Mitsubishi Montero (2002-2004). Manual — part 541
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-95
TRANSFER
DISASSEMBLY AND ASSEMBLY
M1233013300021
<PART TIME 4WD>
AK201404AB
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
34 ± 5 N·m
25 ± 4 ft-lb
34 ± 5 N·m
25 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
18 ± 3 N·m
13 ± 2 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
DISASSEMBLY STEPS
1.
2-4WD DETECTION SWITCH
2.
GASKET
3.
H-L DETECTION SWITCH
4.
GASKET
5.
STEEL BALL
>>K<<
6.
PLUG
>>N<<
7.
SPRING
8.
STEEL BALL
>>K<<
9.
PLUG
>>N<<
10. SPRING
11. STEEL BALL
>>K<<
12. PLUG
>>K<<
13. PLUG
14. DUST SEAL GUARD
15. DYNAMIC DAMPER
16. VEHICLE SPEED SENSOR
DISASSEMBLY STEPS
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-96
AK201405
18 ± 3 N·m
13 ± 2 ft-lb
32 ± 2 N·m
24 ± 1 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
32 ± 2 N·m
24 ± 1 ft-lb
17
18
19
20
21
22
23
24
25
26
27
28
29
AB
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
DISASSEMBLY STEPS
>>M<<
17. TRANSFER CASE PLATE
18. NEEDLE BEARING
19. COUNTERSHAFT GEAR
>>L<<
20. SPACER
>>K<<
21. PLUG
>>J<<
22. H-L SHIFT RAIL PLUG
23. LOW SWITCH
24. GASKET
>>I<<
25. CONTROL HOUSING
>>H<<
26. REAR COVER
>>G<<
27. SPACER
>>F<<
28. OIL SEAL
>>E<<
29. SPRING PIN (H-L SHIFT FORK)
DISASSEMBLY STEPS
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-97
Required Special Tools:
• MB990929: Installer Adapter
• MB990938: Handle
AK000016
34
35
36
33
32
31
37
38
39
40
44
45
46
41
42
47
48
30
43
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
AB
35 ± 6 N·m
26 ± 4 ft-lb
39
DISASSEMBLY STEPS
<<A>>
>>E<<
30. H-L SHIFT RAIL
<<A>>
>>D<<
31. CHAIN COVER
32. H-L SHIFT FORK
33. H-L CLUTCH SLEEVE
>>D<<
34. INTERLOCK PLUNGER
>>C<<
35. SPRING PIN
36. 2-4WD SHIFT LUG
37. DISTANCE PIECE
38. E-CLIP
39. SPRING SEAT
40. SPRING
41. 2-4WD SHIFT RAIL
42. 2-4WD SHIFT FORK
<<B>>
>>B<<
43. REAR OUTPUT SHAFT
<<B>>
>>B<<
44. CHAIN
<<B>>
>>B<<
45. FRONT OUTPUT SHAFT
47. DUST SEAL GUARD
>>A<<
48. OIL SEAL
49. TRANSFER CASE
DISASSEMBLY STEPS
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-98
DISASSEMBLY SERVICE POINT
.
<<A>> H-L SHIFT RAIL/CHAIN COVER REMOVAL
NOTE: If the 2-4WD shift rail is at the 2WD position, the
chain cover cannot be removed because interlock is actu-
ated.
1. Shift the 2-4WD shift rail at the 4WD position.
2. Remove the chain cover, and then remove the H-L shift rail.
.
<<B>> REAR OUTPUT SHAFT/CHAIN/FRONT OUTPUT
SHAFT REMOVAL
Remove the rear output shaft, chain and front output shaft as a
set.
ADJUSTMENT BEFORE ASSEMBLY
.
SPACER SELECTION FRO ADJUSTMENT OF COUNTER-
SHFT GEAR END PLAY
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.
AKX00162
2-4WD SHIFT RAIL
AB
AKX00163
AKX00164
SOLDER
AB
AKX00165
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