Mitsubishi Montero (2002-2004). Manual — part 545

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23B-111

CAUTION

Then engage the indicated hole of drive sprocket to the
protrusion of the synchronizer cone.

2. Install the chain, the drive sprocket and the front output shaft

onto the transfer case in combined state.

.

>>N<< REAR OUTPUT SHAFT INSTALLATION
Apply MITSUBISHI genuine grease Part number 0101011 or
equivalent to the indicated O-ring, and then install the rear out-
put shaft.

.

>>O<< CHAIN COVER INSTALLATION
1. Apply MITSUBISHI genuine grease Part number 0101011 or

equivalent to the indicated 2-4WD shift rail insertion part.

2. Apply sealant MITSUBISHI genuine sealant Part number

MD997740 or equivalent to the chain cover, and then install
the chain cover.

AKX00227

AKX00226

AKX00228

AKX00229

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23B-112

CAUTION

Squeeze the sealant out evenly to apply it in an unbroken,
non-excessive quantity.

.

>>P<< SNAP RING INSTALLATION
1. Install the snap ring onto the bearing groove of the rear

output shaft.

2. Measure the clearance between the chain cover and snap

ring while pushing the rear output shaft to chain cover side.

3. Select the snap ring of a value which the standard value is

added to the measured clearance value.

Standard value: 0

− 12 − 0.24 mm (0.005 − 0.009 inch)

4. Remove the snap ring of the bearing groove of the rear

output shaft, and install the selected snap ring. Then install
again the snap ring on the bearing groove of the rear output
shaft.

.

>>Q<< SPACER INSTALLATION

CAUTION

Then, measure it with the snap ring installed.
1. Measure the protrusion amount A of bearing from the chain

cover while pushing the rear output shaft to the chain cover
side.

2. Measure the depression B at indicated part of the rear cover.
3. Calculate the clearance between the bearing and rear cover

by subtracting the measurement value A from measurement
value B of the procedure 2, and then select and install the
spacer so that the clearance is the standard value.

Standard value: 0

− 0.12 mm (0 − 0.005 inch)

AKX00230

AKX00231

AKX00232

A

AB

AKX00233

B

AB

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>>R<< OIL SEAL INSTALLATION
1. Use special tools MB990932 and MB990938 to install the oil

seal.

2. Apply MITSUBISHI genuine grease Part number 0101011 or

equivalent to the lip of the oil seal.

.

>>S<< 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, and then install the
rear cover.

.

>>T<< MAIN SHIFT RAIL/SHIFT ACTUATOR INSTALLATION
1. Apply MITSUBISHI genuine grease Part number 0101011 or

equivalent to the O-ring at indicated location.

2. Insert the combination of the key of the main shift rail and

the key of the actuator into the transfer case.

.

AKX00234

MB990938

MB990932

AB

AKX00235

AK201503 AB

Z

Z

A

B

50.5 mm

AKX00236

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>>U<< SHIFT RAIL DRIVE GEAR INSTALLATION
Install so that the mating mark of the shift rail drive gear
engages 3 teeth of each shift rail drive gear.

.

>>V<< TRANSFER CASE 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 transfer case, and then install
the transfer case cover.

.

>>W<< 2-4WD DETECTION SWITCH/4H DETECTION
SWITCH/CENTER DIFFERENTIAL LOCK DETECTION
SWITCH/2WD DETECTION SWITCH/4LLC DETECTION
SWITCH INSTALLATION
Install with care. Do not make a mistake when locating each
switch.

AKX00237

MARK

THREE TEETH

AB

AKX00238

DETECTION
SWITCH NAME

TUBE COLOR

CONNECTOR
COLOR

A

4LLC Black

Brown

B

2WD

Black

Black

C

CENTER
DIFFERENTIAL
LOCK

Blue

Brown

D

4H

Blue

White

E

2-4WD

Blue

Black

AKX00239

E

A

D

B

C

AB