL-3 SAE 75W-
them to the specified torque. 85 until the level comes to the lower portion of
Tightening torque: 37 ± 11 N⋅m filler plug hole.
Quantity:
2.3 L <2WD>
3.4 L <4WD>
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37 ± 11 N⋅m
ON-VEHICLE SERVICE
TRANSFER OIL LEVEL CHECK TRANSFER OIL REPLACEMENT

M1221102500117 M1221102600147
Filler plug Filler plug
Drain plug Drain plug
AC502640AB AC502640AB
Filler plug hole Filler plug hole
Gasket Gasket
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Filler plug Filler plug
Transfer oil Transfer oil

AC700330AM AC700330AM
1. Remove the filler plug and gasket. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and gasket, and then drain
the filler plug hole. the oil.
3. Check that the oil is not noticeably dirty. 3. Install the drain plug and new gasket, then tighten
4. Install the filler plug and new gasket, then tighten them to the specified torque.
them to the specified torque. Tightening torque: 32 ± 2 N⋅m
Tightening torque: 32 ± 2 N⋅m 4. Fill with gear oil API classification GL-3 SAE 75W-
85 or API classification GL-4 SAE 75W-85 until
the level comes to the lower portion of filler plug
hole.
Quantity: 2.5 L
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 32 ± 2 N⋅m
4WD DETECTION SWITCH CONTINUITY

CHECK <EASY SELECT 4WD>
M1221102700122
AC503108AB
ON-VEHICLE SERVICE
22A-5
Check the continuity between terminals of the black Transfer lever position Specified condition
connector and earth indicated in the illustration.
4HLc and 4LLc Continuity (Less than 2
Transfer lever position Specified condition Ω)
2H Open circuit 2H and 4H Open circuit
4H, 4L Continuity (Less than 2
Ω) 2WD/4WD DETECTION SWITCH
CONTINUITY CHECK <SUPER SELECT
HIGH/LOW DETECTION SWITCH 4WD>
CONTINUITY CHECK <EASY SELECT M1221103200119
4WD>
M1221102800141
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AC509434AB
Check the continuity between terminals of the black

AC503107AB
Check the continuity between terminals of the grey Transfer lever position Specified condition
2H Open circuit
Transfer lever position Specified condition
4H, 4HLc and 4LLc Continuity (Less than 2
While switching between Open circuit Ω)
4H and 4L
2H, 4H, 4L Continuity (Less than 2 CENTRE DIFFERENTIAL LOCK
Ω) OPERATION DETECTION SWITCH
CENTRE DIFFERENTIAL LOCK
4WD>
DETECTION SWITCH CONTINUITY M1221103300075
CHECK <SUPER SELECT 4WD>
M1221103100112
AC509434AD
Check the continuity between terminals of the black

AC509434AC
Check the continuity between terminals of the brown
connector and earth indicated in the illustration. Transfer lever position Specified condition
2H and 4H Open circuit
4HLc and 4LLc Continuity (Less than 2
Ω)
ON-VEHICLE SERVICE
4WD OPERATION DETECTION SWITCH Check the continuity between terminals of the white
CONTINUITY CHECK <SUPER SELECT connector and earth indicated in the illustration.
4WD> Transfer lever position Specified condition
M1221103400038
While switching between Open circuit
4HLc and 4LLc
2H, 4H, 4HLc and 4LLc Continuity (Less than 2
Ω)
4LLc SWITCH CONTINUITY CHECK

<HIGH POWER ENGINE>
M1221144400024
AC509434AF
Check the continuity between terminals of the brown

Transfer lever position Specified condition
2H Open circuit
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4H, 4HLc and 4LLc Continuity (Less than 2
Ω) AC509434AE
HIGH/LOW DETECTION SWITCH Check the continuity between terminals of the white
4WD> Transfer lever position Specified condition
M1221102800152 2H, 4H, and 4HLc Continuity (Less than 2
Ω)
4LLc Open circuit
AC509434AG
TRANSMISSION CONTROL
22A-7
REMOVAL AND INSTALLATION
M1221102200116
<2WD>
Pre-removal Operation Post-installation Operation
Move the transmission control lever to the Neutral position. Check that the transmission control lever is moved to each
position smoothly and correctly.
1
4
4
3.2 ± 0.2 N·m
2 19 ± 3 N·m
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5
3 N 5
Semi-drying sealant:
3M ATD Part No.8660 or
equivalent
AC609267AB
Removal steps Removal steps (Continued)

1. Shift knob 4. Transmission control lever assembly
• Front floor console assembly (Refer 5. Gasket
to GROUP 52A, Floor Consol
Assembly .)
2. Dust cover retaining plate
3. Dust cover
<4WD>
Pre-removal Operation Post-installation Operation
Move the transmission control lever and transfer control Check that the transmission control lever and the transfer
lever to the following positions. control lever are moved to each position smoothly and
• Transmission control lever: Neutral correctly.
• Transfer control lever: 4H
3.2 ± 0.2 N·m

4
7
5
1
2
3
Semi-drying sealant:
3M ATD Part No.8660 or equivalent
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19 ± 3 N·m
19 ± 3 N·m
AC509473AB
Removal steps INSTALLATION SERVICE POINT

1. Shift knob >>A<< SLEEVE INSTALLATION
>>A<< 2. Sleeve
3. Transfer shift lever knob
• Front floor console assembly
<Vehicles with front floor consol
assembly> (Refer to GROUP 52A,
Floor Consol Assembly .) Sleeve
4. Dust cover retaining plate
5. Control lever cover <Vehicles without
front floor consol assembly>
6. Dust cover Shift knob
7. Transmission control lever assembly
AC503137AB
and transfer control lever assembly
Install the sleeve with its groove facing to the direc-
tion shown in the figure, and then install the shift
knob.
TRANSMISSION ASSEMBLY
22A-9
REMOVAL AND INSTALLATION <2WD>
M1221102400488
Pre-removal and Post-installation Operations

• Transmission Control Lever Assembly Removal and
Installation (Refer to P.22A-7).
• Transmission Oil Draining and Refilling (Refer to P.22A-
3).
• Under Skid Plate and Engine Room Under Cover
Removal and Installation.
• Propeller Shaft Assembly Removal and Installation (Refer
to GROUP 25 − Propeller Shaft ).
• Clutch Release Cylinder Assembly and Clutch Damper
Assembly Removal and Installation (Disconnect the con-
nection with transmission only and do not disconnect the
clutch line.).
• Starter Assembly Removal and Installation (Refer to
GROUP 16 − Starter Motor Assembly ).
• No.2 Crossmember Assembly and Transmission Mount
Insulator Assembly Removal and Installation (Refer to
GROUP 32 − Rear Engine Mounting ).
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4 6
25 ± 4 N·m 48 ± 6 N·m
5
3
48 ± 6 N·m 1
11 ± 1 N·m
9.0 ± 1.0 N·m AC807940 AC

1. Transmission harness connector 3. Transmission assembly lower part
connection coupling bolts
• Support the transmission with a 4. Front exhaust pipe bracket
transmission jack 5. Transmission assembly upper part
2. Bell housing cover coupling bolts
6. Transmission assembly
REMOVAL AND INSTALLATION <4WD>

M1221102400499
Pre-removal and Post-installation Operations

• Transmission Control Lever Assembly and Transfer Con-
trol Lever Assembly Removal and Installation (Refer to
P.22A-7).
• Transmission Oil Draining and Refilling (Refer to P.22A-
3).
• Transfer Oil Draining and Refilling (Refer to P.22A-4).
• Under Skid Plate and Engine Room Under Cover
Removal and Installation (Refer to GROUP 51 − Under
Cover ).
• Front and Rear Propeller Shaft Removal and Installation
(Refer to GROUP 25 ).
• Front Exhaust Pipe Removal and Installation (Refer to
GROUP 15 − Front Exhaust Pipe and Main Muffler .)
• Clutch Release Cylinder Assembly and Clutch Damper
Assembly Removal and Installation (Disconnect the con-
nection with transmission only and do not disconnect the
clutch line.) (Refer to GROUP 21A − Clutch Release Cyl-
inder Assembly ).
• Starter Assembly Removal and Installation (Refer to
GROUP 16 − Starter Motor Assembly ).
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• Transfer Mount Bracket Assembly Removal and Installa-
tion (Refer to GROUP 32 − Transfer Mounting ).
• No.2 Crossmember Assembly and Transmission Mount
Insulator Assembly Removal and Installation (Refer to
GROUP 32 − Rear Engine Mounting ).
6
4
1
25 ± 4 N·m
48 ± 6 N·m
5
3
48 ± 6 N·m
11 ± 1 N·m 9.0 ± 1.0 N·m

AC809607AB

1. Transmission harness connector 3. Transmission assembly lower part
connection coupling bolts
• Support the transmission with a 4. Front exhaust pipe bracket
transmission jack 5. Transmission assembly upper part
2. Bell housing cover coupling bolts
6. Transmission assembly
4WD INDICATOR-ECU
22A-11
4WD INDICATOR-ECU
REMOVAL AND INSTALLATION
M1221102900029
<Vehicles with LHD>
<Vehicles with RHD>
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AC509527AB
Removal steps 1. Measure the voltage with the control unit and
• Glove Box Cover (Refer to GROUP harness still connected.
52A, Instrument Panel Assembly ). 2. Earth terminal (8) and then measure the terminal
1. 4WD indicator-ECU voltage.
INSPECTION
M1221101200157 EASY SELECT 4WD
4WD INDICATOR-ECU
VIEW A
A
AC504329AB
Terminal Inspection item Ignition switch Transfer shift position Terminal voltage
No.
1 Free wheel engage switch ON 2H System voltage
4H*1 1 V or less
2 4WD detection switch ON 2H System voltage
4H, 4L 1 V or less
3 Ignition switch ON − System voltage
OFF − 1 V or less
6 High/low detection switch ON While switching between System voltage
4H and 4L
2H, 4H, 4L 1 V or less
4WD INDICATOR-ECU
No.
7 Free wheel clutch changeover ON 4H, 4L 1 V or less
solenoid valve System voltage
2H*2
10 4WD indicator lamp ON 2H 1 V or less
4H, 4L System voltage
NOTE: .
*1
: When vehicle has been moved once.
*2:
Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
<SUPER SELECT 4WD>
No.
1 Free wheel engage switch ON 2H System voltage
4H*1 1 V or less
2 4WD operation detection ON 2H System voltage
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switch 4H, 4HLc, 4LLc 1 V or less
3 Ignition switch ON − System voltage
OFF − 1 V or less
4 Centre differential lock indicator ON 4H 1 V or less
lamp 4HLc System voltage
5 Rear wheel indicator lamp ON While switching between 1 V or less
4HLc and 4LLc
2H, 4H, 4HLc, 4LLc System voltage
6 High/low detection switch ON While switching between System voltage
4HLc and 4LLc
2H, 4H, 4HLc, 4LLc 1 V or less
7 Centre differential lock ON 4HLc 1 V or less
operation detection switch System voltage
4H*2
9 Centre differential lock ON 4HLc 1 V or less
detection switch System voltage
4H*2
10 Front wheel indicator lamp ON While switching between 1 V or less
4HLc and 4LLc
4H, 4HLc, 4LLc System voltage
NOTE: .
*1
: When vehicle has been moved once.
*2: Shift the lever from 4HLc to 4H, and then turn the ignition switch to OFF and then back to ON.
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
<R5MB1>
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CONTENTS
GENERAL INFORMATION . . . . . . . . 22B-2 INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-29

