Mitsubishi Montero (2002-2004). Manual — part 544

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>>B<< 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.

.

>>C<< REAR BEARING RETAINER 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.

.

>>D<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the H-L clutch
hub end play to the standard value.

Standard value: 0

− 0.08 mm (0 − 0.003 inch)

.

>>E<< H-L SHIFT FORK/H-L CLUTCH SLEEVE
INSTALLATION
Apply MITSUBISHI genuine grease Part number 0101011 or
equivalent to the high-low shift fork lift inserting part at indicated
in drawing. Install the high-low shift fork and the high low clutch
sleeve in the combined state onto the transfer case.

.

AKX00211

MB990938

MB990932

AB

AKX00212

AKX00213

AKX00214

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>>F<< SPACER INSTALLATION
1. Place pieces of solder [approximately 10 mm (0.4 inch) in

length and 1.6 mm (0.06 inch) in diameter] in the transfer
case housing as shown.

2. Install the countershaft gear into the transfer case.
3. Install the transfer case plate and tighten the bolts.

4. Using a micrometer, measure the thickness of the crushed

solder. Based on the result, select a spacer which adjusts
the end play to the standard value shown below:

Standard value: 0

− 0.15 mm (0 − 0.006 inch)

NOTE: If the solder is not crushed, repeat steps 1 and 2
using thicker solder.

.

>>G<< TRANSFER CASE PLATE INSTALLATION
1. Apply MITSUBISHI genuine grease Part number 0101011 or

equivalent to the high-low shift rail inserting part indicated in
the drawing

2. Face the notched section of the input gears in the direction

shown in the illustration.

AKX00215

SOLDER

AB

AKX00165

AKX00217

AKX00218

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CAUTION

Squeeze the sealant out evenly to apply it in an unbroken,
non-excessive quantity.
3. Apply MITSUBISHI genuine sealant Part number

MD997740 or equivalent to the transfer case.

CAUTION

In case the sub-gear is difficult to engage the counter shaft
gear, install securely by rotating the transfer drive shaft
and such.
4. Install the transfer case plate together with the input gear.

Slide the input gear tooth aligned in Step 2 along the tooth
space of the countershaft gear.

.

>>H<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the differential
lock hub end play to the standard value.

Standard value: 0

− 0.08 mm (0 − 0.003 inch)

.

>>I<< STEEL BALL/SPACER INSTALLATION
Install the steel ball at the indicated location on the transfer
drive shaft, and then install so that the oil groove of spacer is
the chain cover side.

.

>>J<< 2-4WD SHIFT FORK/2-4WD CLUTCH SLEEVE
INSTALLATION
Apply MITSUBISHI genuine grease Part number 0101011 or
equivalent to 2-4WD shift fork shaft inserting part indicated in
drawing, and then install the 2-4WD shift fork and the 2-4WD
clutch sleeve in combined state on the transfer case.

.

AKX00219

AKX00220

AKX00221

STEEL BALL

AB

AKX00222

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>>K<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the 2-4WD clutch
hub end play to the standard value.

Standard value: 0

− 0.08 mm (0 − 0.003 inch)

.

>>L<< SYNCHRONIZER OUTER RING/SYNCHRONIZER
CONE/SYNCHRONIZER INNER RING INSTALLATION
1. Push the synchronizer outer ring, synchronizer corn and the

synchronizer inner ring into the drive sprocket in combined
state, and then measure the indicated dimension of the drive
sprocket and synchronizer outer ring.

LIMIT: 0.3 mm (0.012 inch)

2. In case that the value is out of limit, exchange as the

synchronizer ring set.

3. Combine the synchronizer outer ring, the synchronizer cone

and the synchronizer inner ring, and install them by mating
the notch of 2-4WD clutch hub and protrusion of the
synchronizer outer ring.

.

>>M<< DRIVE SPROCKET/FRONT OUTPUT SHAFT/CHAIN
INSTALLATION
1. Engage the chain to the drive sprocket and the sprocket of

front output shaft.

AKX00223

AKX00224

AKX00225