Mitsubishi Galant

1990 — 2001 of release

Repair and car operation

Mitsubishi Galant
+ Identification numbers of the car
+ Governing bodies
+ Settings and routine maintenance
+ Engine
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Control systems of the engine
- Manual transmission
   - 5-step manual box of gear shifting (RKPP)
      General information
      Adjustment of a drive of gear shifting
      Removal and installation of the sensor switch of fires of a backing
      Removal and transmission installation
      Major maintenance of RKPP
   + Automatic transmissions (AT)
   + Transfer case
+ Coupling and transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment

Major maintenance of RKPP

RKPP F5М21 and F5М22 design

1 — the transmission Sensor switch
2 — Sealing laying
3 — the Back cover
4 — the Sensor switch of fires of a backing
5 — Sealing laying
6 — a clamp Stopper
7 — a clamp Spring
8 — a clamp Ball
9 — Assembly of a drive of a speedometer
10 — Sapun of ventilation of a case of RKPP
11 — Podpruzhinenny a pin
12 — the Lock-nut
13 — the Lock-nut
14 — Assembly of the synchronizer of the 5th transfer
15 — the Fork of inclusion of the 5th transfer
16 — the Blocking ring of the synchronizer
17 — the Gear wheel of the 5th transfer
18 — the Needle bearing
19 — the bearing Coupling
20 — the Bolt of a face cover
21 — the Lock ring (steals up)
22 — the Remote ring (steals up)
23 — the Roller bearing
24 — the Intermediate gear wheel of the 5th transfer
25 — the Bolt of an axis of an intermediate gear wheel of a reverse gear
26 — Sealing laying
27 — the Bolt
28 — Carter of transmission
29 — the Trench маслотока
30 — the Bolt
31 — the Spring washer (Grover's washer)
32 — the Persistent level
33 — Assembly of a ball emphasis

34 — Sealing laying
35 — the External ring
36 — the Epiploon
37 — the Remote ring (steals up)
38 — the Remote ring (steals up)
39 — the External holder of the bearing
40 — the Remote ring (steals up)
41 — the Bolt
42 — Lever assembly of a drive of inclusion of a reverse gear
43 — the Boot of assembly of a drive of inclusion of a reverse gear
44 — the Axis of an intermediate gear wheel of a reverse gear
45 — the Intermediate gear wheel of a reverse gear
46 — Podpruzhinenny a pin
47 — Podpruzhinenny a pin
48 — Assembly of a rod of switching
49 — Assembly of a rod of switching
50 — the Bolt
51 — the Bolt
52 — the Holder of the bearing
53 — Assembly of an intermediate gear wheel
54 — Assembly of primary shaft
55 — Assembly of a target (secondary) shaft
56 — the External holder of the bearing
57 — differential Assembly
58 — Directing supply of oil
59 — the Epiploon
60 — the Epiploon
61 — a coupling Dome
62 — the Magnet
63 — the Holder of a magnet

RKPP F5M31/F5M33 design

1 — the Bolt
2 — the Back cover
3 — the Reversive brake cone
4 — the Wavy spring
5 — Samorez
6 — the Sensor switch of fires of a backing
7 — Sealing laying
8 — a clamp Stopper
9 — a clamp Spring
10 — a clamp Ball
11 — the Bolt
12 — Assembly of a drive of a speedometer
13 — Sapun of case ventilation
14 — Podpruzhinenny a pin
15 — the Lock-nut
16 — the Lock-nut
17 — Assembly of the synchronizer of the 5th transfer
18 — the Fork of inclusion of the 5th transfer
19 — the Blocking ring of the synchronizer
20 — the Gear wheel of the 5th transfer
21 — the Needle bearing
22 — the Intermediate gear wheel of the 5th transfer
23 — the Bolt of an axis of an intermediate gear wheel of a reverse gear
24 — Sealing laying
25 — the Bolt
26 — Carter RKPP
27 — the Trench маслотока
28 — the Bolt
29 — the Spring washer (Grover's washer)
30 — the Persistent level
31 — Assembly of a ball emphasis
32 — Sealing laying
33 — the Epiploon
34 — the External holder of the bearing

