Mitsubishi F5MR1 Manual
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Mitsubishi F5MR1 Manual

Mitsubishi F5MR1 Manual

Manual transmission
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TRANSMISSION
F5MR1, F5MR2, F5MR3
E
Mitsubishi Motors Corporation
MANUAL
CONTENTS
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May 1996
PWEE9508-B
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22A-0-1
22A-6-1
Revised

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Summary of Contents for Mitsubishi F5MR1

  • Page 1: Table Of Contents

    22A-0-1 MANUAL TRANSMISSION F5MR1, F5MR2, F5MR3 CONTENTS GENERAL INFORMATION ........
  • Page 2 22A-0-2 NOTES Mitsubishi Motors Corporation May 1995 PWEE9508...

  • Page 3: General Information

    22A-0-3 MANUAL TRANSMISSION (E - W) - General Information GENERAL INFORMATION F5MR1, F5MR2 - Five-speed front wheel drive transmission 7 6 5 9 10 11 12 13 14 15 16 17 1. Clutch housing 14. 3rd speed gear 2. Input shaft 15.
  • Page 4 9. 5th speed synchronizer assembly 20. Differential 10. 5th gear wheel 21. Differential bearing 11. Output shaft 22. Shim 12. Output shaft bearing 23. Lock nut 13. 4th speed gear 24. Output shaft bearing Added Mitsubishi Motors Corporation May 1996 PWEE9508-B...

  • Page 5: Specifications

    22A-1-1 MANUAL TRANSMISSION (E - W) - Specifications 1. SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Model F5MR1 <For CARIS- F5MR1 F5MR3 MA>, F5MR2 <For SPACE STAR> Type Manual, 5-speed, Manual, 5-speed, Manual, 5-speed, front wheel drive front wheel drive front wheel drive Gear ratio 3.363...

  • Page 6: Lubricants

    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 Revised Mitsubishi Motors Corporation May 1996 PWEE9508-B...

  • Page 7: Special Tools

    Special Tools 2. SPECIAL TOOLS Tool Number Name 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...
  • Page 8 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> May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1996 PWEE9508-B PWEE9508-B Revised Revised...
  • Page 9 Spring pin installer Installation of spring pin and lock pin MD998348 Bearing and gear Removing 5th gear wheel puller 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>...
  • Page 10 Special Tools Tool Number Name MD998813 Installer - 100 Fitting 4th gear wheel bearing bush <F5MR3> MD998819 Installer adapter Fitting 4th gear wheel bearing bush <F5MR3> (40) May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1996 PWEE9508-B PWEE9508-B Revised Added...

