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I’m Gregoria, your friendly neighborhood mechanic, and today I’m going to guide you through the detailed process of gearbox reconditioning on a Mitsubishi Montero Sport. This task requires a good understanding of mechanical systems, patience, and a variety of tools. Let’s dive into the world of gearboxes!
### Tools and Equipment Required
Before we get into the steps, it’s essential to gather all the necessary tools and equipment. Here’s a comprehensive list:
1. **Socket Set**: A complete socket set (both metric and imperial) will be necessary for removing bolts and nuts. Look for sizes ranging from 10mm to 19mm, as these are commonly found in Mitsubishi vehicles.
2. **Torque Wrench**: This tool is crucial for tightening bolts to the manufacturer’s specified torque settings. An adjustable torque wrench will allow you to apply the right amount of force.
3. **Screwdrivers**: Both flathead and Phillips screwdrivers will be needed for various fasteners throughout the gearbox assembly.
4. **Pliers**: Needle-nose pliers and standard pliers will help with gripping and pulling various components.
5. **Hammer and Punch**: A soft-faced hammer and a punch can aid in dislodging stubborn components without damaging them.
6. **Gear Oil**: You will need fresh gear oil suitable for the Mitsubishi Montero Sport. Check the manufacturer’s specifications for the correct type and viscosity.
7. **Cleaning Supplies**: Brake cleaner, rags, and a parts washer will be essential for cleaning components during the reconditioning process.
8. **Gasket Maker/Sealant**: A quality gasket maker or sealant is essential to ensure that everything is sealed properly once reassembled.
9. **Parts Kit**: It’s often wise to have a kit that includes all necessary gaskets, seals, and bushings for the gearbox reassembly. Check your specific model for compatibility.
10. **Transmission Jack**: This specialized jack will help support the gearbox during removal and installation, making it safer and easier.
11. **Inspection Tools**: A caliper or micrometer for measuring wear on gears and bearings, and possibly a magnifying glass to examine small parts.
### Step-by-Step Process of Gearbox Reconditioning
#### 1. Preparation
Before starting, ensure you have a clean, well-lit workspace. Gather all your tools and materials, and wear safety equipment such as gloves and safety glasses.
#### 2. Remove the Gearbox
– **Disconnect the Battery**: Safety first! Disconnect the negative terminal of the battery to prevent any electrical issues.
– **Lift the Vehicle**: Use a hydraulic lift or jack stands to elevate the vehicle safely.
– **Drain Transmission Fluid**: Locate the transmission fluid pan and remove the drain plug to allow the old fluid to drain completely into a suitable container.
– **Disconnect Linkages**: Remove the shift linkage and any other connections to the gearbox. This may involve unbolting brackets or clips.
– **Unbolt the Gearbox**: Using your socket set, remove the bolts securing the gearbox to the engine block. There may be several bolts at the bell housing and on the sides of the gearbox.
– **Support the Gearbox**: Use the transmission jack to support the gearbox as you remove the final bolts.
– **Carefully Lower the Gearbox**: Once all bolts are removed, gently lower the gearbox from the vehicle. Ensure that all connections are fully detached.
#### 3. Disassemble the Gearbox
– **Clean the Exterior**: Before opening, clean the outside of the gearbox to prevent dirt from entering the internals.
– **Remove the Gearbox Cover**: Use your socket set to unbolt the cover. Be cautious of any clips or additional fasteners.
– **Take Notes**: As you disassemble, take notes or photos of the arrangement of parts. This will be invaluable during reassembly.
– **Remove Internal Components**: Carefully extract the gears, bearings, and synchronizers. Use your pliers and soft hammer as necessary to avoid damage.
#### 4. Inspect Components
– **Measure Wear**: Using your caliper or micrometer, measure the gears
and bearings for wear. Check the manufacturer’s specifications for acceptable tolerances.
– **Look for Damage**: Inspect all components for cracks, pitting, or excessive wear. You’ll need to replace any damaged parts.
– **Clean All Parts**: Use brake cleaner and rags to clean all components thoroughly. A parts washer is ideal for this task.
#### 5. Replace worn Components
– **Order Replacement Parts**: If you find any worn or damaged parts, order replacements from a reputable supplier. Be sure to get OEM parts where possible for the best fit and quality.
– **Install New Components**: Once you have your new parts, install them in the reverse order of removal. Use your gasket maker/sealant on any gaskets to ensure a proper seal.
#### 6. Reassemble the Gearbox
– **Reassemble Internal Components**: Carefully place the gears, synchronizers, and bearings back into their respective positions. Ensure everything is seated correctly.
– **Install Gearbox Cover**: Bolt the cover back onto the gearbox, ensuring that all screws are tightened to the manufacturer’s specifications using your torque wrench.
#### 7. Reinstall the Gearbox
– **Lift the Gearbox**: Use the transmission jack to raise the gearbox back into position. Align it carefully with the engine block.
– **Bolt the Gearbox**: Reinstall all the bolts you removed earlier, ensuring they are tightened adequately.
– **Reconnect Linkages**: Reattach the shift linkage and any other connections that were detached during removal.
#### 8. Fill with New Gear Oil
– **Refill Transmission Fluid**: Locate the fill plug on the gearbox and refill with the appropriate gear oil until it reaches the proper level. Consult the owner’s manual for specifications regarding the type and amount of fluid.
#### 9. Reconnect the Battery and Test Drive
– **Reconnect the Battery**: Finally, reconnect the negative terminal of the battery.
– **Test Drive**: Start the vehicle and take it for a short test drive to ensure everything is functioning smoothly. Pay attention to shifting and listen for any unusual noises.
### Conclusion
Congratulations! You’ve successfully reconditioned the gearbox of a Mitsubishi Montero Sport. This process requires diligence and attention to detail, but with the right tools and a methodical approach, you can ensure a longer life for the gearbox and a smoother ride. If you have any further questions or need assistance, don’t hesitate to reach out. Happy wrenching!
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