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Mitsubishi Delica L300 factory workshop and repair manual download

- Safety first (read and follow these before touching the vehicle)
- Wear safety glasses, gloves, and sturdy closed-toe shoes.
- Work on a level surface, engage parking brake, and put wheel chocks on wheels remaining on the ground.
- Disconnect the negative battery terminal before major drivetrain work (prevents starter clutches, electrical shorts).
- Never rely on a jack alone — always support the vehicle on rated jack stands placed at factory lift points.
- If anything feels stuck or requires excessive force, stop and reassess — using too much force can break parts or cause injury.
- Get a repair manual (Haynes, Chilton, or factory service manual) for torque specs, diagrams, and model-specific steps.

- Basic drivetrain overview (what “drivetrain” includes on a Delica L300)
- Transmission (manual or automatic) — transfers engine power into gears.
- Clutch (manual only) — engages/disengages engine to transmission.
- Driveshafts/axles (front CV axles on FWD/4WD front, rear drive shafts on RWD/4WD).
- CV joints / universal joints (U-joints) — allow axle rotation while steering/suspension moves.
- Differential/transfer case (on 4WD models) — splits power to wheels and handles gear reduction.
- Mounts and seals — hold components in place and keep fluids in.

- Tools you probably already have (detailed descriptions and how to use each)
- Basic socket set (metric sockets 8–24 mm, 1/4", 3/8" and 1/2" drive ratchets, extensions)
- Description: Sockets fit over nuts/bolts; ratchets allow one-handed turning; extensions reach recessed fasteners.
- How to use: Choose correct socket size snugly; pull back on the ratchet release to attach. Use extensions for deep bolts. Apply steady pressure; avoid rounding heads by using correct sizes.
- Combination wrench set (metric)
- Description: Open-end and box-end on each wrench for different access angles.
- How to use: Use the box end for more torque; open end for quick slip-on/off. Ensure full seating to avoid rounding bolt heads.
- Breaker bar (long non-ratcheting bar)
- Description: Long handle for extra leverage to break loose tight fasteners.
- How to use: Fit a socket on the end and push slowly and evenly. Don’t jerk; use controlled force.
- Torque wrench (click-type, 3/8" or 1/2" drive)
- Description: Measures applied torque and clicks at set value.
- How to use: Set desired torque, tighten steadily until the click. Re-check orientation and value from the manual.
- Hydraulic floor jack (rated for vehicle weight)
- Description: Lifts the vehicle so you can place jack stands.
- How to use: Position on factory lift point, pump handle to lift, never get under vehicle supported only by the jack.
- Jack stands (pair, rated capacity)
- Description: Support the vehicle safely after lifting.
- How to use: Lower vehicle onto stands placed under secure lift points. Shake vehicle slightly to confirm stability.
- Wheel chocks
- Description: Wedges placed behind wheels to prevent roll.
- How to use: Place on downhill side of wheels remaining on ground.
- Screwdrivers (flat and Phillips) and pry bar
- Description: For trim, clamps, and light prying.
- How to use: Use correct tip size and pry bar for leverage (protect painted surfaces).
- Pliers (needle-nose, slip-joint) and locking pliers (Vise-Grips)
- Description: Grip, bend, and hold small parts; locking pliers clamp and hold firmly.
- How to use: Use needle-nose for tight spots, locking pliers to hold stubborn parts while you work.
- Hammer and rubber mallet
- Description: Light strikes to free stuck parts; rubber mallet avoids damage.
- How to use: Tap controlled; use penetrating oil first on rusted parts.
- Penetrating oil (e.g., PB Blaster) and brake cleaner
- Description: Penetrating oil helps loosen rusted bolts; brake cleaner cleans grease.
- How to use: Spray penetrating oil, let soak; clean surfaces before reassembly with brake cleaner.
- Pry bar or large flat screwdriver for separating components
- How to use: Use leverage points; protect surfaces with wood blocks to avoid damage.
- Hammer and drift/punch set
- Description: To drive out pins or align holes.
- How to use: Use for punches or roll pins carefully; avoid striking threaded studs.