INPUT SHAFT DISASSEMBLY AND REASSEMBLY
GENERAL SPECIFICATIONS . . . . . . 22B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-29
INPUT SHAFT INSPECTION . . . . . . . . . . . 22B-30
SERVICE SPECIFICATIONS. . . . . . . 22B-2
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B-31
SNAP RING, SPACER AND THRUST PLATE OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . 22B-31
FOR ADJUSTMENT. . . . . . . . . . . . . . 22B-3 OUTPUT SHAFT INSPECTION . . . . . . . . . 22B-35
TORQUE SPECIFICATIONS . . . . . . . 22B-4 COUNTERSHAFT. . . . . . . . . . . . . . . . 22B-37

COUNTERSHAFT DISASSEMBLY AND
SEALANT(S) AND ADHESIVE(S) . . . 22B-5 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-37
COUNTERSHAFT INSPECTION . . . . . . . . 22B-38
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-6
REVERSE IDLER GEAR . . . . . . . . . . 22B-39
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-6 REVERSE IDLER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-39
TRANSMISSION . . . . . . . . . . . . . . . . 22B-8 REVERSE IDLER GEAR INSPECTION . . . 22B-39
TRANSMISSION DISASSEMBLY AND REASSEMBLY
...................................... 22B-8 EXTENSION HOUSING . . . . . . . . . . . 22B-40
TRANSMISSION INSPECTION . . . . . . . . . 22B-27 EXTENSION HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-40
22B-2 MANUAL TRANSMISSION OVERHAUL <R5MB1>
GENERAL INFORMATION
GENERAL INFORMATION
M1222000101275
MANUAL TRANSMISSION MODELS

Transmission model Engine model Vehicle model
R5MB1-J-NC 4D56 DI-D DOHC KA4T
R5MB1-J-ND1
GENERAL SPECIFICATIONS
M1222000200785
Item Specifications
Transmission model R5MB1
Transmission type 5-speed transmission, floor shift
Transmission gear ratio 1st 4.313
2nd 2.330
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3rd 1.436
4th 1.000
5th 0.789
Reverse 4.220
SERVICE SPECIFICATIONS
M1222000300492
Item Standard value Limit

Transmission
Gear spline piece No.5 end play mm 0 − 0.1 −
Clearance between the synchronizer ring and the gear mm 0.52 - 1.88 0.52
Counter shaft gear No.5 thrust 0.10 - 0.35 0.35
clearance mm
radial 0.015 − 0.068 0.068
clearance mm
inside diameter 38.015 − 38.040 38.040
mm
Input shaft
Input shaft radial ball bearing end play mm 0 − 0.1 −
clearance between the synchronizer ring and the 4th gear mm 0.70 − 1.70 0.70
Output shaft
Thrust clearance mm 1st gear 0.20 − 0.45 0.45
2nd gear 0.10 − 0.25 0.25
3rd gear 0.10 − 0.25 0.25
MANUAL TRANSMISSION OVERHAUL <R5MB1>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22B-3
Radial clearance mm 1st gear 0.020 − 0.073 0.073
2nd gear 0.015 − 0.068 0.068
3rd gear 0.015 − 0.068 0.068
Transmission clutch hub No.1 end play mm 0 − 0.1 −
5th gear end play mm 0 − 0.1 −
Clearance between the synchronizer ring and the 1st gear 0.65 − 1.75 0.65
each gear mm 2nd gear 0.65 − 1.75 0.65
3rd gear 0.65 − 1.75 0.65
Clearance between the each sleeve and the shift sleeve No.1 0.15 − 0.41 0.41
fork mm sleeve No.2 0.15 − 0.35 0.35
sleeve No.3 0.26 − 0.84 0.84
Output shaft outer shape of the needle roller A 37.984 − 38.000 37.984
bearing race mm
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B 46.984 − 47.000 46.984
C 38.979 − 38.995 38.979
Output shaft flange thickness mm − 4.800
Output shaft runout mm − 0.015
Each gear inside diameter mm 1st gear 46.015 − 46.040 46.040
2nd gear 53.015 − 53.040 53.040
3rd gear 44.015 − 44.040 44.040
Counter shaft
Counter gear shaft cylindrical roller bearing end play mm 0 − 0.1 −
Counter shaft outer shape of the needle roller D 34.000 − 34.105 34.000
bearing race mm E 29.984 − 30.000 29.984
Reverse idler gear
Reverse idler gear radial clearance mm 0.040 − 0.082 0.082
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000595
Shaft snap ring (For adjustment of gear spline piece No.5 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.80 − 2.85 A 3.00 − 3.05 E
2.85 − 2.90 B 3.05 − 3.10 F
2.90 − 2.95 C 3.10 − 3.15 G
2.95 − 3.00 D
TORQUE SPECIFICATIONS
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
2.10 − 2.15 A 2.30 − 2.35 E
2.15 − 2.20 B 2.35 − 2.40 F
2.20 − 2.25 C 2.40 − 2.45 G
2.25 − 2.30 D
Shaft snap ring (For adjustment of transmission clutch hub No.2 end play)
1.80 − 1.85 A 2.00 − 2.05 E
1.85 − 1.90 B 2.05 − 2.10 F
1.90 − 1.95 C 2.10 − 2.15 G
1.95 − 2.00 D
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2.30 − 2.35 A 2.50 − 2.55 E
2.35 − 2.40 B 2.55 − 2.60 F
2.40 − 2.45 C 2.60 − 2.65 G
2.45 − 2.50 D
Shaft snap ring (For adjustment of 5th gear end play)
2.75 − 2.80 C 3.05 − 3.10 J
2.80 − 2.85 D 3.10 − 3.15 K
2.85 − 2.90 E 3.15 − 3.20 L
2.90 − 2.95 F 3.20 − 3.25 M
2.95 − 3.00 G 3.25 − 3.30 N
3.00 − 3.05 H 3.30 − 3.35 P
Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
2.05 − 2.10 A 2.20 − 2.25 D
2.10 − 2.15 B 2.25 − 2.30 E
2.15 − 2.20 C 2.30 − 2.35 F
M1222013900494
Item N⋅m
Intermediate plate − reverse shift arm bracket mounting bolt 18 ± 5
Transmission case − clutch housing mounting bolt 36 ± 7
Transmission case − clutch housing mounting bolt (with seal) 34 ± 6
Transmission case − front bearing retainer sub-assembly mounting bolt 16.5 ± 5.0
SEALANTS
22B-5
Item N⋅m
Transmission case − back-up lamp switch assembly 44 ± 9
Transmission case − shift position switch assembly <R5MB1-J-NC> 34 ± 5
Transmission case − vehicle speed sensor mounting bolt 11 ± 1
Extension housing − straight screw plug with head 18.5 ± 5.5
Transmission case − extension housing sub-assembly, and intermediate plate 37 ± 11
mounting bolt
Intermediate plate − straight screw plug with head 18.5 ± 5.5
Gear shift fork No.1 mounting bolt 19.5 ± 3.9
Gear shift fork No.2 mounting bolt 19.5 ± 3.9
Intermediate plate − rear bearing output retainer mounting bolt 18 ± 5
Oil receiver pipe mounting bolt 11 ± 4
Shift lever housing mounting bolt 33 ± 3
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SEALANTS
M1222000501132
Item Specified sealant and adhesive

Between transmission case sub-assembly and Mitsubishi Part No.MD974421 or equivalent
intermediate plate
Between front bearing retainer and transmission
case
Between intermediate plate and extension housing
sub-assembly
Straight screw plug with head
Front bearing retainer mounting bolt
Clutch housing mounting bolt
FORM-IN-PLACE GASKET (FIPG) CAUTION
This transmission has several areas where the form- When re-applying liquid gasket (FIPG), be sure
in-place gasket (FIPG) is used for sealing. To ensure that:
that the FIPG fully serves its purpose, it is necessary
1. Residues of FIPG are cleared from all the ins
to observe some precautions when applying it. Bead and outs of parts;
size, continuity and location are of paramount impor-
2. Use Mitsubishi genuine parts cleaner
tance.
(MZ100387) or equivalent to well degrease the
Too thin a bead could cause leaks. Too thick a bead,
FIPG-applied surface.
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To 3. FIPG is correctly applied in accordance with
prevent leaks or blocking of passages, therefore, it is FIPG Application.
absolutely necessary to apply the FIPG evenly with- Disassembly
out a break, while observing the correct bead size. Parts sealed with a FIPG can be easily removed
FIPG hardens as it reacts with the moisture in the without need for the use of a special method. In
atmospheric air, and it is usually used for sealing some cases, however, the FIPG in joints may have to
metallic flange areas. be broken by tapping parts with a mallet or similar
tool.
LUBRICANTS
Surface Preparation FIPG Application

Thoroughly remove all substances deposited on the Applied FIPG bead should be of the specified size
FIPG application surface, using a gasket scraper. and free of any break. FIPG can be wiped away
Make sure that the FIPG application surfaces is flat unless it has completely hardened. Install the mating
and smooth. Also make sure that the surface is free parts in position while the FIPG is still wet. Do not
from oils, greases and foreign substances. Do not fail allow FIPG to spread beyond the sealing areas dur-
to remove old FIPG that may remain in the fastener ing installation. Avoid operating the transmission or
fitting holes. letting oils or water come in contact with the sealed
area before a time sufficient for FIPG to harden
(approximately one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
LUBRICANTS
M1222000400994
Item Specified lubricant
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Transmission oil Gear oil API classification GL-3 SAE 75W-85
SPECIAL TOOLS
M1222000600534
Tool Tool number Name Use

MB990803 Steering wheel puller Removal of gear spline
piece No.5
MB990803
MB990811 Side bearing puller cup Use with Steering wheel

puller
MB990811
MD998812 Installer cap Use with installer and

adapter
MD998813 Installer-100 Use with installer cap and

adapter
SPECIAL TOOLS
22B-7
MD998827 Installer adapter (56) Use with installer cap and
adapter
MD998801 Remover Removal of roller bearing

and ball bearing, input gear
corn ring, transmission
clutch hub No.1 and
transmission clutch hub
No.2
adapter
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MD998823 Installer adapter (48) Installation of ball bearing,
5th gear, transmission
clutch hub No.1 and
transmission hub No.2

adapter
MB990699 Differential oil seal Installation of oil seal

installer
MB990929 Installer adapter Installation of oil seal
MB990938 Installer bar Use with installer adaoter

TRANSMISSION
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001001765
34 ± 5 N·m 44 ± 9 N·m
2 1 18
<R5MB1-J-NC>
3
15
14
19
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16 17 8
7
13
16.5 ± 5.0 N·m 7
36 ± 7 N·m
5
12
34 ± 6 N·m 4
6 11 ± 1 N·m
11
10
18.5 ± 5.5 N·m
9 37 ± 11 N·m
AK701068AD
Disassembly steps Disassembly steps (Continued)

1. Back-up lamp switch assembly 12. Reverse restrict pin assembly
2. Shift position switch assembly 13. Front bearing retainer
<R5MB1-J-NC> 14. Oil seal
3. Clutch housing 15. Shaft snap ring
4. Vehicle speed sensor 16. Shaft snap ring
5. O-ring 17. Transmission case sub-assembly
6. Wiring harness clamp bracket 18. Intermediate plate with shaft sub-
7. Wiring harness clamp bracket assembly
8. Extension housing sub-assembly 19. Transmission magnet
9. Oil receiver pipe
10. Straight screw plug with head
11. Slotted spring pin
TRANSMISSION
22B-9
18.5 ± 5.5 N·m

18.5 ± 5.5 N·m
20 23
20 21
24
22 21
22
26 29
19.5 ± 3.9 N·m
27
25
30
28
19.5 ± 3.9 N·m
33
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32
31
40
38 37 41 35
34 36
39 44
42 43
AK602734 AC