  • Page 11: Transmission

    22A-3-1 MANUAL TRANSMISSION (E - W) - Transmission 3. TRANSMISSION DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2> 80 Nm 135 Nm 25 Nm 22 Nm 22 Nm Lubricate all internal parts with gear oil 38 Nm during reassembly. 24 Nm Disassembly steps "ZA 1.
  • Page 12 AK" "KA 34. Reverse idler gear shaft AR" "AA 45. Input shaft rear bearing AL" "JA 35. Spring pin AR" "AA 46. Snap ring AL" "HA 36. 3rd and 4th shift rail assembly May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 13 AB" "WA 11. Lock nut AG" "RA 24. Poppet spring AC" "XA 12. Spring pin AG" "RA 25. Poppet ball AC" "VA 13. 5th speed shift fork May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 14 AQ" "CA 43. Oil guide AK" "LA 34. Reverse idler gear shaft AS" "BA 44. Output shaft rear bearing cup 35. Spring pin AS" "BA 45. Input shaft rear bearing cup May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 15 (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. MD998348 Mitsubishi Motors Corporation May 1995 PWEE9508...
  • Page 16 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 <F5MR1, F5MR2> REMOVAL Remove the cover plate and withdraw the poppet spring and ball. NOTE Do not lose the poppet spring and ball.
  • Page 17 MANUAL TRANSMISSION (E - W) - Transmission AJ" SPRING PIN/1ST AND 2ND GEAR SHIFT RAIL <F5MR1, F5MR2> 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.
  • Page 18 (1) Take the two shafts out of the clutch housing together. RMT0008 (2) Inspect the input shaft. NOTE The shaft must always be replaced in the event of wear or damage. The shaft cannot be reconditioned. RMT0009 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 19 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 <F5MR1, F5MR2> Remove the plastic cover from the release fork ball and socket joint. <F5MR3>...
  • Page 20 +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 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 21 (2) Introduce the bearing cups from the inside of the transmission case. MB990933 (3) Tap the bearing cup into the transmission case as far as the stop with handle MB990938 and installer MB990933. RMT0014 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 22 Push the breather hose into the transmission case. Fit the breather unit. "EA PLASTIC COVER INSTALLATION <F5MR1, F5MR2> (1) Thoroughly clean the ball and socket joint. (2) Apply Loctite 415 to the ball joint. (3) Fit a new plastic cover on the ball and socket joint (press down firmly).
  • Page 23 (4) Fit a new (short) spring pin in the selector fork. NOTE The slit in the spring pin must be in axial alignment with the shift rail assembly. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508...
  • Page 24 Fit a new spring pin in the shift fork (it must be fully inserted in the shift fork). NOTE The slit in the spring pin must be in axial alignment with the shift rail assembly. RMT0020 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 25 MANUAL TRANSMISSION (E - W) - Transmission "PA MAGNET INSTALLATION Fit the magnet in the differential housing. "QA POPPET BALL/POPPET SPRING/TRANSMISSION <F5MR1, F5MR2> CASE INSTALLATION (1) Apply liquid gasket cement (Loctite 518) to the mating face. NOTE Do not apply too much gasket cement. Let the gasket cement dry for at least thirty minutes before filling the manual transmission with oil.
  • Page 26 (2) Locate the bearing sleeve 11 over the input shaft. (3) Locate the 5th speed gear together with the synchronizer ring over the shaft. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508...
  • Page 27 (1) Place a new O-ring on the transmission case. 25 Nm (2) Locate the rear cover carefully on account of the oil guide. (3) Fit and tighten the bolts. 25 Nm 25 Nm May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 28 MANUAL TRANSMISSION (E - W) - Transmission "ZA BACK-UP LAMP SWITCH INSTALLATION (1) Apply sealant (Loctite 572) to the back-up lamp switch. (2) Fit and tighten the back-up lamp switch. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...

  • Page 29: Output Shaft

    22A-4-1 MANUAL TRANSMISSION (E - W) - Output Shaft 4. OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2> Lubricate all internal parts with gear oil during reassembly. Disassembly steps 1. Shim 14. Serrated ring AA" "NA 2. 4th gear wheel AD" "FA 15. 2nd gear wheel 3.
  • Page 30 "LA 9. 3rd - 4th gear synchronizer hub 20. Output shaft AH" "JA 10. 3rd gear wheel AJ" "CA 21. Bearing cup AH" "HA 11. Bearing bushing May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 31 Output Shaft DISASSEMBLY SERVICE POINTS <F5MR1, F5MR2> AA" 4TH GEAR WHEEL REMOVAL (1) Remove the shim 1. <F5MR1, R5MR2> (2) Remove the bearing and the shim. <F5MR3> (3) Take the gear wheel and synchronizer ring off the shaft. <F5MR3> RMT0025 AB"...
  • Page 32 AI"SYNCHRONIZER SPRINGS REMOVAL (1) Press the hub out of the synchronizer sleeve. (2) Remove the two springs. NOTE Make sure that none of the parts are lost. RMT0027 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 33 (1) Place the output shaft under a press and support the 1st gear wheel. (2) Press the bearing cup on to the output shaft with bearing drift MB996013. MB996013 RMT0031 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 34 Always use new synchronizer springs. (4) Locate the hub together with the synchronizer sleeve <F5MR1, F5MR2> on the shaft. (5) Fit a new snap ring 8 <F5MR1, F5MR2> or synchronizer ring <F5MR3>. NOTE Make sure that the lugs of the synchronizer ring engage the recesses in the synchronizer sleeve.
  • Page 35 (3) Locate the three synchronizer springs together with the rollers in the hub. NOTE Always use new synchronizer springs. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 36 (5) Press the bearing bush down with drift installer cap MD998812 MD998812, installer - 100 MD998813, installer adapter MD998819 until the drift abuts the mating face of the shim. MD998813 MD998819 RMT0040 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 37 In the case of old bearings: fit the old shim. In the case of new bearings: fit a shim with a thickness of 1.6 mm. (4) Fit the bearing. RMT0041 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 38 22A-4-10 MANUAL TRANSMISSION (E - W) - Output Shaft NOTES May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508...

