Mitsubishi Montero Sport (2004+). Manual — part 395

TRANSFER

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23B-83

>>U<<DETECTION SWITCH INSTALLATION
Install with care. Do not make a mistake when locating each
switch.

INSPECTION

M1233013400073

.

TRANSFER SWITCH,LOCK SWITCH AND LOCK RAIL
SWITCH
Check for the continuity between the connector terminal and
switch body.

.

LOW SWITCH
Check for the continuity between the connector terminal and
switch body.

DETECTION SWITCH
NAME

CONNECTOR COLOR

A

LOCK Brown

B

LOCK RAIL

Brown

C

TRANSFER

White

D

LOW

White

AK101125

A

B

C

D

AB

SWITCH STATE

CONTINUITY

Switch end pressed

No

Switch end released

Yes

SWITCH STATE

CONTINUITY

Switch end pressed

Yes

Switch end released

No

AKX00182

TRANSFER CASE PLATE

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23B-84

TRANSFER CASE PLATE

DISASSEMBLY AND ASSEMBLY

M1233024200051

Required Special Tools:

• MB990938: Handle

• MB990936: Installer Adapter

ASSEMBLY SERVICE POINTS

.

>>A<<OIL SEAL INSTALLATION
1. Use special tools MB990938 and MB990936 to install the oil

seal.

2. Apply Mitsubishi genuine grease part number 0101011 or

equivalent to the lip of the oil seal.

.

AKX00438

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

4

5

6

1

2

3

20 ± 3 N·m
14 ± 2 ft-lb

AD

DISASSEMBLY STEPS

>>B<<

1.

BOLT

2.

BEARING RETAINER

3.

TRANSFER INPUT GEAR

>>A<<

4.

OIL SEAL

5.

BAFFLE PLATE

6.

TRANFER CASE PLATE

DISASSEMBLY STEPS (Continued)

AKX00216

MB990938

MB990936

AB

INPUT GEAR

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23B-85

>>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.

INPUT GEAR

DISASSEMBLY AND ASSEMBLY

M1233015100067

Required special tools:

• MD998801: Bearing Remover

• MD998812: Installer Cap

• MD998826: Installer Adapter

AKX00402

AK000422

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

1

2

3

AB

DISASSEMBLE STEPS

>>B<<

1.

SNAP RING

<<A>>

>>A<<

2.

BALL BEARING

3.

SNAP RING

DISASSEMBLE STEPS

INPUT GEAR

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23B-86

DISASSEMBLY SERVICE POINT

.

<<A>>BALL BEARING REMOVAL
Use special tool MD998801 to remove the ball bearing.

ASSEMBLY SERVICE POINTS

.

>>A<<BALL BEARING INSTALLATION
Use special tools MD998812 and MD998826 to install the ball
bearing.

.

>>B<<SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in the snap

ring groove of the transfer input gear.

2. Make sure that the transfer input gear bearing end play

meets the standard value.

Standard value: 0

− 0.06 mm (0 − 0.002 inch)

AKX00253

MD998801

AB

AKX00254

MD998812

MD998826

AB

AKX00255