Mitsubishi F5MR1 User manual

GENERAL INFORMATION 22A-0-3....................................
1. SPECIFICATIONS 22A-1-1.........................................
GENERAL SPECIFICATIONS 22A-1-1.............................
TORQUE SPECIFICATIONS 22A-1-1..............................
LUBRICANTS 22A-1-2...........................................
SEALANTS AND ADHESIVES 22A-1-2............................
2. SPECIAL TOOLS 22A-2-1.........................................
3. TRANSMISSION 22A-3-1..........................................
4. OUTPUT SHAFT 22A-4-1..........................................
5. DIFFERENTIAL 22A-5-1...........................................
6. CLUTCH HOUSING 22A-6-1.......................................
7. CONTROL LEVER 22A-7-1........................................
8. INPUT SHAFT 22A-8-1............................................
22A-0-1
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Revised
MANUAL
TRANSMISSION
F5MR1, F5MR2, F5MR3
CONTENTS

22A-0-2
PWEE9508
EMay 1995Mitsubishi Motors Corporation
NOTES

MANUAL TRANSMISSION (E-W) - General Information 22A-0-3
PWEE9508
EMay 1995Mitsubishi Motors Corporation
GENERAL INFORMATION
F5MR1, F5MR2 - Five-speed front wheel drive transmission
8765 4 3
1
2
21201918
9101112 1314151617
2322
25
24
1. Clutch housing
2. Input shaft
3. Input shaft bearing
4. Transmission case
5. Input shaft bearing
6. Rear cover
7. 5th speed gear
8. 5th speed synchronizer assembly
9. 5th gear wheel
10. Output shaft
11. Output shaft bearing
12. 4th speed gear
13. 3rd - 4th speed synchronizer
assembly
14. 3rd speed gear
15. 2nd speed gear
16. 1st - 2nd speed synchronizer
assembly
17. 1st speed gear
18. Guard ring
19. Spring ring
20. Differential bearing
21. Differential
22. Differential bearing
23. Snap ring
24. Snap ring
25. Output shaft bearing

MANUAL TRANSMISSION (E-W) - General Information
22A-0-4
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Added
F5MR3 - Five-speed front wheel drive transmission
876 5 4
3
1
2
212019
18
9
10 11 12 13 14 15 16 17
23
22
24
RMT0001
1. Clutch housing
2. Input shaft
3. Guide bushing
4. Input shaft bearing
5. Transmission case
6. Input shaft bearing
7. Rear cover
8. 5th speed gear
9. 5th speed synchronizer assembly
10. 5th gear wheel
11. Output shaft
12. Output shaft bearing
13. 4th speed gear
14. 3rd - 4th speed synchronizer assem-
bly
15. 3rd speed gear
16. 2nd speed gear
17. 1st - 2nd speed synchronizer as-
sembly
18. 1st speed gear
19. Differential bearing
20. Differential
21. Differential bearing
22. Shim
23. Lock nut
24. Output shaft bearing

MANUAL TRANSMISSION (E-W) - Specifications 22A-1-1
1. SPECIFICATIONS
GENERAL SPECIFICATIONS
Items Specifications
Model F5MR1 <For CARIS-
MA>, F5MR2
F5MR1
<For SPACE STAR>
F5MR3
Type Manual, 5-speed,
front wheel drive
Manual, 5-speed,
front wheel drive
Manual, 5-speed,
front wheel drive
Gear ratio 1st 3.363 3.727 3.727
2nd 2.047 2.047 2.047
3rd 1.321 1.321 1.321
4th 0.966 0.966 0.971
5th 0.794 0.794 0.756
Reverse 3.545 3.545 3.545
Final reduction ratio 4.066 4.214 3.437
TORQUE SPECIFICATIONS
Items Specifications (Nm)
Bearing housing bolts 25
Input shaft lock nut 135
Output shaft bolt 80
Cover bolts 25
Locating pin 24
Back-up lamp switch 22
Drain plug 22
Filler/level plug 2.25
Sealing plugs 25
Guide bushing bolts <F5MR3> 25
Differential nut <F5MR3> 130
PWEE9508-E
EJun. 1998Mitsubishi Motors Corporation Revised