20. Straight screw plug with head 34. Gear shift fork shaft No.3
21. Compression spring 35. Gear shift fork No.3
22. Ball 36. Roller A
23. Shaft snap ring 37. Ball
24. Gear shift fork shaft No.2 38. Shaft snap ring
25. Gear shift fork No.2 39. Gear shift fork shaft No.4
26. Roller A 40. Ball
27. Shaft snap ring 41. Compression spring
28. Gear shift fork shaft No.1 42. E-ring
29. Straight pin 43. Reverse shift arm
30. Roller A 44. Reverse shift fork
31. Gear shift fork No.1
32. Shaft snap ring
TRANSMISSION
47
65
18 ± 5 N·m 46
45
45
68
61 60
59
66
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63
58 57
67
64
62
18 ± 5 N·m
48
Apply gear oil to
all moving parts
50
before installation. 51
53 49
56 54 55
52 AK701069AB

45. Shaft snap ring 57. Needle roller bearing
46. Rotor 58. 5th gear thrust washer
47. Ball 59. Straight pin
48. Shaft snap ring 60. Rear bearing output shaft retainer
49. Transmission hub sleeve No.3 61. Shaft snap ring
50. Gear spline piece No.5 62. Reverse idler gear
51. Synchronizer outer race No.3 63. Cylindrical roller bearing
52. Counter shaft gear No.5 64. Counter shaft sub-assembly
53. Shaft snap ring 65. Input shaft sub-assembly
54. Synchromesh shifting key spring 66. Output shaft sub-assembly
No.3 67. Reverse shift arm bracket
55. Synchromesh shifting key spring 68. Intermediate plate
No.3
56. Synchromesh shifting key No.3
TRANSMISSION
22B-11
DISASSEMBLY SERVICE POINTS Wiring Wiring harness
harness clamp bracket
<R5MB1-J-NC> clamp
bracket
Shift position switch

Back-up lamp switch assembly AK604895AB
assembly
AK704967AC
4. Remove the extension housing sub-assembly and
<R5MB1-J-ND1> wiring harness clamp bracket.
Back-up lamp switch

assembly
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AK704968AD
1. Remove the back-up lamp switch assembly and AK403777
shift position switch assembly <R5MB1-J-NC>. 5. Remove the oil receiver pipe.
AK403768
AK604896AB
2. Remove the clutch housing.
6. Remove the straight screw plug with head.
AK500816
AK604897AB
3. Remove the vehicle speed sensor.
7. Remove the slotted spring pin.
TRANSMISSION
AK403781 AK403783
8. Remove the reverse restrict pin assembly. 12.Remove the shaft snap ring.
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AK403774 AK403784
9. Remove the front bearing retainer. 13.Remove the transmission case sub-assembly.
AK403775AC AK500257
10.Remove the oil seal. 14.Remove the transmission magnet.
AK403782 AK403786AB
11.Remove the shaft snap ring. 15.Remove the straight screw plug with head (3
places).
TRANSMISSION
22B-13
AK403788AB AK500260
16.Remove the compression spring (3 places). 20.Remove the gear shift fork No.2.
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AK403789AB AK500261
17.Remove the ball (3 places). 21.Remove the roller A.
AK403792 AB AK500262AB
18.Remove the shaft snap ring of the gear shift fork 22.Remove the shaft snap ring of the gear shift fork
shaft No.2 and the washer based hexagon bolt of shaft No.1 and the washer based hexagon bolt of
the gearshift fork No.2. the gear shift fork No.1.
AK500259 AK500263
19.Remove the gear shift fork shaft No.2. 23.Remove the gear shift fork shaft No.1.
TRANSMISSION
AK500270 AK403790AB
24.Remove the straight pin of the gear shift fork shaft 28.Remove the slotted spring pin of the gear shift
No.1. fork No.3 assembly.
Gear shift fork shaft No.3
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Gear shift fork No.3
AK500264 AK500461AB
25.Remove the roller A. 29.Remove the gear shift fork No.3 and the gear shift
fork shaft No.3.
AK500265
AK403800
26.Remove the gear shift fork No.1.
30.Remove the roller A.
AK500266AB
AK403801
27.Remove the shaft snap ring of the gear shift fork
shaft No.3. 31.Remove the ball.
TRANSMISSION
22B-15
AK500453AB AK403805
32.Remove the shaft snap ring of the gear shift fork 35.Remove the compression spring.
shaft No.4.
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AK403806
AK403802
36.Remove the reverse shift fork and the reverse
shift arm.
AK403803
33.Remove the gear shift fork shaft No.4. AK500455
37.Remove the E-ring.

Reverse shift arm
Reverse shift fork
AK403804
34.Remove the ball. AK500454AB
38.Remove the reverse shift arm and reverse shift

fork.
TRANSMISSION
• Steering wheel puller (MB990803)

Rotor • Side bearing puller cup (MB990811)
Ball
Shaft snap ring

AK500818AB
39.Remove the shaft snap ring (2 places). AK403983

40.Remove the rotor.
45.Remove the synchronizer outer race No.3.
41.Remove the ball.
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AK403984
AK403807
46.Remove the counter shaft gear No.5.

42.Remove the shaft snap ring.
Transmission
hub sleeve No.3
AK500526
AK500269AB
47.Remove the shaft snap ring.

43.Remove the transmission hub sleeve No.3.
MB990811 MB990803
AK500456
AK403982 AC
48.Remove the synchromesh shifting key spring

44.Use special tools to remove the gear spline piece
No.3.
No.5.
TRANSMISSION
22B-17
AK500457 AK403785AB
49.Remove the synchromesh shifting key spring 53.Remove the straight pin.
No.3.
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AK403986
AK500458
54.Remove the rear bearing output shaft retainer.
50.Remove the synchromesh shifting key No.3.
AK403987
AK500459
55.Remove the snap ring.
51.Remove the needle roller bearing.
Reverse idler
gear
AK403989 AC
AK403985
56.Remove the reverse idler gear.
52.Remove the 5th gear thrust washer.
TRANSMISSION
REASSEMBLY SERVICE POINTS

Cylindrical roller
bearing
Counter gear
sub-assembly
AK403990AB
AK403993
57.Remove the counter gear sub-assembly and
cylindrical roller bearing. 1. Set the reverse shift arm bracket to the
intermediate plate and tighten the bolts to the
specified torque of 18 ± 5 N⋅m.
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AK403991
58.Remove the input shaft sub-assembly.

AK403992
2. Install the output shaft sub-assembly to the

intermediate plate.
AK403992
59.Remove the output shaft sub-assembly.

AK403991
3. Install the input shaft sub-assembly to the output

shaft sub-assembly.
Cylindrical roller
bearing
Counter gear
sub-assembly
AK403993
60.Remove the reverse shift arm bracket.
AK403990AB
TRANSMISSION
22B-19
4. Insert the counter gear sub-assembly into the
intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.
Reverse idler
gear
AK403785AB
8. Install the straight pin.
Installtion 5th gear

AK403989 AC direction thrust
washer
5. Install the reverse idler gear shaft and reverse
idler gear sub-assembly to the intermediate plate.
Penetration
groove
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Straight pin
AK501229AB
AK403987
6. Install the shaft snap ring to the radial ball bearing

of the input shaft sub-assembly.
AK403985
9. Check the installation direction of 5th gear thrust

washer, and install it.
AK403986AB
7. Set the rear bearing output shaft retainer and

tighten the bolts to the specified torque of 18 ± 5
N⋅m.
NOTE: Fit the rear bearing output shaft retainer
into the reverse idler gear shaft slot. AK500459
10.Install the needle roller bearing.

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

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

AK403984
counter shaft gear No.5.
15.Install the counter shaft gear No.5.
Protrusion
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Key
AK500457
AK403983AB
12.Install the synchromesh shifting key spring No.3
to the counter shaft gear No.5. CAUTION
Fit the protrusions of synchronizer ring between
keys.
16.Install the synchronizer outer race No.3.
AK500456

MD998827
to the counter shaft gear No.5. MD998813
MD998812
AK404049AB
17.Use special tools to install the gear spline piece

No.5.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (56) (MD998827)
AK500526
TRANSMISSION
22B-21
20.Install the ball to the rotor.
21.Install the rotor to the output shaft.
Installation 22.Remove the shaft snap ring to the output shaft (2
direction places).
Reverse shift arm
Reverse shift fork
AK500610 AB
Transmission
hub sleeve No.3
AK500454AB
23.Install the reverse shift arm to the reverse shift

fork.
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AK500269AB
18.Check the installation direction of the

transmission hub sleeve No.3 and install it on the
counter shaft.
NOTE: After installation, check the sleeve operate
smoothly.
AK500455
24.Install the E-ring.
AK403807
19.Select a snap ring which will make the gear spline

pice No.5 end play equal the standard value. AK403806
Standard value: 0 − 0.1 mm 25.Install the reverse shift fork and the reverse shift
arm to the intermediate plate.
Rotor
Ball
Shaft snap ring

AK500818AB
AK403805
TRANSMISSION
26.Install the compression spring into the reverse

shift fork.
AK500453AB
29.Install the shaft snap ring into the gear shift fork
AK403804
shaft No.4.
27.Install the ball into the reverse shift fork.
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AK403801
AK403803
AK403802 AK403800
CAUTION 31.Install the roller A to the intermediate plate.

Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc- Gear shift fork shaft No.3
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
28.Install the gear shift fork shaft No.4 into the
intermediate plate and the reverse shift fork.
AK500461AB
32.Install the gear shift fork No.3 assembly on the

transmission hub sleeve No.3 and hold it. Insert
the gear shift fork shaft No.3 into the gear shift
fork No.3 assembly, the intermediate plate and
the reverse shift fork.
TRANSMISSION
22B-23
AK500267 AK500270
33.Install the slotted spring pin to the gear shift fork 37.Install the straight pin to the gear shift fork shaft
No.3 assembly. No.1.
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AK500266AB AK500263
34.Install the snap ring to the gear shift fork shaft 38.Install the gear shift fork shaft No.1 to the
No.3. intermediate plate and the gear shift fork No.1.
AK500265 AK500262AB
35.Install the gear shift fork No.1 on the reverse gear. 39.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500264
36.Install the roller A to the intermediate plate. AK500261
40.Install the roller A to the intermediate plate.

