Removal and installation of the F5M42 gearbox (Mitsubishi Space Star)

Warning: To prevent damage to the transmission mount supports, the connections in the places marked with "*" in Figures 12.22 and 12.23 should be pre-tightened, and the final tightening should be performed after lowering the engine onto the supports.

Fig. 12.22. Fastening elements of the F5M42 gearbox: 1 - tips of gear selection and shift cables; 2 - Reverse light switch connector; 3 - vehicle speed sensor connector; 4 - starter; 5 - clutch slave cylinder; 6 - upper bolts for fastening the gearbox to the cylinder block, 48 Nm; 7 - gearbox support bracket; 8 - Gearbox support stopper

Removal

• Disconnect the cable from the negative battery terminal.
• Drain the transmission oil from the gearbox.
• Remove the lower engine splash shield.
• Remove the air filter assembly.
• Remove the battery and its support.
• Remove the fuel vapor canister.
• Remove the cotter pins and disconnect the gear selection and shift cables from the gearbox (Fig. 12.22).
• Disconnect the connectors from the reverse light switch and vehicle speed sensor.
• Unscrew the bolts and remove the starter and, without disconnecting the wires from it, secure it in a place where it will not interfere with the removal of the gearbox.
• Remove the clutch hydraulic drive slave cylinder and, without disconnecting the hose from it, secure it in a place where it will not interfere with the removal of the gearbox.
• Remove the upper bolts securing the gearbox to the cylinder block.
• Using a hydraulic jack, carefully lift the gearbox, then loosen the nut, remove the bolt, remove the gearbox retaining flanges and detach the gearbox support bracket.
• To support the engine, install a special tool on the vehicle (engine lift with a hand hoist and a crossbar) (see fig. 12.17).
• Raise the car on a lift.
• Remove the retainer securing the brake hose to the front suspension strut (Fig. 12.23).




Fig. 12.23. Fastening elements of the F5M42 gearbox: 1 - brake hose fastening clamp; 2 - Wheel speed sensor connector (cars with ABS); 3- ball joint of the steering rod end; 4-ball joint lower arm; 5 - anti-roll bar; 6 - central beam assembly, 7 - left drive shaft; 8 - right drive shaft; 9 - gearbox support; 10-Front clutch housing cover; 11 - lower gearbox mounting bolts, 48 Nm; 12 - gearbox





• On a vehicle with ABS, disconnect the connector from the wheel speed sensor.
• Remove the cotter pin and loosen the nut securing the ball joint pin of the tie rod end to the steering knuckle.

Warnings: Do not loosen the nut securing the ball joint pin of the tie rod end to the steering knuckle. To avoid damaging the threads on the ball joint pin, use the special tool MB991113 or MB990635.

• To prevent the special tool MB991113 or MB990635 from falling, secure it to the front suspension strut with a cord.
• Install the special tool MB991113 or MB990635 as shown in figure 12.19, making sure that the jaws of the tool are parallel. Rotate the bolt of the special tool to push the ball joint pin out of the steering knuckle, then unscrew the nut and remove the ball joint pin from the steering knuckle.
• Loosen the nut, remove the bolt and the lower arm ball joint pin from the steering knuckle.
• Unscrew the nuts and remove the bolts securing the stabilizer bar to the lower arms, unscrew the bolts and remove the stabilizer bar mounting clamps, then remove the stabilizer bar from the vehicle.
• Loosen the nuts, remove the bolts and remove the center beam assembly.
• Insert a crowbar between the inner CV joint of the drive shaft and the gearbox and lightly tap the crowbar to remove the drive shaft from the gearbox (Fig. 12.24).

Fig. 12.24. Using a pry bar to remove the drive shaft from the gearbox

Warnings!

• Use the pry bar very carefully to avoid damaging the joint and gearbox housing.
• Do not insert the pry bar too deeply to avoid damaging the differential seal.
• Do not pull on the drive shaft as this will damage the constant velocity joints.

• Together with the hub and steering knuckle, move the drive shaft away from the gearbox.

Warning: Do not separate the drive shaft from the steering knuckle and hub.

• Use soft wire to secure the removed drive shafts inside the wheel arches so as not to allow the CV joints to bend too much.
• Install special plugs instead of drive shafts to prevent dirt from getting into the gearbox.

Warning: Replace the differential seal whenever the drive shaft is removed.

• Remove the bolts and gearbox support.
• Remove the bolts and the front clutch housing cover.
• Remove the lower bolts securing the gearbox to the cylinder block.

Caution: When separating the transmission from the engine, be careful not to damage the transmission input shaft, clutch release bearing guide sleeve, and clutch driven disc.

• Move the gearbox away from the engine and remove it from the vehicle.

Installation

• Installation is carried out in the reverse order of removal, taking into account the following.
• Install the anti-roll bar and tighten the self-locking nut so that the anti-roll bar mounting bolt protrudes above the nut as shown in Figure 12.21.
• Install the gearbox stop so that the arrow on the flange points in the direction shown in Figure 12.25.

Fig. 12.25. Installing the gearbox locking flange

• Connect the gear selector and shift cables to the gearbox and secure them with cotter pins.
• Install the adsorber.
• Install the battery.
• Install the air filter assembly.
• Install the lower protective cover.
• Fill the gearbox with transmission oil.
• Check that the gear shift lever moves smoothly and correctly through all positions.
• Check the operation of the speedometer.