MANUAL TRANSMISSION (E-W) - Specifications
22A-1-2
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Revised
LUBRICANTS
Items Quantity Specified lubricant
Transmission oil 3.4 L Elf Tranself TRX 75W - 80W (XT3556)
Rear cover O-ring As required Elf Tranself TRX 75W - 80W (XT3556)
All internal parts As required Elf Tranself TRX 75W - 80W (XT3556)
Shift lever As required Lithium MoS2
Shift lever bearing bush As required Lithium MoS2
Selector shaft oil seal As required Lithium MoS2
Speedometer driven gear As required Multi-purpose grease
Differential side gear As required Multi-purpose grease
Differential pinion gear As required Multi-purpose grease
Differential pinion washer As required Multi-purpose grease
Differential side oil seal As required Multi-purpose grease
SEALANTS AND ADHESIVES
Items Specified sealants and adhesives
5th gear wheel on output shaft Loctite 242
5th gear wheel bolt Loctite 242
Plastic cover on release fork ball and socket joint Loctite 415
Transmission case mating surface Loctite 518
Locating pin for 5th gear Loctite 572
Back-up lamp switch Loctite 572
Differential nut <F5MR3> Loctite 270

MANUAL TRANSMISSION (E-W) - Special Tools 22A-2-1
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Revised
2. SPECIAL TOOLS
Tool Number Name Use
MB990926 Installer Fitting shift rail assembly oil seal
MB990927 Installer Removing input shaft front bearing <F5MR1,
F5MR2>
MB990930 Installer Removing small differential bearing <F5MR1,
F5MR2>
MB990931 Installer Fitting output shaft bearing
MB990932 Installer Fitting input and output shaft rear bearings
MB990933 Installer Fitting input and output shaft rear bearing cups
<F5MR3>
MB990934 Installer Fitting small differential bearing <F5MR1,
F5MR2>
MB990938 Handle Various installers
MB996000 Spindle Fitting large and small bearing cups <F5MR3>
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Special Tools
22A-2-2
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Revised
Tool UseNameNumber
MB996001 Bearing puller Removing output shaft front bearing
MB996003 Socket wrench Removing and installing differential gear
<F5MR3>
MB996004 Bearing drift Fitting large and small bearing cups <F5MR3>
MB996005 Counterhold Removing and installing differential gear
<F5MR3>
MB996006 Bracket Removing output shaft front bearing
MB996007 Bearing bush drift Fitting selector shaft bushes
MB996008 Bearing drift Fitting large and small bearing cups <F5MR3>
MB996010 Oil seal drift Fitting differential gear assembly oil seal
MB996011 Bearing drift Fitting input shaft bearing cup <F5MR3>
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Special Tools 22A-2-3
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Revised
Tool UseNameNumber
MB996012 Mounting plate Calculate the pre-tention of input and output
shafts with new bearings <F5MR3>
MB996013 Bearing drift Fitting output shaft bearing <F5MR3>
MD998019 Spring pin extractor Removing spring pins
MD998020 Bearing puller Removing 5th gear synchronizer hub
MD998245 Spring pin installer Installation of spring pin and lock pin
MD998348 Bearing and gear
puller
Removing 5th gear wheel
MD998717 Installer Fitting input shaft front bearing <F5MR1,
F5MR2>
MD998801 Bearing remover Removing input and output shaft bearings
<F5MR3>
MD998812 Installer cap Fitting 4th gear wheel bearing bush <F5MR3>
AddedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Special Tools
22A-2-4
PWEE9508-B
EMay 1996Mitsubishi Motors Corporation Revised
Tool UseNameNumber
MD998813 Installer - 100 Fitting 4th gear wheel bearing bush <F5MR3>
MD998819 Installer adapter
(40)
