Mitsubishi Montero Sport (2004+). Manual — part 393
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-75
Required Special Tools:
• MB990929:Installer Adapter
• MB990938:Handle
AK101102
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
70
60
61
62
63
64
65
66
69
68
67
71
AC
20 ± 2 N·m
14 ± 1 ft-lb
20 ± 2 N·m
14 ± 2 ft-lb
8.8 ± 1 N·m
78 ± 9 in-lb
DISASSEMBLY STEPS
60. OIL POOL COVER
61. SIDE COVER
62. SIDE COVER GASKET
>>D<<
63. SNAP RING
>>C<<
64. H-L CLUTCH HUB
65. LOW SPEED GEAR
66. NEEDLE BEARING
>>B<<
67. REAR BEARING RETAINER
68. TRANSFER DRIVE SHAFT
69. DUST SEAL GUARD
>>A<<
70. OIL SEAL
71. TRANSFER CASE
DISASSEMBLY STEPS
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-76
DISASSEMBLY SERVICE POINT
.
<<A>>H-L SHIFT RAIL/CHAIN COVER REMOVAL
NOTE: If the 2-4WD shift rail is at the 2WD position, the
chain cover cannot be removed because interlock is actu-
ated.
1. Shift the 2-4WD shift rail at the 4WD position.
2. Remove the chain cover, and then remove the H-L shift rail.
.
<<B>>REAR OUTPUT SHAFT/CHAIN/FRONT OUTPUT
SHAFT REMOVEAL
Remove the rear output shaft, chain and front output shaft as a
set.
ADJUSTMENT BEFORE ASSEMBLY
.
SPACER SELECTION FRO ADJUSTMENT OF COUNTER-
SHFT GEAR END PLAY
1. Place pieces of solder [approximately 10 mm (0.4 inch) in
length and 1.6 mm (0.06 inch) in diameter] in the transfer
case housing as shown.
2. Install the countershaft gear into the transfer case.
3. Install the transfer case plate and tighten the bolts.
4. Using a micrometer, measure the thickness of the crushed
solder. Based on the result, select a spacer which adjusts
the end play to the standard value shown below.
Standard value: 0
− 0.15 mm (0 − 0.006 inch)
NOTE: NOTE: If the solder is not crushed, repeat steps 1
and 2 using thicker solder.
AK000329
2-4WD SHIFT RAIL
AB
AK101119
AKX00164
SOLDER
AB
AKX00165
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-77
ASSEMBLY SERVICE POINTS
.
>>A<<OIL SEAL INSTALLATION
1. Use special tools MB990929 and MB990938 to install the oil
seal.
2. Apply Mitsubishi genuine grease Part number 0101011 or
equivalent to the lip of the oil seal.
.
>>B<< BOLT INSTALLATION
Apply Mitsubishi genuine sealant part number MD997740 or
equivalent to the threads.
NOTE: The new bolt is precoated with sealant, so sealant does
not need to be applied.
.
>>C<< H-L CLUTCH HUB INSTALLATION
Install the H-L clutch hub in the direction indicated by arrow.
.
>>D<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the H-L clutch
hub end play to the standard value.
Standard value: 0
− 0.08 mm (0 − 0.003 inch)
.
AKX00166
MB990938
MB990929
TRANSFER
CASE
AB
AKX00402
AK101120
TRANSMISSION
FRONT SIDE
INSTALLATION
DIRECTION
AB
AK101121
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-78
>>E<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the differential
lock hub end play to the standard value.
Standard value: 0
− 0.08 mm (0 − 0.003 inch)
.
>>F<<SPRING PIN INSTALLATION
1. Align the 2-4WD shift lug with the 2-4WD shift rail spring pin
hole.
2. Hammer in the spring valve so that the spring pin slit
matches the center of the shift rail shaft.
.
>>G<<FRONT OUTPUT SHAFT/CHAIN/REAR OUTPUT
SHAFT INSTALLATION
1. Make a white paint mark on the deep groove portions (three
places) of the 2-4WD synchronizer.
2. Make a white paint mark on the portions (three places) of
the 2-4WD synchronizer sleeve splines.
3. Place the chain in tight mesh with the 2-4WD synchronizer
and front output shaft sprockets.
4. With both sprockets spaced the farthest apart, install them
on the transfer case simultaneously.
.
AK101122
AK000330
SPRING PIN
AB
2-4WD SHIFT LUG
AK101123
AK101124
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