TRANSMISSION
44.Install the ball to the intermediate plate (3 places).
AK500260
AK403788AB
41.Install the gear shift fork No.2 on the transmission
hub sleeve No.2. 45.Install the compression spring to the intermediate
plate (3 places).
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AK500259
AK403786AB
42.Install the gear shift fork shaft No.2 to the
intermediate plate, the gear shift fork No.1 and the 46.Apply sealant to the threads. Tighten the straight
gear shift fork No.2. screw plug with head to the specified torque of
18.5 ± 5.5 N⋅m (3 places).
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403792 AB
43.Install the shaft snap ring to the gear shift fork

shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500257
47.Install the transmission magnet to the

intermediate plate.
AK403789AB
TRANSMISSION
22B-25
AK500527AB AK403782
48.Completely degrease the FIPG-applied surface 52.Install the snap ring to the radial ball bearing.
so that water and oil including the old sealant
cannot adhere to the surface coated with the
MB990938
sealant.
Never touch the degreased surface by hand.
49.Apply a 1.2 mm diameter bead of liquid gasket to
the intermediate plate mounting surface of the
transmission case sub-assembly.
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Special sealant: Mitsubishi genuine sealant MB990929
AK600320 AB
53.Using special tool, install the oil seal to the front

bearing retainer.
• Installer adapter (MB990929)
• Installer bar (MB990938)
AK701366
50.Install the transmission case sub-assembly to the

intermediate plate.
AK403775AB
54.Completely degrease the FIPG-applied surface

sealant.
AK403783
the transmission case sub-assembly mounting
51.Install the snap ring to the cylindrical roller surface of the front bearing retainer sub-assembly
bearing. with seal.
TRANSMISSION
AK403774
AK604896AB
CAUTION 59.Apply sealant to the threads. Tighten the straight

Do not damage to the oil seal lip during the screw plug with head to the specified torque of
installation. 18.5 ± 5.5 N⋅m.
56.Apply sealant to the threads. Install the front Special sealant: Mitsubishi genuine sealant
bearing retainer to the transmission case sub- Part No. MD974421 or equivalent
assembly and tighten the bolts to the specified NOTE: The new bolt does not require sealant
torque of 16.5 ± 5.0 N⋅m. application as it is precoated with sealant.
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AK403777
60.Install the oil receiver pipe into the extension

housing sub-assembly.
AK403781
57.Install the reverse restrict pin assembly to the

extension housing sub-assembly.
AK500527AB

AK604897AB sealant.
58.Install the slotted spring pin to the reverse restrict Never touch the degreased surface by hand.
pin assembly. 62.Apply a 1.2 mm diameter bead of liquid gasket to
extension housing sub-assembly.
TRANSMISSION
22B-27
Wiring Wiring harness <R5MB1-J-NC>
harness clamp bracket
clamp
bracket

Back-up lamp switch assembly
assembly
AK604895AB AK704967AC
63.Install the extension housing sub-assembly. <R5MB1-J-ND1>

Install the wiring harness clamp bracket (3 places)
and tighten the bolts to the specified torque of 37
± 11 N⋅m.
Back-up lamp switch
assembly
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AK704968AD
66.Tighten the shift position switch assembly of 34 ±

5 N⋅m. <R5MB1-J-NC>
67.Tighten the back-up lamp switch assembly and of
AK500816 44 ± 9 N⋅m.
64.Install the vehicle speed sensor and tighten the INSPECTION
bolts to the specified torque of 11 ± 1 N⋅m. M1222001100491
BACK-UP LAMP SWITCH
AK500460AB
AK500505
CAUTION
Install the bolt and washer (with sealant) to the Check for the continuity between the connector ter-
position having the arrow as shown in the illus- minals.
tration. Switch Connector Continuity
65.Install the clutch housing into the transmission condition terminals
case sub-assembly. Tighten the bolt with washer Switch end 1−2 Conductive
to the specified torque of 36 ± 7 N⋅m (7 places). pressed
Tighten the bolt with washer (with sealant) to the
Switch end 1−2 Open
specified torque of 34 ± 6 N⋅m (2 places).
released
TRANSMISSION
SHIFT POSITION SWITCH 2. Check the needle roller bearing cage for
deformation.
COUNTER SHAFT GEAR No.5

THRUST CLEARANCE
Inspect the thrust clearance of counter shaft gear
No.5.
Standard value: 0.10 − 0.35 mm
Limit: 0.35 mm
AK501632
RADIAL CLEARANCE
Check for the continuity between the connector ter- 1. Fix the output shaft in a vice.
minals. 2. Inspect the radial clearance of counter shaft gear
Switch Connector Continuity No.5.
condition terminals Standard value: 0.015 − 0.068 mm
Switch end 1−2 Open Limit: 0.068 mm
pressed
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Switch end 1−2 Conductive INSIDE DIAMETER
released
SYNCHRONIZER SLEEVE AND HUB

1. Combine the synchronizer sleeve and hub, and
check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
AK404027
Limit: 0.52 mm Using the cylinder gauge, check the inside diameter
of the counter shaft gear No.5.
NEEDLE ROLLER BEARING Standard value: 38.015 − 38.040 mm
1. Combine the needle roller bearing with the shaft Limit: 38.040 mm
and gear, and check that it rotates smoothly
without noise or play.
INPUT SHAFT
22B-29
INPUT SHAFT
M1222001600526
Apply gear oil to

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

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

damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
AK403997 ridges are intact.
1. Select a snap ring to secure the standard
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clearance between the radial ball bearing and the
input shaft sub-assembly.
Standard value: 0 − 0.1 mm
2. Install the selected snap ring.
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
3. After applying oil to the taper portion on gear,

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

of each input shaft sub-assembly for damage and
excessive wear.
AK403999
2. Check the synchronizer cone surface of each
input shaft sub-assembly for roughness, damage, 4. Using the thickness gauge, check the clearance
and excessive wear. between the synchronizer ring and the 4th gear.
3. Check the inside surface and front and back sides Standard value: 0.70 − 1.70 mm
of each input shaft sub-assembly for damage and Minimum limit: 0.70 mm
excessive wear.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input
shaft, and check that it rotates smoothly without
noise or play.
OUTPUT SHAFT
22B-31
2. Check the needle roller bearing cage for
deformation.
OUTPUT SHAFT
M1222002100160
Apply gear oil to

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

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

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

THRUST CLEARANCE FOR EACH GEAR
2nd 1st MD998801
AK404004AB

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

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

AK404001AB SHIFTING KEY No.1 / COMPRESSION SPRING /
TRANSMISSION CLUTCH No.1 HUB /
1. Fix the output shaft by a vice. SYNCHRONIZER RING SET No.1 / 2ND GEAR
2. Inspect the radial clearance of each gear. SUB-ASSEMBLY REMOVAL
1st 0.020 − 0.073 0.073
2nd 0.015 − 0.068 0.068
3rd 0.015 − 0.068 0.068 MD998801
AK404014 AB
Using special tool Bearing remover (MD998801), assembly.

support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No.1, com-
pression spring, the transmission clutch No.1 hub,
synchronizer ring set No.1 and the 2nd gear sub-
OUTPUT SHAFT
22B-33
<<D>> TRANSMISSION CLUTCH HUB No.2 / 2. Using special tools to install the transmission
SYNCHRONIZER SHIFTING KEY No.2 / clutch hub No. 2, synchronizer shifting key No. 2,
COMPRESSION SPRING / TRANSMISSION HUB compression spring, the transmission hub sleeve
SLEEVE No.2 / SYNCHRONIZER RING SET No.2 / No. 2, synchronizer ring set No. 2 and the 3rd
3RD GEAR SUB-ASSEMBLY REMOVAL gear sub-assembly.
MD998801
AK404020AB

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

clearance between the transmission clutch hub
AK500607AB No.2 and the output shaft.
1. Check the installation direction of the transmission Standard value: 0 − 0.1 mm
clutch hub No. 2, and put it on the output shaft. 2. Install the selected snap ring.
MD998812
MD998813
MD998823
AK404029AC
OUTPUT SHAFT
>>C<< REVERSE GEAR / SYNCHRONIZER

SHIFTING KEY No. 1 / COMPRESSION SPRING / >>D<< SHAFT SNAP RING INSTALLATION
TRANSMISSION CLUTCH No. 1 HUB /
SYNCHRONIZER RING SET No. 1 / 2ND GEAR
SUB-ASSEMBLY INSTALLATION
Installation
direction
AK404031

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

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

assembly.
bearing, and put it on the output shaft.
• Installer-200 (MD998814) CAUTION
• Installer adapter (48) (MD998823) Never push on the sealing area when installing.
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
Limit: 0.25 mm • Installer-200 (MD998814)
OUTPUT SHAFT
22B-35
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 − 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
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M1222002300261
Installation SYNCHRONIZER RING
direction
CAUTION
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
AK500609AB
1. Check the installation direction of the 5th gear,

and put it on the output shaft.
MD998812
MD998814 AK500672AB
MD998823 1. Check to ensure that the clutch gear tooth surface

and cone surface are not damaged and broken.
AK404039AB
2. Using special tools to install the 5th gear.

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

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

1. Combine the needle roller bearing with the output
shaft and gear, and check that it rotates smoothly
deformation.
SYNCHRONIZER KEYS
AK404022

1st 0.65 − 1.75 0.65
2nd 0.65 − 1.75 0.65
3rd 0.65 − 1.75 0.65
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AK500680AB
HUB SLEEVE AND SHIFT FORK
Check the synchronizer hub contact surfaces of each
CAUTION
synchronizer key for damage and excessive wear.
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404023
Using the thickness gauge, check the clearance

between the sleeve and the shift fork.
A B C
sleeve Standard Limit mm
value mm AK404024AB
No.1 0.15 − 0.41 0.41 1. Using the micrometer, check the outer shape of
No.2 0.15 − 0.35 0.35 the needle roller bearing race.
No.3 0.26 − 0.84 0.84 Measurement Standard value mm Limit mm
part
SYNCHRONIZER SLEEVE AND HUB A 37.984 − 38.000 37.984

1. Combine the synchronizer sleeve and hub, and B 46.984 − 47.000 46.984
check that they slide smoothly. C 38.979 − 38.995 38.979
COUNTERSHAFT
22B-37
3. Using the dial gauge and V-block, check the
output shaft runout.
Limit: 0.015 mm
AK404025
2. Using the slide gauge, check the flange thickness.

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

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

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

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

AK404041AB
roller bearing, and put it on the counter shaft.
Using the micrometer, check the outer shape of the
CAUTION needle roller bearing race.
Never push the sealing area at the press fit.
Measurement Standard value Limit mm
MD998812
part mm
D 34.000 − 34.105 34.000
MD998813 E 29.984 − 30.000 29.984
MD998817
AK404046AB
REVERSE IDLER GEAR
22B-39
REVERSE IDLER GEAR
M1222012500233
Apply gear oil to

all moving parts
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1
AK500519AB
Disassembly steps INSPECTION

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

Limit: 0.082 mm
EXTENSION HOUSING
EXTENSION HOUSING
M1222004300074
33 ± 3 N·m
5 2
4 3
11 ± 4 N·m
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1
AK500815AB

1. Oil receiver pipe >>A<< OIL SEAL INSTALLATION
2. Extension housing oil deflector
>>A<< 3. Oil seal
4. Shift & select lever
5. Shift lever housing MB990699
6. Extension housing
Oil seal AK500819AB
Using the special tool Differential oil seal installer

(MB990699), install the oil seal.
22C-1
GROUP 22C
MANUAL
TRANSMISSION
OVERHAUL
<V5MB1>
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CONTENTS
GENERAL INFORMATION . . . . . . . . 22C-3 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . 22C-39

OUTPUT SHAFT INSPECTION . . . . . . . . . 22C-43
GENERAL SPECIFICATIONS . . . . . . 22C-3
COUNTERSHAFT. . . . . . . . . . . . . . . . 22C-45
SERVICE SPECIFICATIONS. . . . . . . 22C-3 COUNTERSHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-45
SNAP RING, SPACER AND THRUST PLATE COUNTERSHAFT INSPECTION . . . . . . . . 22C-46
FOR ADJUSTMENT. . . . . . . . . . . . . . 22C-5
REVERSE IDLER GEAR . . . . . . . . . . 22C-47
TORQUE SPECIFICATIONS . . . . . . . 22C-8 REVERSE IDLER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-47
SEALANT(S) AND ADHESIVE(S) . . . 22C-9 REVERSE IDLER GEAR INSPECTION . . . 22C-47
LUBRICANTS . . . . . . . . . . . . . . . . . . 22C-10 TRANSFER . . . . . . . . . . . . . . . . . . . . . 22C-48

TRANSFER DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-48
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22C-10
ADJUSTMENT OF TRANSFER . . . . . . . . . 22C-59
TRANSMISSION . . . . . . . . . . . . . . . . 22C-14 TRANSFER INSPECTION . . . . . . . . . . . . . 22C-60
TRANSMISSION DISASSEMBLY AND REASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-14 TRANSFER CASE PLATE . . . . . . . . . 22C-61
TRANSMISSION INSPECTION . . . . . . . . . 22C-36 TRANSFER CASE PLATE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-61
INPUT SHAFT . . . . . . . . . . . . . . . . . . 22C-37
TRANSFER INPUT GEAR . . . . . . . . . 22C-62
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-37 TRANSFER INPUT GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-62
INPUT SHAFT INSPECTION . . . . . . . . . . . 22C-38
COUNTERSHAFT. . . . . . . . . . . . . . . . 22C-63
OUTPUT SHAFT . . . . . . . . . . . . . . . . 22C-39
COUNTERSHAFT DISASSEMBLY AND
22C-2
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-63 REASSEMBLY <V5MB1-J-NEG, JER> . . . 22C-69