Fitting 4th gear wheel bearing bush <F5MR3>
AddedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Transmission 22A-3-1
PWEE9508
EMay 1995Mitsubishi Motors Corporation
3. TRANSMISSION
DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2>
80 Nm 135 Nm
25 Nm
22 Nm
22 Nm
38 Nm
24 Nm
22
2
3
23
24
25
4
5
1
6
7
12
8
13
16
17
18
19
20
21 10 915
14 11
Lubricate all internal
parts with gear oil
during reassembly.
Disassembly steps
"ZA1. Back-up lamp switch
2. Drain plug
3. Gasket
4. Filler plug
5. Gasket
AA""
YA6. Bolt
AA""
YA7. Rear cover
AA""
YA8. O-ring
AB""
WA9. Bolt
AB""
WA10. Shim
AB""
WA11. Lock nut
AC""
XA12. Spring pin
AC""
VA13. 5th speed shift fork
AC""
VA14. Synchronizer sleeve
AD""
VA15. Synchronizer spring
AD""
VA16. Synchronizer hub
AD""
TA17. Synchronizer ring
AD""
TA18. 5th speed gear
AD""
TA19. Bearing sleeve
AD""
TA20. Retaining ring
AE""
UA21. 5th gear wheel
AF""
SA22. Locating pin
AG""
RA23. Cover plate
AG""
RA24. Poppet spring
AG""
RA25. Poppet ball
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Transmission
22A-3-2
PWEE9508
EMay 1995Mitsubishi Motors Corporation
25 Nm
39
33
34
32
35
36
40
26
30
37
38
43
31
44
46
29
28
41
42
27 45
Lubricate all internal
parts with gear oil
during reassembly.
Disassembly steps
26. Bolt
AH""
QA27. Transmission case
AH""
QA28. Poppet spring
AH""
QA29. Poppet ball
AI""
PA30. Magnet
AI""
NA31. 5th gear shift rail assembly
AJ""
JA32. Spring pin
AJ""
JA33. 1st and 2nd shift rail assembly
AK""
KA34. Reverse idler gear shaft
AL""
JA35. Spring pin
AL""
HA36. 3rd and 4th shift rail assembly
AL""
HA37. Output shaft
AL""
HA38. Input shaft
AN""
FA39. Interlock plungers
AO""
EA40. Plastic cover
AP""
DA41. Breather unit
AP""
DA42. Breather hose
AQ""
CA43. Oil guide
AR""
AA44. Output shaft rear bearing
AR""
AA45. Input shaft rear bearing
AR""
AA46. Snap ring
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Transmission 22A-3-2a
PWEE9508
EMay 1995Mitsubishi Motors Corporation
DISASSEMBLY AND REASSEMBLY <F5MR3>
Lubricate all internal
parts with gear oil
during reassembly.
80 Nm 135 Nm
25 Nm
22 Nm
38 Nm
24 Nm
22
2
3
23
24
25
4
5
1
6
7
12
8
13
16
17
18
19
20
21
10 9
15
14 11
22 Nm
RMT0002
Disassembly steps
"ZA1. Backup lamp switch
2. Drain plug
3. Gasket
4. Filler plug
5. Gasket
AA""
YA6. Bolt
AA""
YA7. Rear cover
AA""
YA8. O-ring
AB""
WA9. Bolt
AB""
WA10. Shim
AB""
WA11. Lock nut
AC""
XA12. Spring pin
AC""
VA13. 5th speed shift fork
AC""
VA14. Synchronizer sleeve
AD""
VA15. Synchronizer spring
AD""
VA16. Synchronizer hub
AD""
TA17. Synchronizer ring
AD""
TA18. 5th speed gear
AD""
TA19. Bearing sleeve
AD""
TA20. Retaining ring
AE""
UA21. 5th gear wheel
AF""
SA22. Locating pin
AG""
RA23. Cover plate
AG""
RA24. Poppet spring
AG""
RA25. Poppet ball
AddedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Transmission
22A-3-2b
PWEE9508
EMay 1995Mitsubishi Motors Corporation
25 Nm
39
33
34
32
35
36
40
26
30
37
38
43
31
44
29
28
41
42
27 45
RMT0003
Lubricate all internal
parts with gear oil
during reassembly.
Disassembly steps
26. Bolt
AH""
QA27. Transmission case
AH""
QA28. Poppet spring
AH""
QA29. Poppet ball
AI""
PA30. Magnet
AI""
NA31. 5th gear shift rail assembly
AJ"32. Spring pin
AJ"33. 1st - 2nd gear shift rail assembly
AK""
LA34. Reverse idler gear shaft
35. Spring pin
"OA36. 3rd - 4th gear shift rail assembly
AM""
MA37. Output shaft
AM""
IA38. Input shaft
AN""
GA39. Interlock plungers
AO""
EA40. Plastic cover
AP""
DA41. Breather unit
AP""
DA42. Breather hose
AQ""
CA43. Oil guide
AS""
BA44. Output shaft rear bearing cup
AS""
BA45. Input shaft rear bearing cup
AddedPWEE9508-BMitsubishi Motors Corporation May 1996
E

