Mitsubishi Montero Sport (2004+). Manual — part 397
2-4WD SYNCHRONIZER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-91
INSPECTION
M1233014300024
.
SYNCHRONIZERRING AND SYNCHRONIZER CONE
Combine the inner and outer synchronizer rings and cone with
the drive sprocket and measure the dimension A limit, replace
them as set.
limit: 0.3 mm (0.12 inch)
AK101275AB
A
DRIVE
SPROCKET
OUTER
SYNCHRONIZER RING
SYNCHRONIZER
CONE
OUTER
SYNCHRONIZER
RING
CENTER DIFFERENTIAL CASE
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-92
CENTER DIFFERENTIAL CASE
DISASSEMBLY AND ASSEMBLY
M1233013900023
ASSEMBLY SERVICE POINTS
.
>>A<<CENTER DIFFERENTIAL INSTALLATION
Pay attention to the position of the dowel pins when reassem-
bling, and make sure that the match marks on the outside cir-
cumference are in alignment.
AK101273
4
5
6
1
2
3
4
3
4
3
4
3
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
69 ± 10 N·m
51 ± 7 ft-lb
AB
DISASSEMBLY STEPS
>>A<<
1.
CENTER DIFFERENTIAL CASE
FRONT
2.
DOWEL PIN
3.
PINION
4.
THRUST WASHER
5.
PINION SHAFT
6.
CENTER DIFFERENTIAL CASE
REAR
DISASSEMBLY STEPS (Continued)
AK101274
DOWEL PIN
DOWEL PIN
AB
REAR OUTPUT SHAFT
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-93
REAR OUTPUT SHAFT
DISASSEMBLY AND ASSEMBLY
M1233013600066
Required special tools
• MD998801: Bearing Remover
• MD998812: Installer Cap
• MD998814: Installer-200
• MD998823: Installer Adapter
AK101106
1
2
3
4
AB
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
DISASSEMBLY STEPS
>>B<<
1.
SNAP RING
<<A>>
>>A<<
2.
BALL BEARING
3.
VISCOUS COUPLING
4.
REAR OUTPUT SHAFT
DISASSEMBLY STEPS
REAR OUTPUT SHAFT
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-94
DISASSEMBLY SERVICE POINT
.
<<A>> BALL BEARING REMOVAL
Use special tool MD998917 to remove the ball bearing.
ASSEMBLY SERVICE POINTS
.
>>A<< BALL BEARING INSTALLATION
Use special tools MD998812, MD998814 and MD998824 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 rear output shaft.
2. Make sure that the rear output shaft bearing end play meets
the standard value.
Standard value: 0
− 0.08 mm (0 − 0.003 inch)
AK101110
MD998801
AB
AK101111
MD998812
MD998814
MD998823
AB
AK101112AB
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