REAR OUTPUT SHAFT INSPECTION <V5MB1-J-
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEG, JER> . . . . . . . . . . . . . . . . . . . . . . . . . 22C-71
NEZ, PD2> . . . . . . . . . . . . . . . . . . . . . 22C-65
2-4WD SYNCHRONIZER DISASSEMBLY AND REAR OUTPUT SHAFT <V5MB1-J-ND2, NEZ,
REASSEMBLY <V5MB1-J-ND2, NEZ, PD2> PD2> . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-65 REAR OUTPUT SHAFT DISASSEMBLY AND
2-4WD SYNCHRONIZER INSPECTION <V5MB1-J- REASSEMBLY <V5MB1-J-ND2, NEZ, PD2>
ND2, NEZ, PD2>. . . . . . . . . . . . . . . . . . . . . 22C-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-72
CENTRE DIFFERENTIAL CASE <V5MB1-J- TRANSFER DRIVE SHAFT <V5MB1-J-ND2,

ND2, NEZ, PD2> . . . . . . . . . . . . . . . . 22C-67 NEZ, PD2> . . . . . . . . . . . . . . . . . . . . . 22C-74
CENTRE DIFFERENTIAL CASE DISASSEMBLY AND TRANSFER DRIVE SHAFT DISASSEMBLY AND
REASSEMBLY <V5MB1-J-ND2, NEZ, PD2> REASSEMBLY <V5MB1-J-ND2, NEZ, PD2>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-74
H-L SHIFT FORK . . . . . . . . . . . . . . . . 22C-68 FRONT OUTPUT SHAFT . . . . . . . . . . 22C-75
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H-L SHIFT FORK DISASSEMBLY AND FRONT OUTPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-68 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-75
REAR OUTPUT SHAFT <V5MB1-J-NEG, JER> SPEEDOMETER GEAR . . . . . . . . . . . 22C-76

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-69 SPEEDOMETER GEAR DISASSEMBLY AND
REAR OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-76
MANUAL TRANSMISSION OVERHAUL <V5MB1>
GENERAL INFORMATION
22C-3
GENERAL INFORMATION
M1222000101606
MANUAL TRANSMISSION MODELS

Transmission model Speedometer gear ratio Combined engine Vehicle model
V5MB1-J-NEZ 25/9 4D56 DI-D DOHC KB4T
V5MB1-J-ND2 24/9 4D56 DI-D DOHC KB4T
V5MB1-J-PD2 24/9 4D56 DI-D DOHC KB4T
V5MB1-J-NEG 25/9 4D56 DI-D DOHC KB4T
V5MB1-J-JER 25/9 4D56 DI-D DOHC KB4T
GENERAL SPECIFICATIONS
M1222000201261
Item Specifications
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Transmission model V5MB1
Applicable engine 4D56
Transmission type 5-speed transmission, floor shift
Transmission gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Reverse 4.220
Transfer type Constant mesh
Transfer gear ratio High 1.000
Low 1.900
M1222000300975

Transmission
Gear spline piece No.5 end play mm 0 − 0.1 −
Clearance between the synchronizer ring and the gear mm 0.52 - 1.88 0.52
Counter shaft gear No.5 thrust clearance 0.10 - 0.35 0.35
mm
radial clearance 0.015 − 0.068 0.068
mm
inside diameter 38.015 − 38.040 38.040
mm
Input shaft
22C-4 MANUAL TRANSMISSION OVERHAUL <V5MB1>

Input shaft radial ball bearing end play mm 0 − 0.1 −
clearance between the synchronizer ring and the 4th gear mm 0.70 − 1.70 0.70
Output shaft
Thrust clearance mm 1st gear 0.20 − 0.45 0.45
2nd gear 0.10 − 0.25 0.25
3rd gear 0.10 − 0.25 0.25
Radial clearance mm 1st gear 0.020 − 0.073 0.073
2nd gear 0.015 − 0.068 0.068
3rd gear 0.015 − 0.068 0.068
5th gear end play mm 0 − 0.1 −
Clearance between the synchronizer ring and 1st gear 0.65 − 1.75 0.65
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the each gear mm 2nd gear 0.65 − 1.75 0.65
3rd gear 0.65 − 1.75 0.65
Clearance between the each sleeve and the sleeve No.1 0.15 − 0.41 0.41
shift fork mm sleeve No.2 0.15 − 0.35 0.35
sleeve No.3 0.26 − 0.84 0.84
Output shaft outer shape of the needle roller A 37.984 − 38.000 37.984
bearing race mm B 46.984 − 47.000 46.984
C 38.979 − 38.995 38.979
Output shaft flange thickness mm − 4.800
Output shaft runout mm − 0.015
Each gear inside diameter mm 1st gear 46.015 − 46.040 46.040
2nd gear 53.015 − 53.040 53.040
3rd gear 44.015 − 44.040 44.040
Counter shaft
Counter gear shaft cylindrical roller bearing end play mm 0 − 0.1 −
Counter shaft outer shape of the needle roller D 34.000 − 34.105 34.000
bearing race mm E 29.984 − 30.000 29.984
Reverse idler gear
Reverse idler gear radial clearance mm 0.040 − 0.082 0.082
Transfer
Countershaft gear end play mm 0 − 0.15 −
H-L clutch hub end play mm 0 − 0.08 −
Differential lock hub end play mm <V5MB1-J-ND2, NEZ, PD2> 0 − 0.08 −
22C-5
Rear output shaft bearing to rear cover <V5MB1-J-NEG, JER> 0 − 0.1 −
clearance mm
<V5MB1-J-ND2, NEZ, 0.025 − 0.150 −
PD2>
Input gear bearing end play mm 0 − 0.06 −
Counter shaft gear bearing end play mm 0 − 0.08 −
2-4WD synchronizer hub end play mm <V5MB1-J-ND2, NEZ, 0 − 0.08 −
PD2>
2-4WD synchronizer ring and gear mm <V5MB1-J-ND2, NEZ, − 0.3
PD2>
Rear output shaft bearing end play mm <V5MB1-J-ND2, NEZ, 0 − 0.08 −
PD2>
Drive sprocket and synchronizer ring mm <V5MB1-J-NEG> − 0.3
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SNAP RING, SPACER AND THRUST PLATE FOR
ADJUSTMENT
M1222012001059
Transmission
Shaft snap ring (For adjustment of gear spline piece No.5 end play)
2.80 − 2.85 A 3.00 − 3.05 E
2.85 − 2.90 B 3.05 − 3.10 F
2.90 − 2.95 C 3.10 − 3.15 G
2.95 − 3.00 D
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
2.10 − 2.15 A 2.30 − 2.35 E
2.15 − 2.20 B 2.35 − 2.40 F
2.20 − 2.25 C 2.40 − 2.45 G
2.25 − 2.30 D
1.80 − 1.85 A 2.00 − 2.05 E
1.85 − 1.90 B 2.05 − 2.10 F
1.90 − 1.95 C 2.10 − 2.15 G
1.95 − 2.00 D
2.30 − 2.35 A 2.50 − 2.55 E
2.35 − 2.40 B 2.55 − 2.60 F
2.40 − 2.45 C 2.60 − 2.65 G
2.45 − 2.50 D
Shaft snap ring (For adjustment of 5th gear end play)
2.75 − 2.80 C 3.05 − 3.10 J
2.80 − 2.85 D 3.10 − 3.15 K
2.85 − 2.90 E 3.15 − 3.20 L
2.90 − 2.95 F 3.20 − 3.25 M
2.95 − 3.00 G 3.25 − 3.30 N
3.00 − 3.05 H 3.30 − 3.35 P
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Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
2.05 − 2.10 A 2.20 − 2.25 D
2.10 − 2.15 B 2.25 − 2.30 E
2.15 − 2.20 C 2.30 − 2.35 F
Transfer
Snap ring (For adjustment input gear bearing end play)
Thickness mm Identification color Thickness mm Identification color
2.30 None 2.45 Blue
2.35 Red 2.50 Green
2.40 White
Spacer (For adjustment of countershaft gear end play)
1.77 None 2.19 White
1.91 Blue 2.33 Red
2.05 Brown
Snap ring (For adjustment of countershaft gear bearing end play)
1.48 Blue 1.62 None
Spacer (For adjustment of rear output shaft to rear cover clearance)
<V5MB1-J-NEG, JER>
2.75 B75 2.95 B95
2.79 B79 2.99 B99
22C-7
2.83 B83 3.03 C03
2.87 B87 3.07 C07
2.91 B91 3.11 C11
<V5MB1-J-ND2, NEZ, PD2>
0.84 84 1.47 47
0.93 93 1.56 56
1.02 02 1.65 65
1.11 11 1.74 74
1.20 20 1.83 83
1.29 29 1.92 92
1.38 38 2.01 01
Snap ring (For adjustment of H-L clutch hub end play)
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2.18 − 2.32 −
2.25 − 2.39 −
Snap ring (For adjustment of differential lock hub end play) <V5MB1-J-ND2, NEZ, PD2>
Thickness mm IdentificatioN color Thickness mm IdentificatioN color
2.56 None 2.84 Yellow
2.63 Red 2.91 Green
2.70 White 2.98 Purple
2.77 Blue
Snap ring (For adjustment of 2-4WD synchronizer hub end play) <V5MB1-J-ND2, NEZ, PD2>
2.56 None 2.77 Blue
2.63 Red 2.84 Yellow
2.70 White
Snap ring (For adjustment of rear output shaft bearing end play) <V5MB1-J-ND2, NEZ, PD2>
2.26 None 2.40 White
2.33 Red 2.47 Blue
M1222013900632
Transmission
Item N⋅m
Reverse shift arm bracket mounting bolt 18 ± 5
Rear bearing output retainer mounting bolt 18 ± 5
Gear shift fork shaft mounting bolt 19.5 ± 3.9
Straight screw plug with head 18.5 ± 5.5
Front bearing retainer sub-assembly mounting bolt 16.5 ± 5.0
Wiring harness clamp bracket mounting bolt 18 ± 3
Transfer adaptor sub-assembly mounting bolt 37 ± 11
Shift lever housing mounting bolt 33 ± 3
Cover mounting bolt 18 ± 5
Reverse restrict pin assembly mounting bolt 37 ± 11
Clutch housing mounting bolt 36 ± 7
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Clutch housing mounting bolt (with seal) 34 ± 6
Shift position switch assembly 34 ± 5
Back-up lamp switch assembly 44 ± 9
Transfer mounting bolt and nut 35 ± 6
Transfer
Item N⋅m
Side cover tightening bolt 9.0 ± 1.0
Chain cover tightening bolt 35 ± 6
Rear cover tightening bolt 35 ± 6
Plug <V5MB1-J-NEG, JER> 35 ± 6
Transfer case tightening bolt and nut 35 ± 6
Speedometer sleeve clamp mounting bolt 19 ± 3
Vehicle speed sensor 25 ± 4
4WD operation detection switch 34 ± 5
Center differential lock detection switch <V5MB1-J-ND2, NEZ, PD2> 35 ± 6
2WD/4WD detection switch <V5MB1-J-ND2, NEZ, PD2> 35 ± 6
Center differential lock operation detection switch <V5MB1-J-ND2, NEZ, PD2> 34 ± 5
High range/Low range detection switch 34 ± 5
4LLc operation detection switch <V5MB1-J-PD2> 34 ± 5
Bearing retainer mounting bolt 19 ± 3
H-L shift fork mounting bolt 9.0 ± 2.0
Rear output shaft lock nut <V5MB1-J-NEG, JER> 255 ± 10
Rear bearing retainer <V5MB1-J-ND2, NEZ, PD2> 20 ± 2
Oil pool cover <V5MB1-J-ND2, NEZ, PD2> 9.0 ± 1.0
SEALANTS
22C-9
Item N⋅m
Plug <V5MB1-J-ND2, NEZ, PD2> 34 ± 5
Plug 32 ± 2
Center differential case mounting bolt <V5MB1-J-ND2, NEZ, PD2> 69 ± 10
SEALANTS
M1222000501251
Transmission
Between transmission case sub-assembly and Mitsubishi genuine sealant Part No.MD974421 or
intermediate plate equivalent
Between front bearing retainer and transmission
case sub-assembly
Between intermediate plate and extension housing
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sub-assembly
Between intermediate plate and transfer adaptor
sub-assembly
Between transfer adaptor sub-assembly and cover
Straight screw plug
Front bearing retainer mounting bolt
Clutch housing mounting bolt
Transfer
Chain cover Mitsubishi genuine sealant Part No.MD997740 or
Rear cover equivalent
Control housing
Transfer case plate
Plug 3M AAD part No.8672 or equivalent
Return spring plug 3M STUD Looking No.4170 or equivalent
Bearing retainer mounting bolt
FORM-IN-PLACE GASKET (FIPG) FIPG hardens as it reacts with the moisture in the
This transmission has several areas where the form- atmospheric air, and it is usually used for sealing
in-place gasket (FIPG) is used for sealing. To ensure metallic flange areas.
that the FIPG fully serves its purpose, it is necessary CAUTION
to observe some precautions when applying it. Bead When re-applying liquid gasket (FIPG), be sure
size, continuity and location are of paramount impor- that:
tance.
1. Residues of FIPG are cleared from all the ins
Too thin a bead could cause leaks. Too thick a bead,
and outs of parts;
on the other hand, could be squeezed out of location,
2. Use Mitsubishi genuine parts cleaner
causing blocking or narrowing of fluid passages. To
(MZ100387) or equivalent to well degrease the
prevent leaks or blocking of passages, therefore, it is
FIPG-applied surface.
absolutely necessary to apply the FIPG evenly with-
out a break, while observing the correct bead size. 3. FIPG is correctly applied in accordance with
FIPG Application.
LUBRICANTS
Disassembly FIPG Application