- Extra/specialty tools you may need (why they’re required and how to use)
- Impact wrench (electric or air) — speeds removal of lug nuts and stubborn bolts
- Why required: Makes removing seized bolts easier; reduces physical effort.
- How to use: Use appropriate sockets, short bursts, and avoid over-torquing reinstallation — finish with a torque wrench.
- Torque angle gauge or torque stick (for some tightening methods)
- Why required: Some bolts need a torque + angle specification.
- How to use: Follow manual steps: torque to initial value then turn specified angle.
- Transmission jack or engine hoist
- Why required: Safely supports and lowers a heavy transmission during removal.
- How to use: Center the transmission on the jack, secure with straps, lower slowly in a controlled way.
- CV axle puller / slide hammer or hub puller
- Why required: Some axles are pressed in and need a puller to remove without damage.
- How to use: Attach to hub/axle and use controlled pulls; follow puller instructions.
- Snap ring pliers
- Why required: To remove/install snap rings in CVs or differentials.
- How to use: Compress/expand ring evenly, slowly release when seating ring.
- Bearing race/seal driver or socket set (various sizes)
- Why required: To install seals and bearings without damage.
- How to use: Drive seals squarely using correct diameter driver to avoid warping.
- Hydraulic press (or shop with one)
- Why required: To press bearings on/off shafts during differential or wheel bearing replacement.
- How to use: Press slowly, support parts squarely, use proper adapters.
- Clutch alignment tool (for manual transmission clutch replacement)
- Why required: Aligns disc to pilot bearing for correct reinstallation of the transmission.
- How to use: Insert tool through clutch disc and pressure plate, center on pilot bearing before torquing bolts.
- Dial indicator (for endplay/shaft runout checks)
- Why required: To check bearing endplay and backlash when rebuilding differentials/transmissions.
- How to use: Mount on a rigid base and measure movement per manual spec.

- Basic diagnostic checks for drivetrain problems (how to inspect, what tools to use)
- Visual inspection of boots and seals
- Tools: flashlight, mirror, gloves.
- What to look for: Torn CV boots, leaking seals at transmission/diff, grease flinging.
- Why: Torn boots allow contamination, destroying CV joints quickly.
- Check for play in joints and bearings
- Tools: pry bar, wheel off and grab hub, rotate & rock hub.
- What to look for: Excessive play or grinding indicates worn wheel bearings, U-joints, or CV joints.
- Drive and listen for noises
- Tools: test drive, listening carefully for clicking on turns, humming at speed, clunks on acceleration.
- What they mean: Clicking on turns = outer CV joint. Humming = wheel bearing or differential gear wear. Clunk = U-joint, driveshaft slip yoke, or worn mount.
- Fluid checks
- Tools: fluid pan, funnel, dipstick (if equipped), rags.
- What to look for: Low fluid, burnt smell, metal particles in fluid (indicates internal wear).
- Why: Low or dirty fluid causes overheating and wear in transmission/differential.
- Shifting behavior (manual or automatic)
- Tools: driving test, feel for clutch engagement and gear selection.
- What to look for: Gear grinding, slipping, delayed engagement—may point to clutch or transmission issues.

- Common repairs you can do as a beginner (step overview + tools needed + why replacement might be required)
- Replace CV axle (outer CV joint or entire axle shaft)
- Symptoms: Loud clicking during turns, torn boot leaking grease, vibration during acceleration.
- Tools needed: basic socket set, breaker bar, torque wrench, jack & jack stands, pry bar, hammer, possibly axle puller.
- Why replace: Outer CV joint wear leads to failure and loss of drive; torn boot allows contamination.
- How (high-level): Remove wheel, remove axle nut, separate hub/knuckle, pry axle from trans/diff or pop out from hub, install new axle, torque to spec, refill any lost fluid if necessary.
- Important notes: Use correct torque on axle nut and wheel; some axles are pressed and need puller—if you feel unsure, get help.
- Replace U-joint or center support bearing (rear driveshaft)
- Symptoms: Clunking, vibration at certain speeds, visible play on U-joint.
- Tools needed: socket set, punch/drift, hammer, snap ring pliers, grease, possibly bearing press or bench vise.
- Why replace: Worn U-joints cause vibration and can fail catastrophically.
- How (high-level): Remove driveshaft, remove old U-joint retaining clips, press/drift out caps, press in new caps and clips, reinstall driveshaft and torque bolts.
- Important notes: Keep driveshaft balanced and mark orientation before removal.
- Replace wheel bearing (front hub)
- Symptoms: Humming or growling that changes with speed, play in hub.
- Tools needed: socket set, breaker bar, hammer, hub puller, bearing press or hub-to-knuckle replacement hub, torque wrench.
- Why replace: Worn bearings cause noise and can lock up, causing danger.
- How (high-level): Remove wheel and hub assembly, press out old bearing, press in new bearing or replace complete hub assembly, reassemble and torque to spec.
- Important notes: Pressing bearings typically requires a press — buy a hub assembly (complete unit) if you want to avoid press work.
- Change transmission/differential/transfer case fluids and seals
- Symptoms: Routine service, fluid contamination, leaks.
- Tools needed: fluid catch pan, funnel, ratchets, seal puller, seal driver, replacement fluid and gasket/seals.
- Why: Old fluid loses lubricating properties; seals leak causing low fluid and possible damage.
- How (high-level): Drain fluid, inspect for metal debris, replace drain/fill plug washers, replace seals if leaking, refill to correct level per manual.
- Important notes: Use specified fluid type and torque drain/fill plugs correctly.
- Replace transmission or engine mounts
- Symptoms: Excessive engine/transmission movement, clunks during acceleration or shifting.
- Tools needed: socket set, floor jack with block of wood to support engine/transmission, torque wrench.
- Why replace: Worn mounts allow movement that stresses driveline components.
- How (high-level): Support engine/transmission, remove mount bolts, replace mount, torque bolts to spec.

