Mitsubishi Galant
+ Identification numbers of the car
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+ The engine
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+ Engine electric equipment
+ Control systems of the engine
- Manual transmission
- 5-step manual box of a gear change (РКПП)
The general information
Adjustment of a drive of a gear change
Removal and installation of the gauge-switch of fires of a backing
Removal and transmission installation
Major repairs РКПП
+ Automatic transmissions (АТ)
+ Distributing box
+ Coupling and transmission a line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
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Major repairs РКПП
Design РКПП F5М21 and F5М22
Design РКПП F5М31/F5М33
Design of primary shaft РКПП
Components of assemblage of intermediate shaft РКПП
Design of differential of main transfer РКПП
The general information
Composers of the present Management do not recommend to owners of cars to undertake performance of major repairs РКПП independently. During performance of procedures of dismantling and transmission assemblage it is necessary to remove, and then to establish into place set of small components. It is necessary to make weight of the most precise measurements and, by selection of adjusting washers, rings and remote plugs, accurately to expose set of backlashes. In view of all aforesaid, it will be more reasonable to charge performance of major repairs РКПП to experts of car-care centre. We will notice, that in many cases there is a possibility on an exchange basis to get the restored block, that often there is more cheaply, than a carrying out of difficult repair.
Despite the told, independent performance of repair РКПП by the mechanic-fan at all is not absolutely impossible action. Indispensable conditions are only presence of the necessary special tool and accuracy in the approach to performance of all procedures.
The number necessary for performance of regenerative repair РКПП of tools includes nippers for removal of internal and external lock rings, a stripper of bearings, a hammer with sliding brisk, a set выколоток and кернеров, циферблатный measuring instrument DTI and, probably, hydraulic press. Besides, certainly, the workbench, or the special assembly stand is required strong, equipped with a vice.
During performance of procedures of dismantling РКПП try to remember, and it is better to write down, an order of installation of each of removed details.
Before to start transmission dismantling, it will be reasonable to try to analyse symptoms of its refusals for the purpose of approximate definition of their reasons. Many refusals are unequivocally connected with failure of quite certain components. The Section devoted to diagnostics of malfunctions РКПП, in the Management beginning see also.
Let's consider more in detail three of applied on cars of a box of a gear change considered in the present Management: F5М31 (Galant), F5М21 (Mirage 1.5) and F5М22 (Mirage 1.8).
Dismantling РКПП
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1. Design РКПП is presented on illustrations.
2. On models F5М21 remove the gauge-switch of transmission with a sealing lining. On all other models remove a back cover. Remove the gauge-switch of fires of a backing with the sealing lining. Remove a wavy spring, give bolts and remove a reversive brake cone. Turn out stoppers and take fixing springs and balls.
3. Remove from a dome of coupling assemblage of a drive of a speedometer and сапун ventilation картера. Take подпружиненный a pin from a plug of inclusion of 5th transfer. Расчеканьте lock nuts of primary and intermediate shaft.
4. By means of control levers and a choice switch transmission to a reverse gear. Throw a pin of a primary shaft with a cutting face key with a collar. Screw in a dome of coupling a bolt on 10 mm and rest against it a key collar, having blocked thereby a primary shaft from проворачивания. Give a lock nut (counternut).
5. Remove assemblage of the synchronizer and a plug of inclusion of 5th transfer. Remove blocking ring of the synchronizer and a gear wheel of 5th transfer. On models F5М21 remove the needle bearing, a remote ring, муфту the bearing, a lock ring and the roller bearing.
6. On all models remove an intermediate gear wheel of 5th transfer. Turn out a bolt of an axis of an intermediate gear wheel of a reverse gear, remove a sealing lining. Remove картер РКПП and directing oil givings. Turn out a bolt of a persistent lath and remove a spring washer. Remove assemblage of a ball clamp with a sealing lining.
7. On models F5М21 remove an external ring. On all models remove an epiploon. On models F5М21 remove three remote rings and an external holder of one bearing. On all other models remove three remote rings and external holders of three bearings.
