22B-1GROUP 22BMANUAL TRANSMISSION OVERHAULCONTENTSGENERAL INFORMATION . . . . . . . . 22B-3GENERAL SPECIFICATIONS . . . . . . 22B-6SERVICE SPECIFICATI
SEALANTS AND ADHESIVESMANUAL TRANSMISSION OVERHAUL22B-10SEALANTS AND ADHESIVESM1222000500139FORM-IN-PLACE GASKET (FIPG)This transmission has several a
SPECIAL TOOLSMANUAL TRANSMISSION OVERHAUL22B-11SPECIAL TOOLSM1222000600158Tool Number Name ApplicationMB990935 Installer adapter Installation of diffe
SPECIAL TOOLSMANUAL TRANSMISSION OVERHAUL22B-12MD998825 Installer adapter (52) Installation of 1st-2nd speed synchronizer hub <F5M42>, 3rd-4th s
SPECIAL TOOLSMANUAL TRANSMISSION OVERHAUL22B-13MD999566 Claw Removal of taper roller bearing outer raceMD998772 Valve spring compressorRemoval of outp
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-14TRANSMISSIONDISASSEMBLY AND REASSEMBLYM1222001000159<F5M41>AK30021570 ± 10 N·m70 ± 10 N·m3.9 ± 1.0
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-15AK300214Apply gear oil to allmoving parts beforeinstallation.18 ± 3 N·m30 ± 3 N·m44 ± 5 N·m48 ± 6 N·m18
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-16AK300216302931453534383946433718 ± 3 N·m36324133424044ABApply gear oil to allmoving parts beforeinstalla
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-17 <F5M42>AK20315132 ± 2 N·m3.9 ± 1.0 N·m70 ± 10 N·m18 ± 3 N·m438697101152170 ± 10 N·m18 ± 3 N·m3.9
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-18AK204218Apply gear oil to allmoving parts beforeinstallation.18 ± 3 N·m30 ± 3 N·m44 ± 5 N·m48 ± 6 N·m6.9
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-19DISASSEMBLY SERVICE POINTS<<A>> SEALING CAP REMOVAL1. Drive a screwdriver into the center of
22B-2CONTROL HOUSING . . . . . . . . . . . . 22B-48CONTROL HOUSING DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 22B-48CLU
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-20<<B>> TRANSAXLE CASE REMOVAL1. Remove all sixteen bolts securing the transaxle case to the c
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-212. Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hol
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-22REASSEMBLY SERVICE POINTS>>A<< OUTPUT SHAFT/INPUT SHAFT INSTALLATIONInstall the input and ou
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-233. While sliding the reverse shift lug in the direction shown, install the 5th speed shift fork, 5th spe
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-242. Using special tools, press the outer race into the transaxle case.• Installer adapter (MB990935)• Han
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-25>>K<< SEALING CAP INSTALLATION1. Using special tools, press install the sealing cap onto the
TRANSMISSIONMANUAL TRANSMISSION OVERHAUL22B-26Tightening torque: 18 ± 3 N⋅mNOTE: After installation, keep the sealed area away from the oil for approx
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-27INPUT SHAFTDISASSEMBLY AND REASSEMBLYM1222001600140<F5M41>AK300291910111214131516182194206718317596
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-28<F5M42>DISASSEMBLY SERVICE POINTS<<A>> BALL BEARING REMOVAL1. Using special tool Bearin
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-29<<B>> 5TH SPEED-REVERSE SYNCHRONIZER HUB REMOVAL1. Using special tool Bearing remover (MD9989
GENERAL INFORMATIONMANUAL TRANSMISSION OVERHAUL22B-3GENERAL INFORMATIONM1222000100120MANUAL TRANSMISSION MODELSTransmission model Combined engine Vehi
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-30REASSEMBLY SERVICE POINTS>>A<< OIL SEAL INSTALLATIONInstall the oil seal into the end of the
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-311. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft,
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-32>>J<< 5TH SPEED GEAR INSTALLATION1. Using special tool Bearing remover (MD998801), support th
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-334. Make sure that the synchronizer ring on the 5th speed gear side can rotate freely.>>N<< SY
INPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-341. Install the thickest snap ring that can be fitted in the groove of the input shaft.2. Make sure that t
