Mitsubishi Montero (2002-2004). Manual — part 542
TRANSFER
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AUTOMATIC TRANSMISSION OVERHAUL
23B-99
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<< FRONT OUTPUT SHAFT/CHAIN/REAR OUTPUT
SHAFT INSTALLATION
1. Engage the chain precisely with the sprocket of the rear
output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch sleeve.
While passing them beside the 2-4WD shift rail, install the
front output shaft, and chain and rear output shaft.
.
>>C<< 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.
.
>>D<< 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 unbroken,
non-excessive quantity.
2. Apply sealant MITSUBISHI genuine sealant Part number
MD997740 or equivalent to the chain cover, and then install
the chain cover.
.
AKX00166
MB990938
MB990929
TRANSFER
CASE
AB
AKX00163
AKX00167
2-4WD
SHIFT LUG
SPRING PIN
AB
TRANSFER
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AUTOMATIC TRANSMISSION OVERHAUL
23B-100
>>E<< 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.
.
>>F<< 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.
.
>>G<< 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
− 0.08 mm (0 − 0.003 inch)
.
AKX00169
SLIT
H-L
SHIFT
RAIL
AB
AKX00170
MB990938
MB990929
AB
AKX00171
A
B
REAR COVER
SPACER
AB
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AUTOMATIC TRANSMISSION OVERHAUL
23B-101
>>H<< REAR COVER INSTALLATION
CAUTION
Squeeze the sealant out evenly to apply it in an unbroken,
non-excessive quantity.
Apply sealant Mitsubishi genuine sealant Part number
MD997740 or equivalent to the chain cover.
.
>>I<< CONTROL HOUSING INSTALLATION
CAUTION
Squeeze the sealant out evenly to apply it in an unbroken,
non-excessive quantity.
Apply sealant Mitsubishi genuine sealant Part number
MD997740 or equivalent to the control housing.
.
>>J<< H-L SHIFT RAIL PLUG INSTALLATION
Apply sealant 3M
ä 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.
.
>>K<< PLUG INSTALLATION
Apply sealant 3M
ä 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.
.
AKX00172
2 mm(0.1 in)
DIAMETER
AB
AK000033
2 mm (0.1 in)
DIAMETER
AC
AKX00176
AKX00177
TRANSFER
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AUTOMATIC TRANSMISSION OVERHAUL
23B-102
>>L<< SPACER INSTALLATION
Install the previously selected spacer (see ADJUSTMENT
BEFORE ASSEMBLY).
.
>>M<< TRANSFER CASE PLATE INSTALLATION
1. Face the notched section of the input gears in the direction
shown in the illustration.
CAUTION
Squeeze the sealant out evenly to apply it in an unbroken,
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.
.
>>N<< SPRING INSTALLATION
Install the spring with its tapered end toward the ball.
AKX00178
NOTCHED
SECTION
COUNTER
SHAFT
AB
AKX00179
2 mm(0.1 in)
DIAMETER
AB
AKX00181
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