8. Remove lever assemblage of a drive of inclusion of a reverse gear, a boot of lever assemblage, take an axis with an intermediate gear wheel of a reverse gear.
9. Take подпружиненные pins of rods of plugs of switching of 1/2 and 3/4 transfers. Translate a corresponding plug of switching in positions of 2nd transfer, the second plug - in position of 4th transfer.
10. On models F5М21 and F5М22 turn assemblages of rods of switching to a conclusion of uvulas of switching from gearing with operating finger and a fixing plate. Having pulled rods upwards, liberate from the ends from a coupling dome. Remove rods and switching plugs.
11. On models F5М31/F5М33 remove assemblage of a rod of a plug of switching. On all models remove the holder of the bearing. Lift a primary shaft and remove assemblage of an intermediate gear wheel.
12. Remove assemblages of primary and secondary shaft. Remove differential assemblage. Remove from primary and secondary shaft external holders of bearings. At a corresponding complete set take holders of bearings from landing nests of differential in a coupling dome. Remove from a coupling dome directing givings of oil and epiploons. Remove a magnet with the holder. |
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Dismantling, check of a condition of components and assemblage of knots РКПП
The synchronizer of 5th transfer
Dismantling
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Remove blocking ring, a persistent plate, the springs, sliding муфту, sliding keys and a synchronizer nave. |
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Check
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1. Fill a synchronizer nave in муфту and manually check up freedom of rotation of components. Check up муфту on presence of signs of deterioration or damages of forward and back internal edges. Check up a condition of fifth transfer of a surface of a nave interfaced to a gear wheel. Estimate degree of deterioration of the top ledges of sliding keys. Check up springs on presence of signs of easing of effort, deformations, cracks and other mechanical damages.
2. Replace defective components.
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Replacement sliding муфты is made in gathering with a nave. |
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Assemblage
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1. Enclose in муфту the synchronizer a nave with the sliding keys established in it, - track correctness of introduction of components in gearing.
2. Establish springs so that sliding keys rested against their ledges. Track, that springs have appeared are parted by locks.
3. In summary establish a persistent plate and blocking ring. |
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Primary shaft РКПП F5М21
Dismantling
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1. The design of assemblage of a primary shaft is presented on an illustration.
2. Remove a lock ring and dismantle from a shaft pin the forward bearing.
3. Remove an internal ring (the back bearing), a remote ring and a gear wheel of 4th transfer.
4. Remove a gear wheel of 3rd transfer, assemblage of the synchronizer of 3/4 transfers and муфту the bearing. |
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Check
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1. Estimate deterioration degree подшипниковых surfaces and шлицов a shaft. Establish on a shaft the needle bearing and check up density of its planting and rotation freedom. Make sure of absence of deformations of the case of the bearing.
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2. Check up integrity of teeths of a blocking ring of the synchronizer. Make sure of absence of signs of damages and integrity of coils of a carving of an internal surface. Wring out a ring of the synchronizer towards a gear wheel and measure backlash size between components. If the result of measurement exceeds 0.5 mm, replace blocking ring. |
3. Fill a synchronizer nave in муфту and check up freedom of moving of components from each other. Check up a condition of forward and back edges муфты, estimate degree of deterioration of a surface of a nave interfaced to a gear wheel and working ledges of sliding keys. Check up a condition of springs of the synchronizer.
4. Replace defective components.
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Replacement sliding муфты is made in gathering with a nave. |
5. Check up smoothness of a surface of a cone of the synchronizer. Estimate a condition of forward and back interfaced surfaces. Make sure of integrity of teeths of all gear wheels. |
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Assemblage
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1. Assemblage is made in an order, the return to an order of dismantle of components. Plant a synchronizer nave (marks forward) in sliding муфту. Track correctness of a joint of components, - the central tooth of a nave should get between two passed teeths муфты and to enter into gearing with a sliding key. |
2. Establish synchronizer springs so that sliding keys rested against their acting sections. Track, that springs have been parted by locks.