35 — the Remote ring (steals up)
36 — the External holder of the bearing
37 — the Remote ring (steals up)
38 — the Filter (only F5М33)
39 — the External holder of the bearing (only F5М33)
40 — the Remote ring (steals up) (only F5М33)
41 — the External holder of the bearing
42 — the Remote ring (steals up)
43 — the Bolt
44 — Lever assembly of a drive of inclusion of a reverse gear
45 — the Boot of assembly of a drive of inclusion of a reverse gear
46 — the Axis of an intermediate gear wheel of a reverse gear
47 — the Intermediate gear wheel of a reverse gear
48 — Podpruzhinenny a pin
49 — Podpruzhinenny a pin
50 — Assembly of a rod of switching
51 — the Bolt
52 — the Bolt
53 — the Holder of the bearing
54 — Assembly of an intermediate gear wheel
55 — Assembly of primary shaft
56 — Assembly of a target (secondary) shaft
57 — differential Assembly
58 — the External holder of the bearing
59 — the External holder of the bearing
60 — Directing supply of oil
61 — the External holder of the bearing
62 — the External holder of the bearing
63 — the Epiploon
64 — the Epiploon
65 — the Magnet
66 — the Holder of a magnet
67 — a coupling Dome

Design of primary shaft of RKPP


1 — the Lock ring 2 — the Ball or konusny bearing 3 — the bearing Coupling 4 — the Lock ring (steals up) 5 — the Ball or konusny bearing 6 — the Remote ring (steals up) 7 — the Lock ring (steals up) 8 — Konusnaya a spring 9 — Podpruzhinennoye a gear ring 10 — the Gear wheel of the 4th transfer 11 — the Needle bearing	12 — the bearing Coupling 13 — the Blocking ring of the synchronizer 14 — a synchronizer Spring 15 — the Sliding coupling of the synchronizer of 3/4 transfers 16 — the Sliding key of the synchronizer 17 — the Nave of the synchronizer of 3/4 transfers 18 — the Blocking ring of the synchronizer 19 — the Gear wheel of the 3rd transfer 20 — the Needle bearing 21 — Primary shaft

Components of assembly of an intermediate shaft of RKPP


1 — the Lock ring (steals up) 2 — the Ball or konusny bearing 3 — the bearing Coupling 4 — the Gear wheel of the 1st transfer 5 — the Needle bearing 6 — the Blocking ring of the synchronizer 7 — a synchronizer Spring 8 — the Sliding coupling of the synchronizer of 1/2 transfers 9 — the Sliding key of the synchronizer	10 — the Nave of the synchronizer of 1/2 transfers 11 — the External blocking ring of the synchronizer (only F5М33) 12 — a synchronizer Cone (only F5М33) 13 — the Internal blocking ring of the synchronizer 14 — the Gear wheel of the 2nd transfer 15 — the Needle bearing 16 — the Ball or konusny bearing 17 — the Intermediate gear wheel

Design of differential of the main transfer of RKPP


1 — Konusny the roller bearing (F5М22, F5M31/F5M33) 2 — the Axis of satellites 3 — the Lock pin 4 — the Washer 5 — the Remote ring (steals up) 6 — the Ball bearing (F5M21/F5M210) 7 — the Satellite 8 — the Bolt	9 — the Ball bearing (F5M21/F5M210) 10 — a differential Box 11 — the Remote ring (steals up) 12 — the Washer 13 — the Satellite 14 — Lateral gear wheels 15 — the Conducted gear wheel of the main transfer

General information

Originators of the real Management do not recommend to owners of cars to undertake performance of major maintenance of RKPP independently. During performance of procedures of dismantling and assembly of a transmission it is necessary to remove, and then to establish into place a set of small components. It is necessary to make mass of the most exact measurements and, by selection of adjusting washers, rings and remote plugs, accurately to expose a set of gaps. In view of all aforesaid, it will be more reasonable to charge performance of major maintenance of RKPP to specialists of car-care center. Let's notice that in many cases there is a possibility on an exchange basis to get the restored block that often there is cheaper, than a carrying out difficult repair.

Despite the told, independent performance of repair of RKPP by the amateur mechanic at all is not absolutely impossible action. Indispensable conditions are only existence of the necessary special tool and accuracy in an approach to performance of all procedures.

The number necessary for performance of regenerative repair of RKPP of tools includes nippers for removal of internal and external lock rings, a stripper of bearings, a hammer with sliding brisk, a set of drifts and center punches, a tsiferblatny measuring instrument of DTI and, probably, a hydraulic press. Besides, certainly, the workbench, or the special assembly stand is required strong, equipped with a vice.