MANUAL TRANSMISSION (E-W) - Transmission 22A-3-3
PWEE9508
EMay 1995Mitsubishi Motors Corporation
DISASSEMBLY SERVICE POINTS
AA"BOLT/REAR COVER/O-RING REMOVAL
(1) Remove the bolts and lift off the rear cover carefully to
avoid damaging the oil pipe on the rear cover.
(2) Remove the O-ring.
AB"BOLT/SHIM/LOCK NUT REMOVAL
(1) Engage two gears: first engage reverse gear and then
push the 5th gear synchronizer sleeve over the 5th speed
gear.
(2) Remove the bolt 1, shim 2 and lock nut 3.
AC"SPRING PIN/5TH SPEED SHIFT FORK/
SYNCHRONIZER SLEEVE REMOVAL
(1) Support the shift rail assembly and remove the spring
pin with spring pin extractor MD998019.
(2) Tap the 5th speed shaft fork 4 together with the
synchronizer 5 off the shift rail assembly.
NOTE
Do not lose the spring pin.
AD"SYNCHRONIZER HUB/SYNCHRONIZER RING/
SYNCHRONIZER SPRING/5TH SPEED GEAR/
BEARING SLEEVE/RETAINING RING REMOVAL
(1) Locate bearing puller MD998020 with attachments No.85
under the teeth of the synchronizer hub.
(2) Pull the synchronizer hub off the shaft.
(3) Remove the 5th speed gear 6, bearing sleeve 7 and
retaining ring 8.
AE"5TH GEAR WHEEL REMOVAL
(1) Locate gear puller MD998348 over the 5th gear wheel.
(2) Pull the gear wheel off the shaft.
1
2
3
MD998019
5
MD998020
7
8
6
MD998348

MANUAL TRANSMISSION (E-W) - Transmission
22A-3-4
PWEE9508
EMay 1995Mitsubishi Motors Corporation
AF"LOCATING PIN REMOVAL
Unscrew and remove the locating pin.
NOTE
Do not lose the adjusting ring (if fitted).
AG"COVER PLATE/POPPET SPRING/POPPET BALL
REMOVAL
Remove the cover plate and withdraw the poppet spring and
ball.
NOTE
Do not lose the poppet spring and ball.
AH"TRANSMISSION CASE/POPPET BALL/POPPET
SPRING REMOVAL
(1) Remove the retaining bolts.
(2) Tap lightly to separate the transmission case and clutch
housing.
(3) Remove the transmission case; note the shim on the
output shaft.
NOTE
When removing the transmission case, hold the poppet
springs and balls of both selector shafts in position with
two hex nut drivers.
AI"MAGNET/5TH GEAR SHIFT RAIL ASSEMBLY
REMOVAL
(1) Remove the magnet from the clutch housing.
(2) Remove the shift rail assembly 9 from the transmission
case.
NOTE
Catch the poppet spring and ball and put them to one
side.
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
ERevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E
<F5MR1, F5MR2>
<F5MR3>
RMT0004
9

MANUAL TRANSMISSION (E-W) - Transmission 22A-3-5
PWEE9508
EMay 1995Mitsubishi Motors Corporation
AJ"SPRING PIN/1ST AND 2ND GEAR SHIFT RAIL
ASSEMBLY REMOVAL
(1) Cover the differential drive gear with a cleaning rag.
(2) Tap out the spring pin as far as possible with spring pin
extractor MD998019.
(3) Move 3rd and 4th gear into neutral.
(4) Raise the reverse gear shaft as high as possible and
remove the shift rail assembly 10.
AK"REVERSE IDLER GEAR SHAFT REMOVAL
(1) Raise the input and output shafts.
(2) Take the reverse idler gear shaft out of the clutch housing.
NOTE
Hold the output shaft at the bottom.
(3) Inspect the reverse idler gear shaft.
NOTE
The shaft must always be renewed in the event of wear
or damage. The shaft cannot be reconditioned.
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
ERevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E
MD998019
10
<F5MR1, F5MR2>
<F5MR3>
MD998019
10
RMT0005
<F5MR1, F5MR2>
<F5MR3>
RMT0006
<F5MR1, F5MR2>

