M/T - Synchronizer Modifications
84mitsubishi03SUBJECT:
TRANSMISSION SYNCHRONIZER MODIFICATIONS
NO. STB-84-21-010
DATE September 1984
MODEL 1984 Starion, Montero, Truck
DESCRIPTION OF MODIFICATIONS
To improve shift quality in the 5-speed manual transmission used in 1984-model Starion, Montero and Truck models, a redesigned 1-2 synchronizer entered production in May 1984, beginning with transmission number ABO788.
FIGURE 1:
PARTS INTERCHANGEABILITY
The modified shift fork (key no. 5 in Table I) is interchangeable individually with the previous part. Other components (key nos. 1, 2, 3, and 4 in Table I and Figure 1) are replaced as a complete set only.
IDENTIFICATION OF PARTS
The descriptions which follow correspond to the key numbers In Table I.
FIGURE 2:
FIGURE 3:
FIGURE 4:
(1) Synchronizer ring: The new ring is thinner by 0.3 mm, the 1st gear chamfer angle is changed, and three identification notches are added on the 1st gear side. See Figs. 2, 3, and 4.
FIGURE 5:
IDENTIFICATION OF PARTS
(2) Synchronizer key: The new key has a slightly smaller radius, and two identification grooves have been added on the underside. (Fig. 5)
FIGURE 6:
(3) Synchronizer sleeve and hub assembly:
Angles have been changed, the shift fork groove diameter has been increased, and the chamfer angle on the 1st gear side has been changed to match the synchronizer ring. See Fig. 6.
FIGURE 7:
IDENTIFICATION OF PARTS
(4) The synchronizer spring has been made smaller in diameter and thicker in crosssection as shown in Fig. 7.
FIGURE 8:
(5) The new shift fork has pads at both ends 180~ apart. Figure 8 compares the earlier and new configurations.