Parts sealed with a FIPG can be easily removed Applied FIPG bead should be of the specified size
without need for the use of a special method. In and free of any break. FIPG can be wiped away
some cases, however, the FIPG in joints may have to unless it has completely hardened. Install the mating
be broken by tapping parts with a mallet or similar parts in position while the FIPG is still wet. Do not
tool. allow FIPG to spread beyond the sealing areas dur-
ing installation. Avoid operating the transmission or
Surface Preparation letting oils or water come in contact with the sealed
Thoroughly remove all substances deposited on the area before a time sufficient for FIPG to harden
FIPG application surface, using a gasket scraper. (approximately one hour) has passed.
Make sure that the FIPG application surfaces is flat FIPG application method may vary from location to
and smooth. Also make sure that the surface is free location. Follow the instruction for each particular
from oils, greases and foreign substances. Do not fail case described later in this manual.
to remove old FIPG that may remain in the fastener
fitting holes.
LUBRICANTS
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M1222000400381
Item Specified lubricant Quantity

Transmission oil Gear oil API classification GL-3 SAE 75W-85W As required
Transfer oil
Oil seal Mitsubishi Part No. 0101011 or equivalent
SPECIAL TOOLS
M1222000601139
Transmission
MB990803 Steering wheel puller Removal of gear spline
piece No.5
MB990803
MB990811 Side bearing puller cup Use with Steering wheel

puller
MB990811

adapter
SPECIAL TOOLS
22C-11
adapter

adapter
MB990938 Installer bar Installation of oil seal
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MB990929 Installer adapter
MD998801 Remover Removal of roller bearing

and ball bearing, input gear
corn ring, transmission
clutch hub No.1 and
transmission clutch hub
No.2
adapter
MD998823 Installer adapter (48) Installation of ball bearing,

5th gear, transmission
clutch hub No.1 and
transmission hub No.2

adapter
SPECIAL TOOLS
Transfer
Tool Number Name Use
MB990938 Installer bar Installation of oil seal
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MD998801 Remover Removal and installation

of bearing

installer adapter

installer-200
SPECIAL TOOLS
22C-13
MD998824 Installer adapter (50) Installation of transfer
input gear bearing
MD998368 Bearing Installer Installation of

countershaft gear bearing
MD998818 Installer adapter (38) Installation of

countershaft gear
bearing, front output shaft
bearing
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MB991013 power steering lock nut Removal and installation
special spanner of output shaft locking nut

installer adapter
MD998829 Installer adapter (60) Installation of rear output

shaft ball bearing and
stopper plate
MD998821 Installer adapter (44) Installation of clutch hub

and rear output shaft ball
bearing
MD998917 Bearing remover Removal of rear output

shaft bearing <V5MB1-J-
ND2, NEZ, PD2>
TRANSMISSION

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

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

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

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

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

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

25. Shift lever housing 40. Gear shift fork shaft No.3
26. Straight screw plug with head 41. Gear shift fork No.3
27. Compression spring 42. Roller A
28. Ball 43. Ball
29. Shaft snap ring 44. Shaft snap ring
30. Gear shift fork shaft No.2 45. Gear shift fork shaft No.4
31. Gear shift fork No.2 46. Ball
32. Roller A 47. Compression spring
33. Shaft snap ring 48. E ring
34. Gear shift fork shaft No.1 49. Reverse shift arm
35. Straight pin 50. Reverse shift fork
36. Roller A
37. Gear shift fork No.1
38. Shaft snap ring
TRANSMISSION
22C-17
68
18 ± 5 N·m
71
64 63
62
69
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66
61 60
70
67
65
18 ± 5 N·m
51
Apply gear oil to
all moving parts
53
56 52
59 57 58
55 AK603036AB
51. Shaft snap ring 64. Shaft snap ring

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

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

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

places).
26.Remove the gear shift fork shaft No.2.
TRANSMISSION
22C-21
AK500260 AK500270
27.Remove the gear shift fork No.2. 31.Remove the straight pin of the gear shift fork shaft
No.1.
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AK500261
AK500264
AK500262AB
AK500265
shaft No.1 and the washer based hexagon bolt of 33.Remove the gear shift fork No.1.
the gear shift fork No.1.
AK500266AB
AK500263
30.Remove the gear shift fork shaft No.1. shaft No.3.
TRANSMISSION
38.Remove the ball.
AK403790AB
AK500453AB
35.Remove the slotted spring pin of the gear shift
fork No.3 assembly. 39.Remove the shaft snap ring of the gear shift fork
shaft No.4.
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AK500461AB
AK403802
36.Remove the gear shift fork No.3 assembly and
the gear shift fork shaft No.3.
AK403803
AK403800
40.Remove the gear shift fork shaft No.4.
AK403804
AK403801
41.Remove the ball.
TRANSMISSION
22C-23
AK403805 AK403807
42.Remove the compression spring. 46.Remove the shaft snap ring.
Transmission
hub sleeve No.3
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AK403806 AK500269AB
43.Remove the reverse shift fork and the reverse 47.Remove the transmission hub sleeve No.3.
shift arm.
MB990811 MB990803
AK403982 AC
AK500455
48.Use special tools to remove the gear spline piece
44.Remove the E ring. No.5.
• Steering wheel puller (MB990803)
Reverse shift arm • Side bearing puller cup (MB990811)
Reverse shift fork
AK500454AB
45.Remove the reverse shift arm. AK403983
49.Remove the synchronizer outer race No.3.

TRANSMISSION
AK403984 AK500458
50.Remove the counter shaft gear No.5. 54.Remove the synchromesh shifting key No.3.
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AK500526 AK500459
51.Remove the shaft snap ring. 55.Remove the needle roller bearing.
AK500456 AK403985
52.Remove the synchromesh shifting key spring 56.Remove the 5th gear thrust washer.
No.3.
AK403785AB
AK500457
57.Remove the straight pin.
53.Remove the synchromesh shifting key spring
No.3.
TRANSMISSION
22C-25
AK403986 AK403991
58.Remove the rear bearing output shaft retainer. 62.Remove the input shaft sub-assembly.
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AK403987 AK403992
59.Remove the snap ring. 63.Remove the output shaft sub-assembly.

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

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

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

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

intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.
AK403785AB
Reverse idler gear Reverse idler
sub-assembly gear shaft 8. Install the straight pin.
AK403989 AB
TRANSMISSION
22C-27
Installtion 5th gear

direction thrust
washer
Penetration
groove
Straight pin
AK501229AB AK500457

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

AK500456
washer, and install it.
to the counter shaft gear No.5.
AK500459
10.Install the needle roller bearing.

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

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

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

TRANSMISSION
CAUTION 18.Check the installation direction of the

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

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

Install it into the counter gear sub-assembly.
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Reverse shift arm
Reverse shift fork
MD998827 MD998812
MD998813
AK404049AB
17.Using special tools to install the gear spline piece

No.5.
• Installer-100 (MD998813) AK500454AB

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

hub sleeve No.3
AK500269AB
TRANSMISSION
22C-29
CAUTION
Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc-
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
AK403806
22.Install the reverse shift fork and the reverse shift

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

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

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

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

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

AK500266AB
intermediate plate and the gear shift fork No.1.
TRANSMISSION
22C-31
AK500262AB AK403792 AB
36.Install the shaft snap ring to the gear shift fork 40.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m. bolt to the specified torque of 19.5 ± 3.9 N⋅m.
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AK500261 AK403789AB
37.Install the roller A to the intermediate plate. 41.Install the ball to the intermediate plate (3 places).
AK500260 AK403788AB
38.Install the gear shift fork No.2 on the transmission 42.Install the compression spring to the intermediate
hub sleeve No.2. plate (3 places).
AK500259 AK403786AB
39.Install the gear shift fork shaft No.2 to the 43.Apply sealant to the threads. Tighten the straight
intermediate plate, the gear shift fork No.1 and the screw plug with head to the specified torque of
gear shift fork No.2. 18.5 ± 5.5 N⋅m (3 places).
TRANSMISSION

AK403783
48.Install the snap ring to the cylindrical roller

bearing.
AK500257
44.Install the transmission magnet to the

intermediate plate.
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AK403782
49.Install the snap ring to the radial ball bearing.
AK500527AB MB990938

sealant.
Never touch the degreased surface by hand. MB990929
the intermediate plate mounting surface of the AK600320 AB
transmission case sub-assembly.

