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
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Major maintenance of RKPP
RKPP F5М21 and F5М22 design
RKPP F5M31/F5M33 design
Design of primary shaft of RKPP
Components of assembly of an intermediate shaft of RKPP
Design of differential of the main transfer of RKPP
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
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| 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. |
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Dismantling, check of a condition of components and assembly of RKPP hubs
Synchronizer of the 5th transfer
Dismantling
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Remove blocking ring, a persistent plate, the springs, the sliding coupling, sliding keys and a synchronizer nave. |
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Check
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| 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.
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Replacement of the sliding coupling is made assembled with a nave. |
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Assembly
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| 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. |
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Primary shaft of RKPP F5М21
Dismantling
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| 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. |
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Check
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| 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 of the case of the bearing.
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2. Check integrity of teeths of a blocking ring of the synchronizer. Make sure of lack of signs of damages and integrity of rounds of a carving of an internal surface. 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 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.
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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. |
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Assembly
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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.
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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).
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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.
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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. |
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Primary shaft of RKPP F5М22 and F5M31/F5M33
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 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. |
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Check
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| 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.
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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. |
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Assembly
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| 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.
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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).
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In the absence of marking the ring can be planted any way. Plant the back bearing with the coupling. |
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 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 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.
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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. |
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Check
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| 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.
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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. |
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Assembly
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| 1. Assembly is made as it should be, the return to an order of dismantle of components. By means of the special adaptation plant on a shaft the bearing, - track, that the opravka of 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 (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.
3. Establish synchronizer springs so that sliding keys rested against their acting sections. Track, that springs were developed by locks in different directions.
4. Plant assembly of the synchronizer of 1/2 transfers on a shaft.
5. By means of the special adaptation plant on a shaft the bearing coupling. Establish a gear wheel of the 1st transfer with the bearing coupling, in summary plant on a shaft the bearing. |
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Final (secondary) shaft
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| 1. The design of assembly of a secondary shaft is shown on illustrations.
2. Remove from a shaft bearings, - at assembly they are subject to replacement without fail, replacement of internal and external holders is made in a set. Estimate a condition of a shaft and degree of wear of its working components. Plant on a shaft new bearings. Assembly is made upside-down. |
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Gear shifting forks
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| 1. Remove a fork of switching of 1.2 transfers. Remove assembly of a rod of switching.
2. Remove assembly of a fork of switching of 3/4 transfers and a switching rod 5-y/back transfers. Remove a rod of a fork of switching of 3/4 transfers. Remove a doggie of switching of a reverse gear.
3. Assembly is made upside-down. Track hit of a plunzher of a blocking clamp in a 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 design of differential is presented on an illustration.
2. Turn out fixing bolts and remove a conducted gear wheel of a reverse gear. Squeeze out of a differential box bearings, - at assembly 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 existence of signs of excessive wear and mechanical damages. Defective units replace. |
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Assembly
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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 the demanded thickness.
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At installation of new lateral gear wheels it is necessary to complete them with identical remote rings of 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. Press in a differential box new bearings.
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Opravka of the tool should rest only against an internal holder of the bearing! |
5. Before a vvorachivaniye of 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 rounds, 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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RKPP assembly
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The remote rings used at installation of a pretightness, and also lock rings are subject to selection. |
1. Assembly is made as it should be, the return to an order of dismantle of components.
2. Establish epiploons driving and primary in bulk. At the same time fill in a case of transmission of assembly of intermediate and primary shaft.
3. Grease the bolt of fastening of the bearing of primary shaft next to differential with fixing hermetic of type 3М STUD (4170), - try not to allow hermetic hits on a bolt head. Screw bolts and tighten them with demanded effort
(16 ÷ 22 H • м).
4. Plant the coupling of switching of 1/2 transfers to a gear wheel of the 2nd transfer, the coupling of 3/4 transfers - respectively, in a gear wheel of the 4th transfer. Enter forks of assemblies of switching into gearing with flutes in couplings. Pass rods of forks in the corresponding openings in a dome of coupling and turn them for a joint of doggies with operating finger and a blocking plate.
5. By means of a suitable drift plant new spring pins (a cut on a rod axis). Establish an axis of an intermediate gear wheel (a carving opening 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 a case of transmission and tighten bolts of its fastening with demanded effort. Again turn out bolts, remove a case, dismantle external holders of bearings and take the flattened-out solder. Measure thickness of solder by a micrometer and pick up the corresponding remote rings, this procedure will allow to pick up correctly axial люфт components (see. Specifications).
8. Plant in a transmission case directing supply of oil. Put on assembly 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 the corresponding thickness between an external holder of the bearing and RKPP case. Make sure that the axis of an intermediate gear wheel of a reverse gear is developed by a carving opening in a head in the correct party, then can start installation of a case of a transmission.
9. Evenly impose on interfaced to a coupling dome a case surface a hermetic pillow in thickness of 1.0 ÷ 2.0 mm (use Mitsubishi MD997740 or Three Bond 1216 hermetic). Press a case to a dome.
10. By means of a drift (a cross-shaped screw-driver) in diameter of 8.0 mm achieve combination of a carving opening in an axis of an intermediate gear wheel of a reverse gear with the corresponding boltovy opening in a transmission case. Screw a bolt and tighten it with demanded effort (43 ÷ 55 H • м). Tighten with demanded effort other bolts of fastening of a case of transmission.
11. At the corresponding complete set pick up a lock ring of a landing flute of 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 primary shaft. Check density of a clip of a flange of the coupling to the bearing.
12. Establish a fork of inclusion of the 5th transfer (complete with the synchronizer). Block a shaft from a provorachivaniye by means of a face natural a cutting head and a 10-millimetric bolt screwed in a dome of coupling.
13. By means of control levers and a choice switch RKPP to a reverse gear. Screw new lock-nuts, tighten from with demanded effort (140 ÷ 160 H • м) and зачеканьте.
14. Establish new spring forks of inclusion of the 5th transfer (a cut on a rod axis).
15. Grease with type 3М Super Weatherstrip (8001) hermetic on a fixing surface air сапуна and establish a coupling dome. Establish a back cover of a dome of coupling, previously having imposed on its interfaced surface a uniform pillow of hermetic (Mitsubishi MD997740 or Tree Bound 1216 type) in thickness of 1 ÷ 2 mm.
16. Establish RKPP assembly on the engine (see. Section Removal and transmission installation). |
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