Contents: Removal ⤓ Installation ⤓
Warning: To prevent damage to the gearbox mounting supports, the connections at the points marked with "*" in Figures 12.16 and 12.18 should be pre-tightened and final tightening should be performed after the engine has been lowered onto the supports.
Fig. 12.16. Fastening elements of the F5MR1 gearbox: 1 - Reverse light switch connector; 2 - starter; 3 - clutch slave cylinder; 4 - upper gearbox to cylinder block mounting bolts, 50 Nm; 5 - gearbox support bracket; 6 - gearbox support stopper; 7 - lower gearbox mounting bracket
Fig. 12.18. Fastening elements of F5MR1 gearboxes:1 - brake hose fastening clamp; 2 - Wheel speed sensor connector (cars with ABS); 3 - ball joint of the steering rod end; 4 - lower arm ball joint; 5 - anti-roll bar; 6 - central beam assembly; 7 - left drive shaft; 6 - spring pin; 9 - right drive shaft; 10-gearbox support; 11 - Front clutch housing cover; 12 - lower gearbox mounting bolts, 50 Nm; 13 - gearbox; A - place of lubrication application; B - place of application of sealant MITSUBISHI GENUINE PART MD970369
Removal
- Disconnect the cable from the negative battery terminal.
- Drain the transmission oil from the gearbox.
- Remove the lower protective cover.
- Remove the air filter assembly.
- Remove the battery and its support.
- Remove the fuel vapor canister.
- Remove the shift and selector rods as an assembly.
- Disconnect the electrical connector from the reversing light switch (Fig. 12.16).
- 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 unscrew the nut and remove the bolt; remove the gearbox support stopper and detach the L gearbox support bracket.
- To support the engine, install a special tool on the vehicle (an engine lift with a hand hoist and a crossbar) (Fig. 12.17).
Fig. 12.17. Using a crossbeam to lift the engine from the engine compartment
- Loosen the bolts securing the lower gearbox support bracket.
- Raise the car on a lift.
- Remove the retainer securing the brake hose to the front suspension strut (Fig. 12.16).
- 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 MB990b35 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.
Fig. 12.19. Using a special tool to push the ball joint pin out of the steering knuckle
- Loosen the nut, remove the bolt and the lower arm ball joint pin from the steering knuckle.
- Remove the nuts and bolts securing the stabilizer bar to the lower control arms. Remove the bolts and clamps securing the stabilizer bar, then remove the stabilizer bar from the vehicle.
- Loosen the nuts, remove the bolts and remove the center beam assembly.
- Disconnect the left drive shaft from the gearbox and, together with the hub and steering knuckle, move it away from the gearbox.
Warning: Do not separate the drive shaft from the steering knuckle and hub.
- Knock out the spring pin and disconnect the right drive shaft.
- Use soft wire to secure the removed drive shafts inside the wheel arches so as to prevent the CV joints from being severely bent.
- Remove the bolts and gearbox support.
- Remove the bolts and remove the front clutch housing cover.
- Remove the lower bolts securing the gearbox to the cylinder block.
- Pull the transmission away from the engine and remove it from the vehicle. When separating the transmission from the engine, be careful not to damage the transmission input shaft, the clutch release bearing guide sleeve, and the clutch driven disc.
Installation
- Installation is carried out in the reverse order of removal, taking into account the following.
- After applying multi-purpose grease to the splined portion of the right drive shaft, align the split pin hole on the end of the drive shaft with the split pin hole on the end of the shaft on the transmission side, then install the drive shaft.
- If the split pin hole is slightly misaligned, rotate the right drive shaft 180° and then try installing it again.
Warning: Because the drive shaft has an odd number of splines, the pin hole will be offset by half a diameter if the shaft is rotated 180°.
- Apply MITSUBISHI GENUINE PART MD970389 or equivalent sealant to the split spring pin, and then insert it into the drive shaft.
- After installing the pin, apply MITSUBISHI GENUINE PART MD970389 sealant to both sides of the pin hole to completely seal them.
- Install the gearbox stop so that the arrow on the flange points in the direction shown in Figure 12.20.
Fig. 12.20. Installing the gearbox locking flange
- 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.
Fig. 12.21. Distance (A) of the stabilizer mounting bolt protrusion: A = 22 mm
- Install the gear shift rod assembly.
- Install the battery.
- Install the adsorber.
- 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.