Mitsubishi Montero Sport (2004+). Manual — part 394
TRANSFER
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AUTOMATIC TRANSMISSION OVERHAUL
23B-79
>>H<<INTERLOCK PLUNGER/CHAIN COVER
INSTALLATION
1. Insert the interlock plunger into a position where it does not
interfere with 2-4WD shift rail.
CAUTION
• Squeeze the sealant out evenly to apply it in an unbro-
ken, non-excessive quantity.
2. Apply sealant Mitsubishi genuine sealant Part number
MD997740 or equivalent to the chain cover, and then install
the chain cover.
.
>>I<<H-L SHIFT RAIL/SPRING PIN INSTALLATION
1. Insert the H-L shift rail from the H-L shift rail hole, paying
attention to the direction of the shift rail.
2. Align the spring pin holes on the shift rail with the shift fork.
Then tap in the spring pin so that the slit of the spring pin is
facing the shaft center of the shift rail.
.
>>J<<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 oil seal.
.
AKX00168
2 mm(0.1in)
DIAMETER
AB
AK000331
AB
H-L SHIFT RAIL
SLIT
AKX00170
MB990938
MB990929
AB
TRANSFER
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AUTOMATIC TRANSMISSION OVERHAUL
23B-80
>>K<<SPACER INSTALLATION
1. Measure projection A of the rear output shaft bearing and
depth B of the second stage of the rear cover.
2. Subtract A from B and let the answer be C. Select a spacer
so that the subtracted value will be the standard value
shown below.
Standard value: 0
− 0.1 mm (0 − 0.004 inch)
.
>>L<< OIL COVER INSTALLATION
Install the oil cover so that the oil hole shown in the illustration.
.
>>M<<REAR COVER INSTALLATION
CAUTION
• Squeeze the sealant out evenly to apply it in an unbro-
ken, non-excessive quantity.
Apply sealant Mitsubishi genuine sealant Part number
MD997740 or equivalent to the chain cover.
.
AKX00171
A
B
REAR COVER
SPACER
AB
AK000423
OIL HOLE
AB
OIL COVER
AKX00172
TRANSFER
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AUTOMATIC TRANSMISSION OVERHAUL
23B-81
>>N<<RETURN SPRING/SUPPORT PIN INSTALLATION
1. Insert the bent section of the return spring into the control
housing as shown.
2. Apply sealant 3M
ADD Part number 8672 or equivalent to
the support pin section as shown, and Mitsubishi genuine
adhesive Part number MB160450 or equivalent to the
threads.
3. Insert the support pin and install the nut.
.
>>O<<CONTROL HOUSING INSTALLATION
CAUTION
• Squeeze the sealant out evenly to apply it in an unbro-
ken, non-excessive quantity.
Apply sealant Mitsubishi genuine sealant Part number
MD997740 or equivalent to the control housing.
.
>>P<<SPACER INSTALLATION
Install the previously selected spacer (see ADJUSTMENT
BEFORE ASSEMBLY).
.
>>Q<<TRANSFER CASE PLATE INSTALLATION
1. Face the notched section of the input gears in the direction
shown in the illustration.
AKX00173
RETURN SPRING
AB
AKX00174
AK000033
2 mm (0.1 in)
DIAMETER
AC
AKX00178
NOTCHED
SECTION
COUNTER
SHAFT
AB
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-82
CAUTION
• Squeeze the sealant out evenly to apply it in an unbro-
ken, non-excessive quantity.
2. Apply Mitsubishi genuine sealant Part number MD997740 or
equivalent to the transfer case plate.
CAUTION
• The transfer case plate must be installed smooth and
straight to get a good seal.
3. Install the transfer case plate together with the input gear.
Slide the input gear tooth aligned in Step 1 along the tooth
space of the countershaft gear.
.
>>R<<SPEEDOMETER DRIVEN GEAR SLEEVE ASSEMBLY
INSTALLATION
Install the speedometer driven gear sleeve assembly into the
rear cover as shown in the illustration.
.
>>S<<SPRING INSTALLATION
Install the spring with its tapered end toward the ball.
.
>>T<<PLUG INSTALLATION
Apply sealant 3M
ADD Part number 8672 or equivalent to the
threads.
NOTE: The new plug is precoated with sealant, so sealant
does not need to be applied.
.
AKX00179
2 mm(0.1 in)
DIAMETER
AB
AK201070AB
MATING MARKS
AKX00181
AKX00177
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