3. Plant assemblage of the synchronizer of 3/4 transfers on a shaft.
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Track, that sliding keys have got to flutes in a blocking ring, check up freedom of rotation of a gear wheel of 3rd transfer. |
4. By means of the special adaptation plant on a shaft муфту the bearing. Establish a remote ring (an identification label “1” towards a gear wheel of 4th transfer).
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In the absence of marks the ring can be planted any way. Plant on a shaft an internal ring (the back bearing). |
5. By means of the special adaptation plant on a shaft the forward bearing and fill in a flute a new lock ring.
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Lock rings of a various thickness are issued, - pick up maximum, located in a flute.
Try not to damage a surface of a pin of a shaft contacting to an epiploon. |
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Primary shaft РКПП F5М22 and F5М31/F5М33
Dismantling
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1. Remove a lock ring and dismantle from a shaft pin the forward bearing. Remove the back bearing, a remote ring and a gear wheel of 4th transfer with the bearing.
2. Remove муфту the bearing, assemblage of the synchronizer of 3/4 transfers and a gear wheel of 3rd transfer.
3. Remove the needle bearing. |
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Check
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1. Estimate deterioration degree подшипниковых surfaces and шлицов a shaft. Establish on a shaft the needle bearing and check up density of its planting and rotation freedom. Make sure of absence of deformations and damages of the case of the bearing.
2. Check up integrity of teeths of a blocking ring of the synchronizer. Make sure of absence of signs of damages and an internal surface of integrity of coils of the carving put on it. Wring out a ring of the synchronizer towards a gear wheel and measure backlash size between components. If the result of measurement exceeds 0.5 mm, replace blocking ring.
3. Fill a synchronizer nave in sliding муфту and check up freedom of moving of components from each other. Check up a condition of forward and back edges муфты, estimate degree of deterioration of a surface of a nave interfaced to a gear wheel and working ledges of sliding keys. Check up a condition of springs of the synchronizer.
4. Replace defective components.
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Replacement sliding муфты is made in gathering with a nave. |
5. Check up smoothness of a surface of a cone of the synchronizer. Estimate a condition of forward and back interfaced surfaces. Make sure of integrity of teeths of all gear wheels. |
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Assemblage
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1. Plant a synchronizer nave (marks forward) in sliding муфту. Track correctness of a joint of components, - the central tooth of a nave should get between two passed teeths муфты and to enter into gearing with a sliding key.
2. Establish synchronizer springs so that sliding keys rested against their acting sections. Track, that springs have been parted by locks.
3. Plant assemblage of the synchronizer of 3/4 transfers on a shaft.
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Track, that sliding keys have got to flutes in a blocking ring, check up freedom of rotation of a gear wheel of 3rd transfer. |
4. By means of the special adaptation plant on a shaft муфту the bearing. Establish a remote ring (an identification label “1” towards a gear wheel of 4th transfer).
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In the absence of marks the ring can be planted any way. Plant the back bearing with муфтой. |
5. By means of the special adaptation plant on a shaft the forward bearing, fill in a flute a new lock ring.
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Lock rings of a various thickness are issued, - pick up maximum, located in a flute. Try not to damage a surface of a pin of a shaft contacting to an epiploon. |
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Intermediate shaft
Dismantling
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1. The design of assemblage of an intermediate shaft is presented on an illustration.
2. Remove a lock ring and dismantle from a shaft the bearing with муфтой.
3. Remove the needle bearing and a gear wheel of 1st transfer.
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The bearing is subject to replacement without fail. |
4. Remove from a shaft assemblage of the synchronizer of 1/2 transfers, a gear wheel of 2nd transfer and the needle bearing.
5. Remove the back bearing of assemblage. |
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Check
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1. Estimate deterioration degree подшипниковых assemblage surfaces. Establish on a shaft the needle bearing and check up density of its planting and rotation freedom. Make sure of absence of deformations and damages of the case of the bearing.