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-353. Check that the gear inside diameter and front and rear surfaces are not damaged and worn.OUTPUT SHAFT
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-36<F5M42><<G>> >>A<<25. Roller bearing inner race26. Output shaftDisassembly
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-37DISASSEMBLY SERVICE POINTS<<A>> BALL BEARING REMOVAL1. Using special tools, support the ball
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-38<<E>> 2ND SPEED GEAR SLEEVE REMOVAL1. Using special tool Bearing remover (MD998917), support
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-39>>B<< SNAP RING INSTALLATION1. Install the thickest snap ring that can be fitted in the groo
GENERAL INFORMATIONMANUAL TRANSMISSION OVERHAUL22B-4SECTIONAL VIEW<F5M41>AK300634
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-40• Installer cap (MD998812)• Installer-200 (MD998814)• Installer adapter (MD998822) <F5M41>• Instal
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-41>>I<< SNAP RING INSTALLATION1. Install the thickest snap ring that can be fitted in the groo
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-423. Check that the 5th speed-reverse synchronizer hub is oriented correctly for installation, and fit it
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-431. Install the thickest snap ring that can be fitted in the groove of output shaft.2. Make sure that the
OUTPUT SHAFTMANUAL TRANSMISSION OVERHAUL22B-44SYNCHRONIZER SLEEVE AND HUB1. Combine the synchronizer sleeve and hub, and check that they slide smoothl
REVERSE IDLER GEARMANUAL TRANSMISSION OVERHAUL22B-45REVERSE IDLER GEARDISASSEMBLY AND REASSEMBLYM1222012500103<F5M42>AK2043964561237ABApply gear
SPEEDOMETER GEARMANUAL TRANSMISSION OVERHAUL22B-46SPEEDOMETER GEARDISASSEMBLY AND REASSEMBLYM1222003400108AK2043974231ABApply gear oil to allmoving pa
SELECT LEVERMANUAL TRANSMISSION OVERHAUL22B-47SELECT LEVERDISASSEMBLY AND REASSEMBLYM1222012800096REASSEMBLY SERVICE POINT>>A<< DUST COVER
CONTROL HOUSINGMANUAL TRANSMISSION OVERHAUL22B-48CONTROL HOUSINGDISASSEMBLY AND REASSEMBLYM1222013100131DISASSEMBLY SERVICE POINT<<A>> LOC
CONTROL HOUSINGMANUAL TRANSMISSION OVERHAUL22B-49REASSEMBLY SERVICE POINTS>>A<< NEEDLE BEARING INSTALLATIONPress fit the needle bearing in
GENERAL INFORMATIONMANUAL TRANSMISSION OVERHAUL22B-5<F5M42>AK300023
CLUTCH HOUSINGMANUAL TRANSMISSION OVERHAUL22B-50CLUTCH HOUSINGDISASSEMBLY AND REASSEMBLYM1222003700132DISASSEMBLY SERVICE POINT<<A>> OUTER
CLUTCH HOUSINGMANUAL TRANSMISSION OVERHAUL22B-51<<B>> OUTER RACE REMOVAL1. Set special tools as indicated in the figure.• Valve spring com
CLUTCH HOUSINGMANUAL TRANSMISSION OVERHAUL22B-52>>D<<OIL SEAL INSTALLATION1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W conform
TRANSMISSION CASEMANUAL TRANSMISSION OVERHAUL22B-53TRANSMISSION CASEDISASSEMBLY AND REASSEMBLYM1222013400109REASSEMBLY SERVICE POINTS>>A<<
TRANSMISSION CASEMANUAL TRANSMISSION OVERHAUL22B-542. Be sure the bushing is fully seated as shown. It must be 3 mm below the housing surface.>>
DIFFERENTIALMANUAL TRANSMISSION OVERHAUL22B-55DIFFERENTIALDISASSEMBLY AND REASSEMBLYM1222002500124DISASSEMBLY SERVICE POINT<<A>> BALL BEAR
DIFFERENTIALMANUAL TRANSMISSION OVERHAUL22B-56<<B>> TAPER ROLLER BEARING REMOVAL1. Using special tool Bearing remover (MD998801), support
DIFFERENTIALMANUAL TRANSMISSION OVERHAUL22B-57>>C<< TAPER ROLLER BEARING INSTALLATIONUsing special tools, install the taper roller bearing
GENERAL SPECIFICATIONSMANUAL TRANSMISSION OVERHAUL22B-6GENERAL SPECIFICATIONSM1222000200161TRANSMISSION MODEL TABLEGEAR RATIO TABLESERVICE SPECIFICATI
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENTMANUAL TRANSMISSION OVERHAUL22B-7SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENTM1222012000153SPACE
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENTMANUAL TRANSMISSION OVERHAUL22B-8SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY) <
TORQUE SPECIFICATIONSMANUAL TRANSMISSION OVERHAUL22B-9SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEAR AND PINION) <F5M42>TORQU
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