However, an experienced mechanic can still overhaul a transmission if he has the right tools and if the work is done step by step so that nothing is missed.
The tools needed include pliers for removing inner and outer snap rings, bearing pullers, a sliding hammer, a set of pin press mandrels, a micrometer, and if possible, a hydraulic press. A large work table and a vice or gearbox stand are also needed.
When disassembling the gearbox, pay attention to how each part is removed, the relative positions of the parts, and the fastening elements. The locations of the parts are shown in the attached exploded view (see illustrations) - but if you memorize how the parts are actually installed, it will make assembly much easier.
4.4a. Typical parts of a 4-speed gearbox - exploded view. 1. Reverse light switch, 2. Gasket, 3. Steel ball, 4. Bolt, 5. Locking plate, 6. Speedometer drive gear, 7. Bolt, 8. Gearbox housing, 9. Outer bearing race, 10. Spacers, 11. Breather, 12. Gasket, 13. Detent plugs, 14. Gasket, 15. Detent springs, 16. Detent balls, 17. Reverse idler shaft, 18. Reverse gear gear, 19. Bolts, 20. Reverse gear engagement lever, 21. Reverse gear guide, 22. Spring pins, 23. 1st/2nd gear guide, 24. 1st/2nd gear shift fork, 25. Guide 3/4 gear, 26. 3/4 gear shift fork, 27. Intermediate locking plungers, 28. Output shaft, 29. Spacer, 30. Differential, 31. Idle gear, 32. Bolts, 33. Bearing holder, 34. Input shaft, 35. Outer bearing race, 36. Clutch housing.
The text of the article was taken from the website: MitsubishiMan.ru
4.4b. Details of a typical five-speed gearbox - exploded view. 1. Fifth gear drive, 2. Sleeve, 3. Sealing ring, 4. Seat, 5. Locking plate, 6. Gear selection fork and guide, 7. Seat, 8. Input shaft, 9. Bearing holder, 10. Spacer, 11. Bearing outer race, 12. Idle gear, 13. Speedometer drive gear, 14. Reverse idler gear shaft, 15. Reverse idler gear, 16. Reverse gear engagement gear, 17. Output shaft, 18. Bearing outer race, 19. Spacer, 20. Differential, 21. Reverse gear engagement guide, 22. First/second gear engagement guide, 23. First/second gear engagement fork, 24. Third/fourth gear shift fork, 25. Spring pin, 26. Third/fourth gear shift guide, 27. Fifth gear foot, 28. Selector spacer, 29. Detent ball, 30. Detent spring, 31. Plug, 32. Intermediate lock plunger, 33. Intermediate lock plunger, 34. Gearbox bracket, 35. Clutch cable bracket, 36. Reversing light switch, 37. Gasket, 38. Steel ball, 39. Gearbox housing, 40. Breather, 41. Fifth gear actuator sensor, 42. Clutch housing.
Before repairing the gearbox, it is advisable to imagine which part of the gearbox is faulty. Certain problems may be directly related to specific units of the gearbox, which can be checked separately and replaced. Information on possible sources of faults is given in the section "Troubleshooting" at the beginning of this guide.