  • Page 39: Differential

    22A-5-1 MANUAL TRANSMISSION (E - W) - Differential 5. DIFFERENTIAL DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2> Lubricate all internal parts with gear oil during reassembly. Disassembly steps 9. Shim AF" "CA 10. Side gear 1. O-ring 11. Spring pin AA" "HA 2. Oil seal 12.
  • Page 40 12. Shaft AE" "DA 5. Speedometer drive gear AG" "BA 13. Pinion gear 6. Differential case 14. Washer 7. Snap ring AH" "AA 15. Side gear 8. Shim May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 41 AD" SPEEDOMETER DRIVE GEAR/SPRING RING/ GUARD GEAR REMOVAL (1) Take the speedometer drive gear off the differential. (2) Remove the spring ring. (3) Remove the guard ring. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 42 Take the side gear out of the differential case. REASSEMBLY SERVICE POINTS "AA SIDE GEAR INSTALLATION (1) Smear the side gears with grease. (2) Locate the side gear in the differential case. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 43 (4) Locate the bearing. (5) Smear the nut with a locking agent (Loctite 270). MB996003 (6) Fit the nut with the opening facing towards the bearing. RMT0045 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 44 (1) Pack the lip of the new oil seal with grease. MB996010 (2) Place the guide on the shaft and locate the oil. (3) Fit the oil seal with drift MB996010. (4) Fit a new O-ring. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...

  • Page 45: Clutch Housing

    22A-6-1 MANUAL TRANSMISSION (E - W) - Clutch Housing 6. CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY <F5MR1, F5MR2> Lubricate all internal parts with gear oil during reassembly. Disassembly steps AA" "GA 1. Input shaft bearing AC" "EA 2. Output shaft bearing 3.
  • Page 46 AD" "FA 2. Output shaft bearing 3. Oil baffle AC" "BA 4. Large bearing cup AF" "CA 5. Speedometer drive gear 6. Shaft AH" "BA 7. Small bearing cup May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 47 (3) Remove the oil baffle. MB996006 RMT0048 AE" LARGE BEARING REMOVAL Tap the bearing cup out of the housing with a long punch. NOTE Take care not to damage any parts. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Revised...
  • Page 48 (1) Coat the mating faces with the specified sealant. (2) Press in the bearing cups with spindle MB996000 and installers MB996004 and MB996008. MB996008 MB996004 MB996000 RMT0050 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 49 (2) Locate the bearing so that the oil passages of the bearing and the housing are opposed. (3) Press in the bearing with installer MD998717. NOTE The bearing must be flush with the housing. May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 50 "HA INPUT SHAFT BEARING CUP INSTALLATION (1) Coat the mating face with the specified sealant. (2) Press the bearing cup against the stop with installer MB996011. MB996011 RMT0052 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...

  • Page 51: Control Lever

    4. Spring pin 11. Rubber seal 5. Spring pin 12. Rubber seal AA" "CA 6. Selector dog AB" "AA 13. Outer bearing bush "BA 7. Selector shaft oil seal AB" "AA 14. Inner bearing bush Mitsubishi Motors Corporation May 1995 PWEE9508...
  • Page 52 (6) Locate the outer bearing bush and installer MB996007. (7) Fit the remote control arm in the housing. (8) Tap in the bearing bush until it abuts against its seating. (9) Remove the remote control arm and installer MB996007. Mitsubishi Motors Corporation May 1995 PWEE9508...
  • Page 53 (6) Locate the two bearing bushes 6 and fit the shift lever (7) Fit the snap ring 3. (8) Fit the rubber seal over the oil seal. (9) Check for correct operation. (10)Fit the compression spring 2 on the outside. Mitsubishi Motors Corporation May 1995 PWEE9508...

  • Page 54: Input Shaft

    (2) Tap the bearing partway off the input shaft with a chisel. (3) Locate the bearing remover MD998801 behind the bearing. (4) Press the bearing of the input shaft. RMT0055 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 55 In the case of old bearings: Fit the old shim. In the case of new bearings: fit a shim with a thickness of 1.6 mm. (2) Fit the bearing. RMT0057 May 1996 Mitsubishi Motors Corporation Mitsubishi Motors Corporation May 1995 PWEE9508-B PWEE9508 Added...
  • Page 56 NOTES Mitsubishi Motors Corporation May 1995 PWEE9508...

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F5mr3F5mr2

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