During performance of procedures of dismantling of RKPP try to remember, and it is better to write down, an order of installation of each of removed details.

Before starting 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. See also Section devoted to diagnostics of malfunctions of RKPP, at the beginning of the Management.

Let's consider in more detail three of applied on cars of a box of gear shifting considered in the real Management: F5М31 (Galant), F5М21 (Mirage of 1.5 l) and F5М22 (Mirage of 1.8 l).

RKPP dismantling

PERFORMANCE ORDER

1. The design of RKPP is presented on illustrations.
2. On the F5М21 models remove the transmission sensor switch with sealing laying. On all other models remove a back cover. Remove the sensor switch of fires of a backing with the sealing laying. Remove a wavy spring, give bolts and remove a reversive brake cone. Turn out jams and take fixing springs and balls.
3. Remove from a coupling dome assembly of a drive of a speedometer and сапун case ventilation. Take a podpruzhinenny pin from a fork of inclusion of the 5th transfer. To Raschekanta 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 primary shaft with a cutting face natural a collar. Screw in a coupling dome a bolt on 10 mm and rest against it a key collar, having blocked thereby primary shaft from a provorachivaniye. Give a lock nut (lock-nut).
5. Remove assembly of the synchronizer and a fork of inclusion of the 5th transfer. Remove blocking ring of the synchronizer and a gear wheel of the 5th transfer. On the F5М21 models remove the needle bearing, a remote ring, the bearing coupling, a lock ring and the roller bearing.
6. On all models remove an intermediate gear wheel of the 5th transfer. Turn out a bolt of an axis of an intermediate gear wheel of a reverse gear, remove sealing laying. Remove a case of RKPP and directing supply of oil. Turn out a bolt of a persistent level and remove a spring washer. Remove assembly of a ball clamp with sealing laying.
7. On the F5М21 models remove an external ring. On all models remove an epiploon. On the F5М21 models 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 assembly of a drive of inclusion of a reverse gear, a boot of lever assembly, take an axis with an intermediate gear wheel of a reverse gear.
9. Take podpruzhinenny pins of rods of forks of switching of 1/2 and 3/4 transfers. Transfer the corresponding fork of switching to provisions of the 2nd transfer, the second fork - in the provision of the 4th transfer.
10. On the F5М21 and F5М22 models turn assemblies of rods of switching to a conclusion of uvulas of switching from gearing with operating finger and a fixing plate. Having pulled rods up, liberate from the ends from a coupling dome. Remove rods and switching forks.
11. On the F5M31/F5M33 models remove assembly of a rod of a fork of switching. On all models remove the holder of the bearing. Lift primary shaft and remove assembly of an intermediate gear wheel.
12. Remove assemblies of primary and secondary shaft. Remove differential assembly. Remove from primary and secondary shaft external holders of bearings. At the corresponding complete set take holders of bearings from landing nests of differential in a coupling dome. Remove from a coupling dome directing supply of oil and epiploons. Remove a magnet with the holder.

Dismantling, check of a condition of components and assembly of RKPP hubs

Synchronizer of the 5th transfer

Dismantling

PERFORMANCE ORDER

Remove blocking ring, a persistent plate, the springs, the sliding coupling, sliding keys and a synchronizer nave.

Check

PERFORMANCE ORDER

1. Fill a synchronizer nave in the coupling and manually check freedom of rotation of components. Check the coupling on existence of signs of wear or damages of forward and back internal edges. Check a condition of the fifth transfer of a surface of a nave interfaced to a gear wheel. Estimate degree of wear of the top ledges of sliding keys. Check springs on existence of signs of weakening of effort, deformations, cracks and other mechanical damages.
2. Replace defective components.

Replacement of the sliding coupling is made assembled with a nave.

Assembly

PERFORMANCE ORDER

1. Enclose in the synchronizer coupling 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 appeared are developed by locks in different directions.
3. In summary establish a persistent plate and blocking ring.

Primary shaft of RKPP F5М21

Dismantling

PERFORMANCE ORDER

1. The design of assembly of 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 the 4th transfer.
4. Remove a gear wheel of the 3rd transfer, assembly of the synchronizer of 3/4 transfers and the bearing coupling.

