TRANSMISSION Workshop Manual FR A/T(WE) - mitsubishi

TRANSMISSION Workshop Manual FR A/T(WE) - mitsubishi

23D-1-1
R4A51, V4A51 - Specifications
1. SPECIFICATIONS
TRANSMISSION MODEL TABLE - MODEL 2000
Transmission models
EUR
EXP
Vehicle model
Engine model
V4A51-5-DHA3
K96W
6G72
V4A51-5-DHA4
K96W
6G72
R4A51-5-DCA
K86W
6G72
R4A51-5-DEA
K86W
6G72
V4A51-5-DHA3
K96W
6G72
V4A51-5-DHA4
K96W
6G72
V4A51-5-QIA
K97W
4M40
V4A51-5-QIA1
K97W
4M40
TRANSMISSION MODEL TABLE - MODEL 2001
Transmission models
EUR
EXP
MMAL
E Mitsubishi Motors Corporation
Vehicle model
Engine model
V4A51-5-DHA3
K96W
6G72
V4A51-5-DHA4
K96W
6G72
V4A51-7-QBA
V66W, V76W
4M40
V4A51-7-DCA
V63W, V73W
6G72
V4A51-7-DCA1
V63W, V73W
6G72
R4A51-5-DCA
K86W
6G72
R4A51-5-DEA1
K86W
6G72
V4A51-5-DHA3
K96W
6G72
V4A51-5-DHA4
K96W
6G72
V4A51-5-QIA
K97W
4M40
V4A51-5-QIA1
K97W
4M40
R4A51-4-DHA
K66T
6G72
R4A51-4-GDA
K66T
6G72
V4A51-4-DIA
K76T
6G72
V4A51-5-DHA4
K96W
6G72
July 2000
PWEE8920-J
Revised
23D-14-1
R4A51, V4A51 - Transfer <V4A51>
14. TRANSFER <V4A51>
DISASSEMBLY AND ASSEMBLY - V4A51-4 PART TIME 4WD
35 Nm
9
34 Nm
34 Nm
3
10
11
4
5
35 Nm
1
6
7
8
2
12
35 Nm
13
Apply gear oil to all
moving parts before
installation.
14
15
Disassembly steps
1. 2-4WD detection switch
2. Gasket
3. H-L detection switch
4. Gasket
5. Steel ball
"LA 6. Plug
"PA 7. Spring
8. Steel ball
E Mitsubishi Motors Corporation
July 2000
"LA 9.
"PA 10.
11.
"LA 12.
"LA 13.
14.
"OA 15.
PWEE8920-J
18 Nm
Plug
Spring
Steel ball
Plug
Plug
Speedometer sleeve clamp
Speedometer gear
Revised
23D-14-3a
R4A51, V4A51 - Transfer <V4A51>
DISASSEMBLY AND ASSEMBLY - V4A51-5 PART TIME 4WD
35 Nm
9
34 Nm
34 Nm
3
10
11
4
5
35 Nm
1
6
7
8
2
12
35 Nm
13
Apply gear oil to all
moving parts before
installation.
14
15
Disassembly steps
1. 2-4WD detection switch
2. Gasket
3. H-L detection switch
4. Gasket
5. Steel ball
"LA 6. Plug
"PA 7. Spring
8. Steel ball
E Mitsubishi Motors Corporation
July 2000
"LA 9.
"PA 10.
11.
"LA 12.
"LA 13.
14.
"OA 15.
PWEE8920-J
18 Nm
Plug
Spring
Steel ball
Plug
Plug
Speedometer sleeve clamp
Speedometer gear
Revised
23D-14-3b
R4A51, V4A51 - Transfer <V4A51>
21 Nm
18 Nm
32
33
35 Nm
26
29
25
35 Nm
28
27
23
34
35 Nm
22
30
31
16
24
20
17
35 Nm
21
32 Nm
35 Nm
Apply gear oil to all
moving parts before
installation.
19
18
35 Nm
Disassembly steps
"NA 16. Transfer case plate
17. Needle bearing
18. Countershaft gear
"MA 19. Spacer
"LA 20. Plug
"KA 21. H-L shift rail plug
22. Low switch
23. Gasket
24. Dynamic damper
25. Harness bracket
E Mitsubishi Motors Corporation
July 2000
"JA
"IA
"IA
"HA
"QA
"GA
26.
