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Alex
Alex, ASE Master Technician
Category: Car
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Experience:  ASE Certified Master Technician, L1 Advanced Level Specialist
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Mighty max: replace the syncrosin it manual tranny.

Resolved Question:

I have a 92 mitsu Mighty max. I need to replace the syncros
in it manual tranny. How do I do that? I am to cheap and don't
like working on my own truck. Need some step by step if possible.
Submitted: 5 years ago.
Category: Car
Expert:  Alex replied 5 years ago.

Hello. My name is XXXXX XXXXX I'll be assisting you with your question.

 

To do this, the transmission will need to be removed and disassembled.

Transmission









DISASSEMBLY SERVICE POINTS

EXTENSION HOUSING REMOVAL

  1. Pull the extension housing toward the rear while pushing the change shifter toward the left.



MAINSHAFT LOOK NUT REMOVAL



BEARING SLEEVE REMOVAL



MAINSHAFT CENTER BEARING REMOVAL



MAINDRIVE GEAR BEARING REMOVAL

REASSEMBLY SERVICE POINTS



MAINDRIVE GEAR BEARING INSTALLATION

SNAP RING INSTALLATION

  1. Select and install snap ring to that maindrive gear bearing end play may reach standard valve. Standard value: 0-0.06 mm (0-.0024 in.)

SPACER INSTALLATION

  1. Place two pieces of solder measuring about 10 mm (.39 in.) in length and 1.6 mm (.063 in.) in diameter on the bearing outer race as shown in illustration.
  2. Install the front bearing retainer and tighten the nuts to specified torque.
  3. Remove the front bearing retainer and remove the solder.
  4. If the solders are not compressed, use larger diameter solder to perform step (1) to (3).

  1. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play. Standard value: 0-0.1 mm (0-.004 in.)

OIL SEAL INSTALLATION

  1. Apply transmission oil to the lip on the oil seal.
  2. Using special tool, install oil seal.

  1. Apply specified grease to the lip of the front bearing retainer oil seal. Specified grease: Mitsubishi genuine grease Part No.0101011 or equivalent.



MAINSHAFT CENTER BEARING INSTALLATION



SPACER INSTALLATION

  1. Press-fit the outer race and counter gear securely.

  1. Assemble the select spacers and align them with a straight edge.
  2. Select a spacer which will achieve the standard value.



REVERSE IDLER GEAR SHAFT INSTALLATION

  1. Place an M8x5O mm (1.97 in.) bolt in the guide and install the reverse idler gear shaft.

  1. Apply a coating of adhesive to the threaded part of the bolt. Specified adhesive 3M STUD Locking Part No.4170 or equivalent.



OD-R SYNCHRONIZER HUB/OD-R SYNCHRONIZER SLEEVE INSTALLATION



OD-R SYNCHRONIZER KEY/OD-R SYNCHRONIZER SPRING INSTALLATION

  1. Install two synchronizer springs. When installing springs, make sure that steps of front and rear springs are positioned on synchronizer key, but not on the same key.



OVERDRIVE SYNCHRONIZER RING INSTALLATION

  1. Engage synchronizer ring to OD gear as shown in illustration before installing OD gear and ensure that there is certain clearance "A". If dimension "A" exceeds the limit, replace the ring and/or gear. Limit: 0.5 mm (.020 in.)



BEARING SLEEVE INSTALLATION



MAINSHAFT LOCK NUT INSTALLATION

  1. Using the special tool, tighten the mainshaft lock nut.

  1. Stake the area as shown in illustration of lock nut.
  2. Ensure that the OD gear rotates smoothly.



COUNTER OVERDRIVE GEAR/1ST-2ND SPEED SHIFT RAIL INSTALLATION

  1. Install the counter overdrive gear and 1st-2nd speed shift rail at the same time.



COUNTERSHAFT REAR BEARING INSTALLATION



COUNTERSHAFT LOCK NUT INSTALLATION

  1. Tighten the countershaft lock nut to specified torque.

  1. Stake the area as shown in illustration without fail to prevent lock nut from loosening.
  2. Ensure that the OD gear rotates smoothly.



POPPET SPRING INSTALLATION

  1. Insert poppet spring with small end on ball side. Three springs are identical to one another.



EXTENSION HOUSING INSTALLATION

  1. Install the extension housing while pushing the change shifter in the direction of the arrow and fit the control finger into the groove in the selector.



NEUTRAL RETURN PLUNGER (B) / NEUTRAL RETURN PLUNGER (A) / SPRING / SEAL PLUG / STEEL BALL / RESISTANCE SPRING INSTALLATION



SPEEDOMETER GEAR INSTALLATION

  1. Match the mating marks to the number of teeth on the speedometer driven gear and install the speedometer gear.



SPRING PIN INSTALLATION

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