Check

PERFORMANCE ORDER

3. Fill a synchronizer nave in the coupling and check freedom of moving of components from each other. Check a condition of forward and back edges of the coupling, estimate degree of wear of a surface of a nave interfaced to a gear wheel and working ledges of sliding keys. Check a condition of springs of the synchronizer.
4. Replace defective components.

Replacement of the sliding coupling is made assembled with a nave.

5. Check 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.

Assembly

PERFORMANCE ORDER

1. Assembly is made as it should be, the return to an order of dismantle of components. Plant a synchronizer nave (marking forward) in the sliding coupling. Track correctness of a joint of components, - the central tooth of a nave should get between two passed teeths of the coupling 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 were developed by locks in different directions.
3. Plant assembly of the synchronizer of 3/4 transfers on a shaft.

Track, that sliding keys got to flutes in a blocking ring, check freedom of rotation of a gear wheel of the 3rd transfer.

4. By means of the special adaptation plant on a shaft the bearing coupling. Establish a remote ring (an identification label “1” towards a gear wheel of the 4th transfer).

In the absence of marking 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.

Lock rings of 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.

Primary shaft of RKPP F5М22 and F5M31/F5M33

Dismantling

PERFORMANCE ORDER

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 the 4th transfer with the bearing.
2. Remove the bearing coupling, assembly of the synchronizer of 3/4 transfers and a gear wheel of the 3rd transfer.
3. Remove the needle bearing.

Check

PERFORMANCE ORDER

1. Estimate degree of wear of bearing surfaces and шлицов in bulk. Establish on a shaft the needle bearing and check density of its landing and freedom of rotation. Make sure of absence of deformations and damages of the case of the bearing.
2. Check integrity of teeths of a blocking ring of the synchronizer. Make sure of lack of signs of damages and an internal surface of integrity of rounds of the carving put on it. Wring out a synchronizer ring towards a gear wheel and measure gap size between components. If the result of measurement exceeds 0.5 mm, replace blocking ring.
3. Fill a synchronizer nave in the sliding coupling and check freedom of moving of components from each other. Check a condition of forward and back edges of the coupling, estimate degree of wear of a surface of a nave interfaced to a gear wheel and working ledges of sliding keys. Check a condition of springs of the synchronizer.
4. Replace defective components.

Replacement of the sliding coupling is made assembled with a nave.

5. Check 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.

Assembly

PERFORMANCE ORDER

1. Plant a synchronizer nave (marking forward) in the sliding coupling. Track correctness of a joint of components, - the central tooth of a nave should get between two passed teeths of the coupling 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 were developed by locks in different directions.
3. Plant assembly of the synchronizer of 3/4 transfers on a shaft.

Track, that sliding keys got to flutes in a blocking ring, check freedom of rotation of a gear wheel of the 3rd transfer.

5. By means of the special adaptation plant on a shaft the forward bearing, fill in a flute a new lock ring.

Lock rings of 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.

Intermediate shaft

Dismantling

PERFORMANCE ORDER

1. The design of assembly of an intermediate shaft is presented on an illustration.
2. Remove a lock ring and dismantle from a shaft the bearing with the coupling.
3. Remove the needle bearing and a gear wheel of the 1st transfer.

The bearing is subject to replacement without fail.

4. Remove from a shaft assembly of the synchronizer of 1/2 transfers, a gear wheel of the 2nd transfer and the needle bearing.
5. Remove the back bearing of assembly.

Check

PERFORMANCE ORDER

1. Estimate degree of wear of bearing surfaces of assembly. Establish on a shaft the needle bearing and check density of its landing and freedom of rotation. Make sure of absence of deformations and damages of the case of the bearing.
2. Check integrity of teeths of a blocking ring of the synchronizer. Make sure of lack of signs of damages and an internal surface of integrity of rounds of the carving put on it. Wring out a synchronizer ring towards a gear wheel and measure gap size between components. If the result of measurement exceeds 0.5 mm, replace blocking ring.
3. Fill a synchronizer nave in the sliding coupling and check freedom of moving of components from each other. Check a condition of forward and back edges of the coupling, estimate degree of wear of a surface of a nave interfaced to a gear wheel and working ledges of sliding keys. Check a condition of springs of the synchronizer.
4. Replace defective components.

Replacement of the sliding coupling is made assembled with a nave.

5. Check 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.

Assembly

PERFORMANCE ORDER

1. Assembly is made as it should be, the return t