2. Check up integrity of teeths of a blocking ring of the synchronizer. Make sure of absence of signs of damages and an internal surface of integrity of coils of the carving put on it. Wring out a ring of the synchronizer towards a gear wheel and measure backlash size between components. If the result of measurement exceeds 0.5 mm, replace blocking ring.
3. Fill a synchronizer nave in sliding муфту and check up freedom of moving of components from each other. Check up a condition of forward and back edges муфты, estimate degree of deterioration of a surface of a nave interfaced to a gear wheel and working ledges of sliding keys. Check up a condition of springs of the synchronizer.
4. Replace defective components.
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Replacement sliding муфты is made in gathering with a nave. |
5. Check up smoothness of a surface of a cone of the synchronizer. Estimate a condition of forward and back interfaced surfaces. Make sure of integrity of teeths of all gear wheels. |
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Assemblage
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1. Assemblage is made in an order, the return to an order of dismantle of components. By means of the special adaptation plant on a shaft the bearing, - track, that оправка the tool rested only against a face surface of an internal holder of the bearing.
2. Plant a nave of the synchronizer of 1/2 transfers (marks forward) in sliding муфту. Track correctness of a joint of components, - the central tooth of a nave should get between two passed teeths муфты and to enter into gearing with a sliding key.
3. Establish synchronizer springs so that sliding keys rested against their acting sections. Track, that springs have been parted by locks.
4. Plant assemblage of the synchronizer of 1/2 transfers on a shaft.
5. By means of the special adaptation plant on a shaft муфту the bearing. Establish a gear wheel of 1st transfer with муфтой the bearing, in summary plant on a shaft the bearing. |
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Final (secondary) shaft
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1. The design of assemblage of a secondary shaft is shown on illustrations.
2. Remove from a shaft bearings, - at assemblage they are subject to replacement without fail, replacement of internal and external holders is made in the complete set. Estimate a condition of a shaft and degree of deterioration of its working components. Plant on a shaft new bearings. Assemblage is made upside-down. |
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Gear change plugs
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1. Remove a plug of switching of 1.2 transfers. Remove assemblage of a rod of switching.
2. Remove assemblage of a plug of switching of 3/4 transfers and a rod of switching 5-5/back transfers. Remove a rod of a plug of switching of 3/4 transfers. Remove the doggie of switching of a reverse gear.
3. Assemblage is made upside-down. Track hit плунжера a blocking clamp in the doggie of switching of a reverse gear in a groove of a rod of 3/4 transfers. |
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Differential of the main transfer
Dismantling and check of a condition of components
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1. The differential design is presented on an illustration.
2. Turn out fixing bolts and remove a conducted gear wheel of a reverse gear. Squeeze out of a box of differential bearings, - at assemblage bearings are subject to replacement without fail.
3. From a landing flange of a conducted gear wheel take a lock pin. Liberate from a box an axis and gear wheels of satellites, remove washers and take lateral gear wheels.
4. Attentively examine all components on presence of signs of excessive deterioration and mechanical damages. Defective units replace. |
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Assemblage
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1. Plant remote rings behind on lateral gear wheels and establish the last in a differential box. Fill in a differential box both satellites. Establish an axis of satellites.
2. Measure size люфта gearings of satellites with lateral gear wheels. If the result of measurement falls outside the limits an admissible range (0.025 ÷ 0.150 mm), disassemble differential and pick up remote rings of a demanded thickness.
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At installation of their new lateral gear wheels it is necessary to complete with identical remote rings of an average thickness (0.93 ÷ 1.00 mm). |
3. Fix an axis of satellites a new lock pin.
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The pin should not act over a surface of a box of differential more than on 3 mm. |
4. Запрессуйте in a differential box new bearings.