50.Using special tool install the oil seal to the front
Special sealant: Mitsubishi genuine sealant bearing retainer.
Part No. MD974421 or equivalent • Installer adapter (MB990929)
AK500560
AK403775AB
47.Install the transmission case sub-assembly to the
intermediate plate.
TRANSMISSION
22C-33
51.Completely degrease the FIPG-applied surface 54.Install the wiring harness clamp bracket to the
so that water and oil including the old sealant transmission case sub-assembly and tighten the
cannot adhere to the surface coated with the bolt to the specified torque of 18 ± 3 N⋅m.
sealant.
the transmission case sub-assembly mounting
surface of the front bearing retainer sub-assembly
with seal.
AK403781
CAUTION
Do not damage to the oil seal lip during the 55.Install the reverse restrict pin assembly to the
installation. transfer adaptor sub-assembly.
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AK403774 AK403780AB
53.Apply sealant to the threads. Install the front 56.Install the slotted spring pin to the reverse restrict
bearing retainer to the transmission case sub- pin assembly.
assembly and tighten the bolts to the specified
torque of 16.5 ± 5.0 N⋅m.
AK403779
57.Apply sealant to the threads. Tighten the straight

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

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

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

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

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

33 ± 3 N⋅m.
TRANSMISSION
22C-35
68.Tighten the reverse restrict pin assembly to the
CAUTION
Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.
AK500528AB

sealant.
66.Apply a 1.2 mm diameter bead of liquid gasket to AK500460AB
the case mounting surface of the transfer adaptor
sub-assembly. 69.Install the clutch housing into the transmission
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Special sealant: Mitsubishi genuine sealant case sub-assembly. Tighten the bolt with washer
Part No. MD974421 or equivalent to the specified torque of 36 ± 7 N⋅m (7 places).
Tighten the bolt with washer (with sealant) to the
AK403770
67.Install the cover to the transfer adaptor sub-

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

M1222001100899 inside splines ends.
BACK-UP LAMP SWITCH
Limit: 0.52 mm

1. Combine the needle roller bearing with the shaft
and gear, and check that it rotates smoothly
AK500505 2. Check the needle roller bearing cage for
Check for the continuity between the connector ter- deformation.
minals.
COUNTER SHAFT GEAR No.5
Switch Connector Continuity
THRUST CLEARANCE
condition terminals
Inspect the thrust clearance of counter shaft gear
Switch end 1−2 Conductive No.5.
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pressed
Switch end 1−2 Open Limit: 0.35 mm
released
RADIAL CLEARANCE
SHIFT POSITION SWITCH
1. Fix the output shaft in a vice.
2. Inspect the radial clearance of counter shaft gear
No.5.
Limit: 0.068 mm
INSIDE DIAMETER
AK501632
Check for the continuity between the connector ter-

minals.
condition terminals
pressed AK404027
Switch end 1−2 Conductive
Using the cylinder gauge, check the inside diameter
released
of the counter shaft gear No.5.
SYNCHRONIZER SLEEVE AND HUB Standard value: 38.015 − 38.040 mm
1. Combine the synchronizer sleeve and hub, and Limit: 38.040 mm
check that they slide smoothly.
INPUT SHAFT
22C-37
INPUT SHAFT
M1222001600526
Apply gear oil to

all moving parts
5
2
4
3
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AK500516 AB

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

damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
AK403997 ridges are intact.
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clearance between the radial ball bearing and the
input shaft sub-assembly.
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
3. After applying oil to the taper portion on gear,

press and fit the synchronizer ring by hand.
AK500677AB
1. Check the helical gear teeth and clutch gear teeth

of each input shaft sub-assembly for damage and
excessive wear.
AK403999
2. Check the synchronizer cone surface of each
input shaft sub-assembly for roughness, damage, 4. Using the thickness gauge, check the clearance
and excessive wear. between the synchronizer ring and the 4th gear.
3. Check the inside surface and front and back sides Standard value: 0.70 − 1.70 mm
of each input shaft sub-assembly for damage and Minimum limit: 0.70 mm
excessive wear.
1. Combine the needle roller bearing with the input
shaft, and check that it rotates smoothly without
noise or play.
OUTPUT SHAFT
22C-39
deformation.
OUTPUT SHAFT
M1222002100160
Apply gear oil to

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

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

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

THRUST CLEARANCE FOR EACH GEAR
2nd 1st MD998801
AK404004AB

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

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

AK404001AB SHIFTING KEY No. 1 / COMPRESSION SPRING /
1. Fix the output shaft by a vice. SYNCHRONIZER RING SET No. 1 / 2ND GEAR
2. Inspect the radial clearance of each gear. SUB-ASSEMBLY REMOVAL
1st 0.020 − 0.073 0.073
2nd 0.015 − 0.068 0.068
3rd 0.015 − 0.068 0.068 MD998801
AK404014 AB
OUTPUT SHAFT
22C-41
support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No. 1, com- MD998812
pression spring, the transmission clutch No. 1 hub,
synchronizer ring set No. 1 and the 2nd gear sub- MD998813
assembly.
MD998823
<<D>> TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 /
COMPRESSION SPRING / TRANSMISSION HUB AK404029AC
/ 3RD GEAR SUB-ASSEMBLY REMOVAL 2. Using special tools to install the transmission
clutch hub No. 2, synchronizer shifting key No. 2,
compression spring, the transmission hub sleeve
No. 2, synchronizer ring set No. 2 and the 3rd
MD998801 gear sub-assembly.
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AK404020AB

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

SHIFTING KEY No. 1 / COMPRESSION SPRING / >>D<< SHAFT SNAP RING INSTALLATION
SYNCHRONIZER RING SET No. 1 / 2ND GEAR
SUB-ASSEMBLY INSTALLATION
Installation
direction
AK404031

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

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

assembly.
bearing, and put it on the output shaft.
• Installer-200 (MD998814) CAUTION
• Installer adapter (48) (MD998823) Never push on the sealing area when installing.
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
Limit: 0.25 mm • Installer-200 (MD998814)
OUTPUT SHAFT
22C-43
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 − 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
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M1222002300261
Installation SYNCHRONIZER RING
direction
AK500609AB
1. Check the installation direction of the 5th gear,

and put it on the output shaft.
AK500672AB
MD998812
CAUTION
MD998814
When any of the outer ring, inner ring or cone
MD998823 1. Check to ensure that the clutch gear tooth surface
AK404039AB
2. Using special tools to install the 5th gear.

AK500603

OUTPUT SHAFT

1. Combine the needle roller bearing with the output
shaft and gear, and check that it rotates smoothly
deformation.
SYNCHRONIZER KEYS
AK404022

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

1. Combine the synchronizer sleeve and hub, and B 46.984 − 47.000 46.984
check that they slide smoothly. C 38.979 − 38.995 38.979
COUNTERSHAFT
22C-45
3. Using the dial gauge and V-block, check the
output shaft runout.
Limit: 0.015 mm Max
AK404025
2. Using the slide gauge, check the flange thickness.

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

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

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

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

AK404041AB
roller bearing, and put it on the counter shaft.
Using the micrometer, check the outer shape of the
CAUTION needle roller bearing race.
Never push the sealing area at the press fit.
Measurement Standard value Limit mm
MD998812
part mm
D 34.000 − 34.105 34.000
MD998813 E 29.984 − 30.000 29.984
MD998817
AK404046AB
REVERSE IDLER GEAR
22C-47
REVERSE IDLER GEAR
M1222012500233
Apply gear oil to

all moving parts
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1
AK500519AB
Disassembly steps INSPECTION

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

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

all moving parts
AKA00412 AB

1. 4WD operation detection switch >>T<< 8. Spring
2. Gasket 9. Steel ball
3. High range/Low range detection >>U<< 10. Plug
switch 11. Gasket
4. Gasket 12. Vehicle speed sensor
5. Steel ball 13. Speedometer sleeve clamp
>>U<< 6. Plug >>S<< 14. Speedometer driven gear sleeve
>>U<< 7. Plug assembly
TRANSFER
22C-49
Apply gear oil to 35 ± 6 N·m

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

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

<<A>> >>J<< 31. H-L shift rail <> >>B<< 46. Front output shaft
32. H-L shift fork 47. 2-4WD shift fork
>>I<< 33. H-L clutch sleeve 48. Snap ring
34. Harness bracket 49. Spring retainer
35. Harness bracket 50. Return spring
36. Harness bracket 51. 2-4WD shift lug and shift rail
>>H<< 37. Chain cover assembly
38. Interlock plunger >>F<< 52. Spring pin
39. Wave spring 53. 2-4WD shift lug
>>D<< 40. Snap ring 54. Distance piece
>>C<< 41. H-L clutch hub 55. 2-4WD shift rail
42. Low speed gear 56. Dust seal guard
43. Needle bearing >>A<< 57. Oil seal
<> >>B<< 44. Rear output shaft 58. Transfer case
<> >>B<< 45. Chain
TRANSFER
22C-51
<V5MB1-J-ND2, NEZ,PD2>
5 34 ± 5 N·m 26
34 ± 5 N·m
4 6
35 ± 6 N·m
34 ± 5 N·m
35 ± 6 N·m
12
2 34 ± 5 N·m
34 ± 5 N·m
7 31
9
35 ± 6 N·m
<V5MB1-J-PD2>
10
1 8 13 27
11 14
<V5MB1-J-
ND2,NEZ>
32
19 ± 3 N·m
3
28
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29
33 30 19 18
25 17 25 ± 4 N·m
20 24 15
16 32 ± 2 N·m
23 Apply gear oil to

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

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

<<A>> >>J<< 34. H-L shift rail 51. E-ring
35. H-L shift fork 52. Spring seat
>>I<< 36. H-L clutch sleeve 53. Spring
37. Harness bracket 54. 2-4WD shift lug and shift rail
38. Harness bracket assembly
39. Harness bracket >>F<< 55. Spring pin
>>H<< 40. Chain cover 56. 2-4WD shift lug
41. Interlock plunger 57. Spring seat
42. Wave spring 58. Spring
43. Rear output shaft 59. 2-4WD shift rail
44. Needle bearing 60. 2-4WD shift fork
45. Needle bearing 61. 2-4WD synchronizer sleeve
46. Center differential case 62. Spacer
<<C>> >>G<< 47. 2-4WD synchronizer 63. Steel ball
<<C>> >>G<< 48. Chain >>E<< 64. Snap ring
<<C>> >>G<< 49. Front output shaft 65. Differential lock hub
50. Needle bearing
TRANSFER
22C-53
70
Apply gear oil to
all moving parts
71
20 ± 2 N·m
9.0 ± 1.0 N·m
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72
69
68 75
67 74
66
73 AK503403AJ
Disassembly steps 1. Fix the H-L shift rail at the high position.
>>D<< 66. Snap ring 2. Shift the 2-4WD shift rail at the 4WD position.
>>C<< 67. H-L clutch hub
68. Low speed gear
NOTE: If the 2-4WD shift rail is at the 2WD posi-
69. Needle bearing tion, the chain cover cannot be removed because
70. Rear bearing retainer interlock is actuated.
71. Transfer drive shaft
72. Oil pool cover <> REAR OUTPUT SHAFT / CHAIN/FRONT
73. Dust seal guard OUTPUT SHAFT REMOVAL
>>A<< 74. Oil seal
75. Transfer case
DISASSEMBLY SERVICE POINTS

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

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

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

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

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

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

the snap ring groove of the rear output shaft.
2. Make sure that the H-L clutch hub end play meets
the standard value.
TRANSFER
22C-55
>>E<< SNAP RING INSTALLATION
AK101124
AK503398
3. Place the chain in tight mesh with the 2-4WD
1. Install the thickest snap ring that can be fitted in synchronizer and front output shaft sprockets.
the snap ring groove of the transfer drive shaft. 4. With both sprockets spaced the farthest apart,
2. Make sure that the differential lock hub end play install them on the transfer case simultaneously.
meets the standard value.
Standard value: 0 − 0.08 mm >>H<< CHAIN COVER INSTALLATION
CAUTION
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>>F<< SPRING PIN INSTALLATION Squeeze the sealant out evenly to apply it in
an unbroken, non-excessive quantity.
2 mm Diameter
AK503410
AK403508AB
1. Align the e2-4WD shift lug with the 2-4WD shift
rail spring pin hole. 1. Completely degrease the FIPG-applied surface so
2. Hammer in the spring valve so that the spring pin that water and oil including the old sealant cannot
slit matches the center of the shift rail shaft. adhere to the surface coated with the sealant.
>>G<< 2-4WD SYNCHRONIZER/CHAIN/FRONT 2. Apply sealant to the chain cover, and then install
OUTPUT SHAFT INSTALLATION the chain cover.
Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent
>>I<< H-L CLUTCH SLEEVE INSTALLATION
Identification groove
AK101123
1. Make a white paint mark on the deep groove Installation