27.
28.
29.
30.
31.
32.
"FA 33.
"EA 34.
PWEE8920-J
Control housing
Support pin
Return spring
Rear cover
Oil cover
Spacer
Dust seal guard
Oil seal
Spring pin (H-L shift fork)
Revised
23D-14-3c
R4A51, V4A51 - Transfer <V4A51>
47
44
45
44 43
35 Nm
46
40
39
42
35
41
49
48
8.8 Nm
51
36
52
50
37
38
54
Apply gear oil to all
moving parts before
installation.
55
53
AA" "EA
AA" "DA
"DA
"CA
Disassembly steps
35. H-L shift rail
36. Chain cover
37. H-L shift fork
38. H-L clutch sleeve
39. Interlock plunger
40. Spring pin
41. 2-4WD shift lug
42. Distance piece
43. E-clip
44. Spring seat
45. Spring
E Mitsubishi Motors Corporation
July 2000
AB" "BA
AB" "BA
AB" "BA
"AA
PWEE8920-J
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
2-4WD shift rail
2-4WD shift fork
Rear output shaft
Chain
Front output shaft
Side cover
Side cover gasket
Dust seal guard
Oil seal
Transfer case
Revised
23D-14-3d
R4A51, V4A51 - Transfer <V4A51>
DISASSEMBLY AND ASSEMBLY - V4A51-7 PART TIME 4WD
35 Nm
9
10
1
11
34 Nm
3
35 Nm
6
7
8
2
34 Nm
4
15
5
12
14
35 Nm
13
18 Nm
16
17
35 Nm
Disassembly steps
1. 4WD switch
2. Gasket
3. Transfer switch
4. Gasket
5. Steel ball
"LA 6. Plug
"PA 7. Spring
8. Steel ball
"LA 9. Plug
E Mitsubishi Motors Corporation
July 2000
35 Nm
"PA 10.
11.
"LA 12.
"LA 13.
14.
15.
16.
17.
PWEE8920-J
Apply gear oil to all
moving parts before
installation.
Spring
Steel ball
Plug
Plug
Dynamic damper
Dust seal guard
Vehicle speed sensor
Under guard
Revised
23D-14-3e
R4A51, V4A51 - Transfer <V4A51>
35 Nm
18 Nm
24
27
25
29
26
30
35 Nm
23
28
18
35 Nm
22
19
35 Nm
32 Nm
Apply gear oil to all
moving parts before
installation.
21
20
35 Nm
Disassembly steps
"NA 18. Transfer case plate
19. Needle bearing
20. Countershaft gear
"MA 21. Spacer
"LA 22. Plug
"KA 23. H-L shift rail plug
24. Low switch
E Mitsubishi Motors Corporation
July 2000
"JA
"HA
"GA
"FA
"EA
PWEE8920-J
25.
26.
27.
28.
29.
30.
Gasket
Control housing
Rear cover
Spacer
Oil seal
Spring pin (H-L shift fork)
Added
23D-14-3f
R4A51, V4A51 - Transfer <V4A51>
43
42
38
40
41
39
40
35 Nm
44
35
36
31
45
37
33
32
46
Apply gear oil to all
moving parts before
installation.
34
49
47
AA" "EA
AA" "DA
"DA
"CA
Disassembly steps
31. H-L shift rail
32. Chain cover
33. H-L shift fork
34. H-L clutch sleeve
35. Interlock plunger
36. Spring pin
37. 2-4WD shift lug
38. Distance piece
39. E-clip
40. Spring seat
E Mitsubishi Motors Corporation
July 2000
48
AB" "BA
AB" "BA
AB" "BA
"AA
PWEE8920-J
41.
42.
43.
44.
45.
46.
47.
48.
49.
Spring
2-4WD shift rail
2-4WD shift fork
Rear output shaft
Chain
Front output shaft
Dust seal guard
Oil seal
Transfer case
Added
23D-14-9
R4A51, V4A51 - Transfer <V4A51>
"QA OIL COVER INSTALLATION
Install the oil cover so that the oil hole is located as shown
in the illustration.