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Оправка the tool should rest only against an internal holder of the bearing! |
5. Before вворачиванием the bolts which were in the use of fastening of a conducted gear wheel banish their carving a tap of the suitable size for the purpose of removal of traces of corrosion / old hermetic and restoration of the damaged coils, then grease bolts with fresh fixing hermetic. A tightening of bolts with demanded effort (130 ÷ 140 H•м) make in a diagonal order. |
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Assemblage РКПП
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The remote rings used at installation of a pretightness, and also lock rings are subject to selection. |
1. Assemblage is made in an order, the return to an order of dismantle of components.
2. Establish epiploons приводных and primary shaft. Simultaneously fill in картер transmissions of assemblage of intermediate and primary shaft.
3. Grease the bolt of fastening of the bearing of a primary shaft nearest to differential with fixing hermetic of type 3М STUD (4170), - try not to admit hermetic hit on a bolt head. Screw bolts and tighten them with demanded effort
(16 ÷ 22 H•м).
4. Plant муфту switchings of 1/2 transfers to a gear wheel of 2nd transfer, муфту 3/4 transfers - accordingly, in a gear wheel of 4th transfer. Enter plugs of assemblages of switching into gearing with flutes in муфтах. Pass rods of plugs in corresponding apertures in a dome of coupling and turn them for a joint of doggies with operating finger and a blocking plate.
5. By means of approaching выколотки plant new spring pins (a cut on a rod axis). Establish an axis of an intermediate gear wheel (a carving aperture in a head towards differential).
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6. Plant two pieces of solder of 10 mm in length and 1.6 mm in diameter instead of remote rings. |
7. Establish картер transmissions and tighten bolts of its fastening with demanded effort. Again turn out bolts, remove картер, dismantle external holders of bearings and take the flattened out solder. Measure a thickness of solder by a micrometer and pick up the corresponding remote rings, the given procedure will allow to pick up in the correct image axial люфт components (Specifications see).
8. Plant in картер transmissions directing oil givings. Put on assemblage of an intermediate gear wheel remote rings of the picked up thickness, then plant an external holder of the bearing of differential. Establish remote rings of a corresponding thickness between an external holder of the bearing and картером РКПП. Make sure, that the axis of an intermediate gear wheel of a reverse gear is developed by a carving aperture in a head in the correct party, then can start installation картера transmissions.
9. In regular intervals impose on interfaced to a dome of coupling a surface картера a pillow of hermetic in the thickness 1.0 ÷ 2.0 mm (use hermetic Mitsubishi MD997740 or Three Bond 1216). Press картер to a dome.
10. With the help выколотки (крестовидной a screw-driver) diameter 8.0 mm achieve combination of a carving aperture in an axis of an intermediate gear wheel of a reverse gear with corresponding болтовым an aperture in crankcase transmission. Screw a bolt and tighten it with demanded effort (43 ÷ 55 H•м). Tighten with demanded effort other bolts of fastening картера transmissions.
11. At a corresponding complete set pick up a lock ring of a landing flute of a thickness corresponding to the size, - a lock ring are subject to replacement in obligatory to a lock. Plant a lock ring on a pin of a primary shaft. Check up density of a clip of a flange муфты to the bearing.
12. Establish a plug of inclusion of 5th transfer (complete with the synchronizer). Block a shaft from проворачивания by means of a face key with a cutting head and a 10-millimetric bolt screwed in a dome of coupling.
13. By means of control levers and a choice switch РКПП to a reverse gear. Screw new counternuts, tighten from with demanded effort (140 ÷ 160 H•м) and зачеканьте.
14. Establish new spring plugs of inclusion of 5th transfer (a cut on a rod axis).
15. Grease with type hermetic 3М Super Weatherstrip (8001) on a fixing surface air сапуна and establish a coupling dome. Establish a back cover of a dome of coupling, preliminary having imposed on its interfaced surface a uniform pillow of hermetic (type Mitsubishi MD997740 or Tree Bound 1216) thickness 1 ÷ 2 mm.
16. Establish assemblage РКПП on the engine (see Has undressed Removal and transmission installation). |
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