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

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

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

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

1. Use special tools to install the oil seal.
2. Move the 2-4WD shift rail in the direction of the
• Installer adapter (MB990932) <V5MB1-J-NEG,
arrow fully.
JER>
3. After making sure that the plunger is not exposed • Installer adapter (MB990929) <V5MB1-J-ND2,
out of the H-L shift rail hole in the transfer case, NEZ, PD2>
install the H-L shift rail. • Installer bar (MB990938)
2. Apply the specified grease to the lip of oil seal.
>>K<< SPRING PIN INSTALLATION
AK503412
TRANSFER
22C-57
>>M<< SPACER INSTALLATION 2. Subtract A from B and let the answer be C. Select
a spacer so that the subtracted value will be the
<V5MB1-J-NEG, JER>
A
Rear cover standard value shown below.
Standard value:
0 − 0.1 mm <V5MB1-J-NEG, JER>
0.025 − 0.150 mm <V5MB1-J-ND2, NEZ, PD2>
B
>>N<< OIL COVER INSTALLATION
Oil hole
Spacer
Oil cover
AK403729 AC
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In case of <V5MB1-J-NEG, JER> type, install the oil
cover so that the oil hole shown in the illustration.
AK403504AJ
>>O<< REAR COVER INSTALLATION
Rear cover CAUTION
A Squeeze the sealant out evenly to apply it in
2 mm
Diameter
AKX00172 AC
Spacer 1. Completely degrease the FIPG-applied surface so

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

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

AK403617AC
1. Completely degrease the FIPG-applied surface so

that water and oil including the old sealant cannot
adhere to the surface coated with the sealant.
2. Apply the sealant to the transfer case plate.
Specified sealant: Mitsubishi genuine seal-
AK403514AB
CAUTION
The transfer case plate must be installed Apply the sealant to the threads.
smooth and straight to get a good seal. Specified sealant: 3M AAD Part No. 8672 or
3. Install the transfer case plate together with the equivalent
input gear and countershaft. NOTE: .
The new plug is precoated with sealant, so seal-
ant does not need to be applied.
TRANSFER
22C-59
>>V<< DETECTION SWITCH INSTALLATION 1. Put solders (1.0 mm diameter, about 10 mm long)
V V V V
in the illustrated positions of the transfer case
A housing.
B 2. Install the counter shaft into the transfer case.
C 3. Install the transfer case plate and tighten the bolts
E to the specified torque of 35 ± 6 N⋅m.
D 4. Remove the transfer case plate and the counter
1
2 shaft, and then take out crushed solders.
4 6 5 3 5. If the solders have not crushed, use thicker
F
solders (1.6 mm diameter, about 10 mm long) and
AK801184AB repeat steps 2 to 4.
Install with care. Do not make mistake when locating
each switch.
Detection switch name Connector
No./Color
A Center differential lock 1/Brown
detection switch
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B 2WD/4WD detection switch 2/Black
C Center differential lock 4/Blown
operation detection switch AK305233
D 4WD operation detection switch 5/Black

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

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

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

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

High range/low range detection
switch
AK503422

minals.
condition terminals
Switch end 1 − Body earth Open
pressed
AK500510AB
Switch end 1 − Body earth Conductive
released
TRANSFER CASE PLATE
22C-61
TRANSFER CASE PLATE
M1222009100086
Apply gear oil to 19 ± 3 N·m

all moving parts
1
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3
5
4
AK500691AD
Disassembly steps Specified lubricant: Mitsubishi Part No.

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

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

M1222009400139
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Apply gear oil to
all moving parts
AK800993AB
Disassembly steps DISASSEMBLY SERVICE POINT

>>B<< 1. Snap ring <<A>> BALL BEARING REMOVAL
<<A>> >>A<< 2. Ball bearing
3. Transfer input gear
MD998801
AK601073 AC
COUNTERSHAFT
22C-63
Use special tool, Bearing remover (MD998801),
remove the ball bearing. >>B<< SNAP RING INSTALLATION
Ball bearing
Standard value
>>A<< BALL BEARING INSTALLATION
Snap ring
MD998812
MD998826
AK500699AB

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

all moving parts
AK500663 AB

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

the ball bearing.
<> ROLLER BEARING REMOVAL AKX00260
1. Install the thickest snap ring that can be fitted into

MD998801
the snap ring groove of the counter shaft gear.
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MD998368
2. Make sure that the counter shaft gear roller
bearing end play meets the standard value.
>>C<< BALL BEARING INSTALLATION
AKX00258 AC
Use special tools to remove the roller bearing. MD998812

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

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

MD998812 • Installer cap (MD998812)
MD998818 • Installer adapter (38) (MD998818)
AKX00259 AC
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
22C-65
M1222010900020
7
Apply gear oil to
all moving parts
9
8
6 10
5
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4
3
9
2
AK503423AB

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

installation.
>>B<<OUTER SYNCHRONIZER RING CAUTION

INSTALLATION When any of the outer ring, inner ring or cone
1. Check to ensure that the clutch gear tooth surface
AK503427AB
Apply oil the synchronizer ring cone surface before

installation.
>>C<<SNAP RING INSTALLATION AK503424
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Snap ring
AK101272AD
Select and install the snap ring which adjusts the 2-

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

M1222011000020
SYNCHRONIZER RING
Limit: 0.3 mm
AK500672AB
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
22C-67
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
M1222010600041
Apply gear oil to

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

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

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

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

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

spring plug to be an even surface between the
plunger boss end face and the return spring plug.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
REAR OUTPUT SHAFT <V5MB1-J-NEG, JER>
22C-69
M1222010300181
14
15
16
17
18
255 ± 10 N·m
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5
12 9
11 3
13 4
6
8 7 Apply gear oil to
all moving parts
10 before installation.
AK500645AB

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

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

BEARING REMOVAL
2-4WD clutch hub

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

MD998813
MD998814
MD998801
MD998829
Ball bearing
MD998801
AK403521AB
1. Fit the ball bearing and stopper plate onto the rear
AK403518AB
output shaft.
1. Use special tool Remover (MD998801) to support 2. Use special tools to press in the ball bearing.
the ball bearing. • Remover (MD998801)
2. Use a press to push at a rear end of the rear • Installer cap (MD998812)
output shaft, and then remove the radial ball • Installer-100 (MD998813)
bearing. • Installer-200 (MD998814)
22C-71
>>B<< CLUTCH HUB INSTALLATION • Installer cap (MD998812)
MD998812
MD998813
MD998814
NOTE: .
The ball bearing may be fitted loosely on the
MD998821
shaft, so that installation is possible without using a
Installation
direction 2-4WD clutch hub press
MD998801 >>E<< LOCK NUT INSTALLTION
AK500686 AB
MB991013
1. Confirm the clutch hub installation direction, and
fit onto the rear output shaft.
2. Use special tools press in the clutch hub.
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AK500495AB
NOTE: . 1. Hold the drive sprocket in a soft-jaws vice.
The clutch hub may fit loosely on the shaft, so that 2. Shift the clutch sleeve to the drive sprocket side.
installation is possible without using a press. 3. Using special tool Power steering lock nut special
spanner (MB991013) tighten the lock nut to the
>>C<< CLUTCH SLEEVE INSTALLTION specified torque of 255 ± 10 N⋅m.
Installation
direction
AK500685AB AK403516
Check that the clutch sleeve is in the correct direc- 4. Stake the two places of the lock nut as shown in
tion for installation. illustration.
>>D<< BALL BEARING INSTALLATION

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

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

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

M1222010300114
Apply gear oil to

all moving parts
cardiagn.com
3
1
4
AK101106 AC
Disassembly steps
>>B<< 1. Snap ring
3. Viscous coupling
4. Rear output shaft
22C-73
DISASSEMBLY SERVICE POINT Use special tools to install the ball bearing.
<<A>> BALL BEARING REMOVAL • Installer cap (MD998812)

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

remove the ball bearing.
AK101112

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

M1222011200057
Apply gear oil to

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

AK503429 AB
Use special tool Remover (MD998801) to remove • Counter shaft bearing puller (MD998192)
the ball bearing.
FRONT OUTPUT SHAFT
22C-75
FRONT OUTPUT SHAFT
M1222011500025
Apply gear oil to

all moving parts
1
2
cardiagn.com
AKX00425 AC

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

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

SPEEDOMETER GEAR

MD998812
MD998813
MD998818
MD998801
AK403523 AB

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

all moving parts
1 before installation.
3
2
AKX00429 AC

1. O-ring 4. O-ring
>>A<< 2. Spring pin 5. Sleeve
3. Driven gear
SPEEDOMETER GEAR
22C-77
REASSEMBLY SERVICE POINT Drive the spring pin in, while making sure that slit
>>A<< SPRING PIN INSTALLATION does not face gear shaft.
Slit
Spring pin
AK403524 AB
cardiagn.com

Manual Transmission (FR)

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Manual Transmission (FR)

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22-1

MANUAL TRANSMISSION OVERHAUL <R5MB1> . . . . . . . . . 22B

MANUAL TRANSMISSION OVERHAUL <V5MB1> . . . . . . . . . 22C

Item Specified lubricant Quantity L

Item Specified sealant

Filler plug hole Filler plug

Filler plug Filler plug hole

TRANSFER OIL LEVEL CHECK TRANSFER OIL REPLACEMENT

Filler plug Filler plug

Drain plug Drain plug

Filler plug hole Filler plug hole

Transfer oil Transfer oil

4WD DETECTION SWITCH CONTINUITY

Check the continuity between terminals of the black

Check the continuity between terminals of the black

4LLc SWITCH CONTINUITY CHECK

Check the continuity between terminals of the brown

Removal steps Removal steps (Continued)

3.2 ± 0.2 N·m

Removal steps INSTALLATION SERVICE POINT

Pre-removal and Post-installation Operations

Removal steps Removal steps (Continued)

REMOVAL AND INSTALLATION <4WD>

Pre-removal and Post-installation Operations

11 ± 1 N·m 9.0 ± 1.0 N·m

Removal steps Removal steps (Continued)

<Vehicles with LHD>

<Vehicles with RHD>

GENERAL INFORMATION . . . . . . . . 22B-2 INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-29

TORQUE SPECIFICATIONS . . . . . . . 22B-4 COUNTERSHAFT. . . . . . . . . . . . . . . . 22B-37

MANUAL TRANSMISSION MODELS

Item Standard value Limit

SNAP RING, SPACER AND THRUST PLATE FOR

Item Specified sealant and adhesive

Surface Preparation FIPG Application

Item Specified lubricant

Tool Tool number Name Use

MB990811 Side bearing puller cup Use with Steering wheel

MD998812 Installer cap Use with installer and

MD998813 Installer-100 Use with installer cap and

MD998801 Remover Removal of roller bearing

MD998817 Installer adapter (34) Use with installer cap and

MB990699 Differential oil seal Installation of oil seal

MB990929 Installer adapter Installation of oil seal

MB990938 Installer bar Use with installer adaoter

Disassembly steps Disassembly steps (Continued)

18.5 ± 5.5 N·m

Disassembly steps Disassembly steps (Continued)

Disassembly steps Disassembly steps (Continued)

Shift position switch

Back-up lamp switch

1. Remove the back-up lamp switch assembly and AK403777

10.Remove the oil seal. 14.Remove the transmission magnet.

17.Remove the ball (3 places). 21.Remove the roller A.

33.Remove the gear shift fork shaft No.4. AK500455

37.Remove the E-ring.

34.Remove the ball. AK500454AB

38.Remove the reverse shift arm and reverse shift

• Steering wheel puller (MB990803)

Shaft snap ring

39.Remove the shaft snap ring (2 places). AK403983

46.Remove the counter shaft gear No.5.