---===SME_1007_00073_0001.djvu===--- ---===SME_1007_00073_0001.djvu===--- ---===SME_1007_00073_0002.djvu===--- FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi ROSA series bus chassis, and includes proce- dures for adjustment and maintenance services. We ear- nestly look forward to seeing that full use is made of this manual in order to services vehicles correctly and not waste time. As this Shop Manual is published as a supplement to the following Shop Manuals, please refer to the followings for information not included in this manual. • Chassis ROSA BE6. BC6 .. ....... ...................... ....... Pub. No. TWSE0329 For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance ser- vice figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. Applicable models BE BC Oct. 2004 For Panama Shop Manual ©2004 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan GROUP INDEX MODIFICATION SUMMARY.................. MANUAL TRANSMISSION .................. ---===SME_1007_00073_0003.djvu===--- i MODIFICATION SUMMARY ---===SME_1007_00073_0004.djvu===--- ii MODIFICATION SUMMARY • This Shop Manual describes items different from those described in Shop Manual chassis ROSA BE6. BC6 (Pub. No. TWSE0329) with regard to vehicles equipped with the manual transmission, M035S6 model. • Be sure to check the differences described in the following before servicing. Group Contents of different points Service procedure 00 The power train table in the manual must be supplemented with the following: --- * : option 22 The service procedure for the M035S6 6-speed transmission has been added. BGr22 Vehicle model Engine Transmission Propeller shaft Clutch Final reduction BE637J 4D33 130 PS/31 kgf⋅m M035S5 (5.380/0.722) * M035S6 (6.114/0.790) P3 C4W30 D3H 5.714 6.142 * D033H 4.875 BE647J ---===SME_1007_00073_0005.djvu===--- 22 22-1 GROUP 22 MANUAL TRANSMISSION SPECIFICATIONS ................................................................................ 22-2 STRUCTURE AND OPERATION ........................................................ 22-3 TROUBLESHOOTING ......................................................................... 22-6 REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY .......................................................................................... 22-8 GEAR SHIFTER UPPER ...................................................................... 22-12 EXTENSION HOUSING ....................................................................... 22-18 6TH GEAR, REVERSE IDLER GEAR ................................................. 22-22 TRANSMISSION BODY ....................................................................... 22-28 DRIVE PINION ASSEMBLY ................................................................ 22-38 MAINSHAFT ASSEMBLY .................................................................... 22-40 COUNTERSHAFT ASSEMBLY ........................................................... 22-46 TRANSMISSION CONTROL ............................................................... 22-48 BEARING PULLER AND INSTALLER ................................................ 22-60 ---===SME_1007_00073_0006.djvu===--- 22-2 Item Specifications Mode of control Floor shift remote control Transmission model M035S6 Gear ratio 1st 6.114 2nd 3.442 3rd 1.987 4th 1.345 5th 1.000 6th 0.790 Reverse 6.114 Oil capacity dm 3 {L} Approximately 4.4 {4.4} Mass kg Approximately 97.5 SPECIFICATIONS ---===SME_1007_00073_0007.djvu===--- 22 22-3 Transmission Assembly The transmission changes revolution and torque generated by the engine into those that match the vehicle's power re- quirement (driving force). Revolution and torque are increased or decreased by making a selection from several sets of engaged gears. 1 Drive pinion 7 1st and reverse constant-mesh assembly 2 4th and 5th synchronizer assembly 8 Mainshaft 3 Reverse shift lever 9 6th synchronizer assembly 4 Shift rail 10 Reverse idler gear 5 2nd and 3rd synchronizer assembly 11 Countershaft 6 Shift fork 2 34 5 6 7 8 9 10 11 1 42771 STRUCTURE AND OPERATION ---===SME_1007_00073_0008.djvu===--- 22-4 Synchromesh Mechanism • The synchromesh mechanism synchronizes the rotating speed of mainshaft 7 and associated synchronizer hub 8 with the rotating speed of the gears to be selected when shifting gear. • Single cone type < excluding 2nd and 3rd gears > In this cone type, gear taper cone A acts as a cone clutch for synchronization with synchronizer ring 1. So the rotating speed of the gear to be synchronized with synchronizer hub 8 gradually changes to the matching speed. When syn- chronizer sleeve 9 moves into the appropriate position efficiently through this process and engages with the synchro- nizer hub and dog clutch B of the gear to be selected, gear shift is completed. • Triple cone type < only for 2nd and 3rd gear > In this cone type, the synchronizer ring is divided into three (inner synchronizer ring 1, outer synchronizer ring 3, and center cone 4). The center cone is between the inner synchronizer ring and the outer synchronizer ring, the inner syn- chronizer ring is between the center cone and the synchronizer cone 11 and, in addition, the clutch's face is widened; thereby reducing synchronizing time through more efficient operation of the cone clutch, as well making shift operation easily. 1 Synchronizer ring (Single cone type) 7 Mainshaft Inner synchronizer ring (Triple cone type) 8 Synchronizer hub 2 Shifting key (Single cone type) 9 Synchronizer sleeve Shifting plunger (Triple cone type) 10 Drive pinion (Single cone type) 3 Outer synchronizer ring (Triple cone type) 2nd gear (Triple cone type) 4 Center cone (Triple cone type) 11 Synchronizer cone (Triple cone type) 5 4th gear (Single cone type) A: Taper cone 3rd gear (Triple cone type) B: Dog clutch 6 Shifting key spring (Single cone type) Shifting plunger spring (Triple cone type) 3 1 4 11 10 9 8 7 6 2 5 Triple cone type <2ndand3rd> 37156 05751 1 5 2 6 7 8 9 A B 10 Single cone type < Excluding 2nd and 3rd gears > STRUCTURE AND OPERATION ---===SME_1007_00073_0009.djvu===---