MANUAL TRANSMISSION (E-W) - Transmission
22A-3-6
PWEE9508
EMay 1995Mitsubishi Motors Corporation
AL"SPRING PIN/3RD AND 4TH SHIFT RAIL ASSEMBLY/
INPUT SHAFT/OUTPUT SHAFT REMOVAL
(1) Remove the spring pin from the 3rd and 4th gear selector
fork.
(2) Take both shafts together with the shift rail assembly
out of the clutch housing.
(3) Inspect the input shaft.
NOTE
The shaft must always be renewed in the event of wear
or damage. The shaft cannot be reconditioned.
AM"INPUT SHAFT/OUTPUT SHAFT REMOVAL
(1) Take the two shafts out of the clutch housing together.
(2) Inspect the input shaft.
NOTE
The shaft must always be replaced in the event of wear
or damage. The shaft cannot be reconditioned.
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E
<F5MR3>
RMT0007
RMT0008
RMT0009

MANUAL TRANSMISSION (E-W) - Transmission 22A-3-7
PWEE9508
EMay 1995Mitsubishi Motors Corporation
AN"INTERLOCK PLUNGERS REMOVAL
Remove the three interlock plungers and the small interlock
plunger from the 1st and 2nd gear shift rail assembly.
AO"PLASTIC COVER REMOVAL
Remove the plastic cover from the release fork ball and socket
joint.
AP"BREATHER UNIT/BREATHER HOSE REMOVAL
Take the breather unit out of the transmission case. Carefully
remove the breather hose.
AQ"OIL GUIDE REMOVAL
Push in the lug 11 and withdraw the oil guide from the
transmission case.
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E
<F5MR1, F5MR2>
<F5MR3>
RMT0010
11

MANUAL TRANSMISSION (E-W) - Transmission
22A-3-8
PWEE9508
EMay 1995Mitsubishi Motors Corporation
AR"OUTPUT SHAFT REAR BEARING/INPUT SHAFT
REAR BEARING/SNAP RING REMOVAL
(1) Open the snap rings with a pair of pliers.
(2) Tap out the bearings towards the inside of the transmission
case with a plastic-tip hammer.
(3) Remove the two snap rings.
AS"REAR BEARING CUP OUTPUT SHAFT/REAR
BEARING CUP INPUT SHAFT REMOVAL
(1) Tap the bearing cups out of the transmission case with
handle MB990938 and bearing installer MB990931.
ADJUSTMENT BEFORE REASSEMBLY
<F5MR3>
CALCULATE THE PRE-TENSION OF THE INPUT AND
OUTPUT SHAFTS WITH NEW BEARINGS
(1) Introduce the input shaft and the output shaft in the clutch
housing.
(2) Place the transmission case on the clutch housing, insert
a few retaining bolts around the shafts and tighten the
bolts.
(3) Locate the mounting plate MB996012 on the tripod joint
housing and secure it with a bolt.
(4) Locate the magnetic base together with clock gauge on
the mounting plate.
Input shaft
(5) Rotate the input shaft a few times.
(6) Raise the input shaft at the clutch end and read off the
value indicated by the clock gauge.
Repeat this operation several times.
Example A B
new used
bearings bearings
pre-tension
value 0.00 mm - 0.03 mm
shim thickness +0.60 mm +0.60 mm
measured value +0.46 mm +0.46 mm
=1.06 mm =1.03 mm
Select:
A: a shim with a thickness of 1.10 mm
B: a shim with a thickness of 1.50 mm
RevisedPWEE9508-BMitsubishi Motors Corporation May 1996
E
MB990938
MB990931
RMT0011
RMT0012
MB996012
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