- Complex jobs (you can try but consider shop help or renting specialty tools)
- Clutch replacement (manual)
- Why complex: Requires removing the transmission (heavy), alignment of clutch disc, possible resurfacing or replacement of flywheel.
- Tools required: transmission jack, clutch alignment tool, torque wrench, possibly an engine support bar.
- Replacement parts commonly needed: clutch kit (disc, pressure plate, release bearing), pilot bearing, possibly flywheel resurfacing or replacement.
- Why replace parts: Slipping, worn friction material, noise, or failing release bearing.
- Safety note: If you attempt, follow service manual step-by-step and torque specs; consider a helper.
- Transmission removal / rebuild
- Why complex: Many connections, heavy assembly, precise reassembly and torque specs, specialized tools (transmission jack, alignment tools).
- Parts possibly required: seals, gaskets, bearings, synchros, input/output shafts — diagnose before replacing.
- Recommendation: For internal transmission faults, consider professional rebuild unless you have access to tools and service manual.
- Differential overhaul (ring/pinion, bearings)
- Why complex: Requires setting gear backlash and preload with precise shims, dial indicator, and torque specs.
- Tools required: dial indicator, torque wrench, bearing puller/press.
- Recommendation: If differential internals are damaged, this usually requires a machine shop or experienced mechanic.

- How to approach a repair job as a complete beginner (step sequence)
- Start with inspection and simple fixes: check fluids, boots, mounts, and do preventive services (fluids, seals).
- Tackle bolt-on parts first (axles, U-joints, mounts, seals) — these are achievable with basic tools.
- Always get the factory service manual or a quality aftermarket manual for step-by-step diagrams and torque specs.
- If a job requires a press, transmission jack, or precise measurement tools (dial indicator), rent tools or use a shop; don’t jury-rig.
- Keep organized: label bolts and parts, take photos during disassembly, and work in a clean, well-lit area.

- Replacement parts likely needed and why (common parts on a Delica L300)
- CV axle assembly or CV joint boots — torn boots lead to failed joints; replace axle if joint noisy or entire boot/axle if damaged.
- U-joints — wear causes vibration and can break; replacement is cheap and straightforward.
- Wheel bearings or hub assembly — humming/noise or play requires replacement to avoid failure.
- Transmission/differential/transfer case fluid and seals — maintenance prevents internal wear; leaking seals must be replaced.
- Clutch kit (disc, pressure plate, release bearing, pilot bearing) — if slipping, chattering, or hard shifting.
- Mounts (engine/transmission) — replace if cracked or allowing excessive movement.
- Driveshaft center support bearing — if vibration or play in the center support, replacement needed.

- Final checks and test after repairs
- Double-check all fasteners against torque specs from the manual.
- Refill fluids to exact types and levels specified.
- Test drive slowly to verify elimination of noises/vibrations, re-check for leaks and torque of wheels after a short drive.
- Re-inspect jack stands and tools, store removed parts and fluids safely and dispose of old fluids at a recycling center.

- Quick troubleshooting guide (very short)
- Clicking on turns → likely outer CV joint or torn boot.
- Humming that increases with speed → wheel bearing or differential gear wear.
- Clunk on acceleration → U-joint, driveshaft slip yoke, or worn mount.
- Gear slipping or grinding → clutch (manual) or internal transmission problem (automatic requires professional attention).

- Final note (important)
- This is practical guidance but not a substitute for the factory service manual or professional training. If you ever feel unsure or encounter heavy, risky disassembly (transmission/differential removal, pressing bearings), stop and get professional help or rent proper tools.
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