Oil hole
Oil cover
INSPECTION
2-4WD, H-L DETECTION SWITCH
Check for the continuity between the connector terminal and
switch body.
Switch state
Continuity
Switch end pressed
No
Switch end released
Yes
LOW RANGE OPERATION DETECTION SWITCH
Check for the continuity between the connector terminal and
switch body.
E Mitsubishi Motors Corporation
July 2000
Switch state
Continuity
Switch end pressed
Yes
Switch end released
No
PWEE8920-J
Revised
23D-15-1
R4A51, V4A51 - Transfer Case Plate <V4A51>
15. TRANSFER CASE PLATE <V4A51>
DISASSEMBLY AND ASSEMBLY <V4A51-4, 5>
18 Nm
Apply gear oil to all
moving parts before
installation.
1
2
3
6
5
4
Disassembly steps
"BA 1. Bolt
2. Bearing retainer
3. Transfer input gear
"AA 4. Oil seal
5. Baffle plate
6. Transfer case plate
E Mitsubishi Motors Corporation
July 2000
PWEE8920-J
Revised
R4A51, V4A51 -
Rear Output Shaft
<V4A51 - Part Time 4WD>
23D-18-1
18. REAR OUTPUT SHAFT <V4A51 - Part Time 4WD>
DISASSEMBLY AND ASSEMBLY <V4A51-4>
18
3
4
255 Nm
2
1
9
5
6
13
8
7
10
11
12
Apply gear oil to all
moving parts before
installation.
14
16
15
17
Disassembly steps
1. Snap ring
2. Clutch hub
3. Low speed gear
4. Needle bearing
AB" "DA 5. Jam nut
AC" "CA 6. Ball bearing
7. Oil guide
8. Sprocket spacer
9. Steel ball
"FA
AA" "EA
E Mitsubishi Motors Corporation
July 2000
10.
11.
12.
13.
14.
AD" "BA 15.
AD" "AA 16.
AD" "AA 17.
18.
PWEE8920-J
Drive sprocket
Needle bearing
Sprocket sleeve
Steel ball
Clutch sleeve
Clutch hub
Stopper plate
Ball bearing
Rear output shaft
Revised
23D-18-2
R4A51, V4A51 -
Rear Output Shaft
<V4A51 - Part Time 4WD>
DISASSEMBLY AND ASSEMBLY <V4A51-5, 7>
21
22
23
24
25
3
2
255 Nm
9
4
7
<V4A51-7>
1
5
10
12
6
8
<V4A51-5>
19
20
16
10
18
11
13
15
Apply gear oil to all
moving parts before
installation.
14
17
"FA
AA" "EA
AB" "DA
AC" "CA
Disassembly steps
1. Snap ring
2. Clutch hub
3. Low speed gear
4. Needle bearing
5. Snap ring (V4A51-7)
6. Rotor (V4A51-7)
7. Steel ball
8. Jam nut
9. Ball bearing
10. Spacer (V4A51-7)
Oil guide (V4A51-5)
11. Sprocket spacer
12. Steel ball
E Mitsubishi Motors Corporation
July 2000
13.
14.
15.
16.
17.
18.
19.
20.
21.
AD" "BA 22.
AD" "AA 23.
AD" "AA 24.
25.
PWEE8920-J
Drive sprocket
Needle bearing
Sprocket sleeve
Steel ball
Synchronizer inner ring
Synchronizer cone
Synchronizer outer ring
Synchronizer spring
Clutch sleeve
Clutch hub
Stopper plate
Ball bearing
Rear output shaft
Revised
R4A51, V4A51 - Speedometer Gear <R4A51-4, 5, V4A51-4, 5>
23D-20-1
20. SPEEDOMETER GEAR <R4A51-4, 5, V4A51-4, 5>
DISASSEMBLY AND ASSEMBLY
Apply gear oil to all
moving parts before
installation.
1
3
2
5
4
Disassembly steps
1. O-ring
"AA 2. Spring pin
3. Driven gear
4. O-ring
5. Sleeve
Slit
Spring
pin
E Mitsubishi Motors Corporation
July 2000
ASSEMBLY SERVICE POINT
"AA SPRING PIN INSTALLATION
Drive the spring pin in, while making sure that slit does not
face gear shaft.
PWEE8920-J
Revised