Converting from Automatic to Manual: Manual gearbox rebuild

Post by **Growlerbearnz** » Sun May 27, 2018 3:16 pm

I ordered all my parts from Amayama.com. I would use this page: https://www.ilcats.ru/?language=en to look up part numbers which fit your gearbox. There's a somewhat wordy description of how I find part numbers here: http://www.delica.ca/forum/viewtopic.php?f=16&t=17210

Here's most of my parts list, which was for a 1996 V5M21 gearbox. There's probably a few things missing or a few pieces you might not need- it depends what's worn out and what needs replacing in your own gearbox.

-----GEARBOX REBUILDparts-----
MD703748 Mainshaft nut
MD703786 5th gear bearing sleeve
MD716917 (NACHI 35BVV07X6CS) mainshaft double row ball bearing )
MD705848 x2 selector oil seals (2580A003)
MD723202 Input shaft seal
MD736300 Front cover gasket
MD705865 Rear cover gasket
MD703796 Under cover gasket (not needed if you swap to the cast cover)
MR453264 layshaft Taper roller bearing (Koyo HC1788731) x2
2502A008 Cast gearbox pan/cover
MD727531 Cast cover rubber seal
MD703798 Countershaft extension bearing (Koyo DG2256SH2C3)
MD731727 input shaft bearing with felt seals (DON'T USE NTN TMSC0788NRCS40PX1 as it has no seals)

MD701760 3rd needle roller
MD731433 Mainshaft pilot needle roller
MD703760 x2 Mainshaft needle roller
MR581773 Reverse needle roller (split roller case)
MD723201 OD gear needle roller

---Transfer Case---
MR179712 Transfer case gasket kit (inc seals)
-MD704119 Transfer input bearing
MD704198 Tfr rear output shaft brg A (Koyo 6211C3)
MD736823 Tfr rear output shaft brg B (NSK 6307NRC3)
-MD704120 x2 Tfr front output shaft
$105.33

----Clutch----
MR195689 Release bearing Valeo PRB02
MD979428 clutch slave cylinder kit
MB334439 clutch Master cylinder kit

drarnold · Post by **drarnold** » Sun May 27, 2018 4:09 pm

Thank you so much. This is a game changer!!! Thank you!

brodykunze · Post by **brodykunze** » Tue Aug 14, 2018 6:47 pm

This has so far been the most helpful info I've gotten on the L300 transmission, so I will post my question here even though I'm not necessarily doing a tranny swap myself. I've been having tranny issues with my 1991 5spd l300 (Trannys a V5M21), and so I dropped the tranny out and have been going through it to find the cause of the issues. Upon inspection found lots of metal shavings, including some brass. Mainshaft bearing was shot and now replaced and will likely replace synchros as well, they look pretty worn(will include some pictures in a reply). My main concern is having found this chunk of metal that appears to be a seal or something of that nature jammed up in a shift arm. I couldn't figure out where it came from even with schematics of the broken down tranny.

: IMG_3195.jpg (582.02 KiB) Viewed 6113 times

The only other thing I could find is that at some point someone removed an exterior bolt that released a spring holding pressure on a shift arm inside the tranny. But this could not have been the cause for the terrible noises it made near the end, as no one had worked on it for some time before this.
Best case scenario I'm able to order in the new synchros and all is well once put back together (minus the mystery metal...).

Any advice would be greatly appreciated, I'm not a mechanic so I'm learning as I go. Thanks!

Post by **Growlerbearnz** » Wed Aug 15, 2018 9:00 pm

That does indeed look like part of a seal, or some kind of crushable gasket, but I can't think of anything in the gearbox that it would come from. Maybe it got in there when the gearbox was last opened up?

If you've had metal through the gearbox it's a good idea to replace all the ball bearings, and maybe the 5th gear needle rollers and sleeve just to be safe.

brodykunze · Post by **brodykunze** » Mon Aug 20, 2018 5:05 pm

So having dug even deeper into my transmission, I have a theory on what might have happened.

It seems the main input shaft bearing was an upgraded version with felt seals. Assuming that the bearing is fitted with a seal on both sides of it, I've resolved that the aforementioned piece of metal (Looked like a gasket or seal) was actually from the felt seal. When taking the tranny apart, I only found the one felt seal, and it wasn't even seated in the bearing, this was because the bearing was so warn out, I'm assuming it literally just just got thrashed and forced out.

This picture shows the warn out bearing with the one felt seal that survived, and the remaining outer gasket ring of the other felt seal that didn't get shredded on the inside of the transmission box. This also means that all the felt and other metal on the seal got completely chewed up inside.

: IMG_3210.jpg (424.67 KiB) Viewed 6060 times

I'm guessing the internal felt seal then got sucked into 3rd/4th gear synchro, and chewed up a bunch of the brass on the first synchro and the outer gasket that remained proceeded to get lodged in a shift arm where I found it. The 3rd/4th synchro now looks like this... not good..:

: IMG_3211.jpg (436.67 KiB) Viewed 6060 times

I've replaced the main input shaft bearing with a new one (without the felt seals), and need to order in a new synchro.
This seems to be the most challenging part of this rebuild, identifying the correct part number to get a new synchro ordered in. Using the previously mentioned parts search engine ( https://partsouq.com/) I can't find numbers for synchros. This diagram I've been using for the rebuild, only shows me which part it is, number 84 (3rd 4th synchronizing ring):

: V5M21-9-G Transmission.png (209 KiB) Viewed 6060 times

I've talked with a local JDM dealer that sent me this diagram to identify it and get it shipped in. The diagram is low quality somehow doesn't look quite accurate... but my best guess is that it's 22596P ... but it's hard to tell, and possibly it's 22596Q, Any opinions here? :

: WS02.JPG (461.48 KiB) Viewed 6060 times

Anyway, regardless of it's specific part number, upon visual inspection, it appears to be identical to the other synchronizers in the tranny, so I'll likely go with the ring I've identified above, unless anyone else on the forum knows a better way of identifying and/or purchasing this part? Thanks in advance!

This definitely reinforces the fact that the main input shaft bearing is a known weak point, even with the felt seals it seams!! On the bright side, there doesn't seem to be any other severe damage in the tranny after this happened, and once I find a line on this Synchronizer, I should be back on the road!

Cheers

Post by **Growlerbearnz** » Tue Aug 21, 2018 12:37 pm

It's item 22596P, Mitsubishi part number MD701465. The same ring is used on 3rd,4th, 5th, and reverse.

I've been using ilcats.ru lately, much clearer diagrams, and when parts change the changeover dates are right there in the parts listing.

https://www.ilcats.ru/mitsubishi/?funct ... anguage=en

brodykunze · Post by **brodykunze** » Tue Aug 21, 2018 3:12 pm

Growlerbearnz wrote:It's item 22596P, Mitsubishi part number MD701465. The same ring is used on 3rd,4th, 5th, and reverse.

This is excellent, thanks again Growler.

m.h · Post by **m.h** » Thu Feb 20, 2020 9:46 pm

Thread dredge time

What was the reason for changing to manual? Is the auto really weak? I have 3 delicas (1x manual and 2 auto) and the nicest one is auto. I had been told the v5m21 isnt very strong so dont know if it was worth the hassle to change to the v5m21.

I have also thought about getting a v5mt1 from a gen2 4d56 pajero and making a cable shifter and mounts for it as they look significantly stronger