Mitsubishi Montero (1991+). Manual — part 292
4WD shift rail snap ring.
6) Assemble front output shaft assembly, chain and 2WD-4WD
synchronizer assembly. Align match marks made during disassembly. Link
chain tightly onto 2WD-4WD synchronizer and front output shaft
sprockets. Install both sprockets and chain to transfer case at same
time, while keeping them as far apart as possible.
7) Install center differential case assembly, rear output
shaft assembly needle bearings and rear output shaft assembly. Install
interlock plunger so it does not interfere with 2WD-4WD shift rail.
Evenly apply sealant to chain cover and install chain cover.
8) Install high-low shift rail through high-low shift rail
hole into shift fork. Align spring pin holes in high-low shift rail
and shift fork. Tap in spring pin so slit is facing shift rail shaft
center. Install and tighten high-low shift rail plug to specification.
See TORQUE SPECIFICATIONS.
9) Before installing front output shaft cover, measure
protrusion "A" of front output shaft rear bearing and recess "B" of
cover and calculate clearance. See Fig. 11. If clearance is greater
than .079" (2.00 mm), select and install spacer to bring clearance
within specification. If clearance is less than .079" (2.00 mm), use
wave spring alone. Apply sealant to both sides of gasket and install
gasket and cover. Apply Locking Adhesive (3M 4170 Stud Lock) to bolts
and tighten to specification. See TORQUE SPECIFICATIONS.
Fig. 11: Measuring Rear Output Shaft Bearing Clearance (Montero)
Courtesy of Mitsubishi Motor Sales of America.
10) Install rear output shaft ball bearing snap ring. Measure
clearance between chain cover and snap ring. Add .0008-.0039" (.02-.10
mm) to clearance measured and install spacer of similar thickness.
Install rear output shaft oil seal (apply grease to lip of seal).
Install rear cover oil seal (apply grease to lip of seal).
11) Before installing rear cover, snap ring and spacer
thicknesses must be determined. Measure protrusion of rear output
shaft bearing. Measure inset of both stages of cover. Subtract inset
recess from rear bearing protrusion. Select a snap ring which adjusts
difference between inset recess and rear bearing protrusion, and
spacer thickness to 0-.004" (0-0.10 mm). Evenly apply sealant to rear
cover and install cover. Tighten bolts to specification. Refer to the
TORQUE SPECIFICATIONS table.
12) Install speedometer gear, ensuring mating marks match
according to number of gear teeth. Install speedometer gear sleeve
clamp and tighten bolt to specification. See Fig. 10.
13) Apply sealant to poppet plug threads. Install poppet
steel balls, springs and poppet plugs and tighten to specification.
Install detection switches, steel balls and gaskets. See Fig. 12.
Install dynamic damper and tighten bolts to specification.
Fig. 12: Installation Of Detection Switches (Montero)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE
Application Ft. Lbs. (N.m)
Adapter-To-Transfer Bearing Retainer . . . ( 1) 14 (19)
Case Nuts & Bolts . . . . . . .. 22-31 (30-42)
Center Differential Case Bolts . . . . ... 48 (65)
Chain Cover Bolt . . . . . . ... 22-31 (30-42)
Detection Switch . . . . . . . . ( 1) 27 (36)
Drain Plug . . . . . . . . . 22-26 (30-35)
Dynamic Damper . . . . . . . . ... 52 (70)
High-Low Shift Rail Plug . . . . . . ( 1) 24 (33)
Interlock Plunger Plug . . . . . ( 1) 22-26 (30-35)
Lock Plate Bolts . . . . . . ... 11-16 (15-22)
Oil Dam Cover . . . . . . . . ( 1) 14 (19)
Oil Filler Plug . . . . . . . 22-26 (30-35)
Output Shaft Cover Bolt . . . . . 11-16 (15-22)
Poppet Plug . . . . . . . . .. ( 1) 27 (36)
Pulse Rotor Bolt . . . . . ... ( 2) 11-16 (15-22)
Rear Cover Bolt . . . . . . . 11-16 (15-22)
Rear Output Shaft Lock Nut . . . ... 74-96 (100-130)
Seal Plug . . . . . . . .. ( 2) 22-31 (30-42)
Speedometer Sleeve Clamp Bolt . . . .. 11-16 (15-22)
4WD Indicator Light Switch . . . . ... ( 2) 22 (33)
INCH Lbs. (N.m)
Pulse Generator Bolt . . . . .. ( 2) 89-106 (10-12)
Side Cover Bolt . . . . . . . . 71-89 (8-10)
(1) - Montero.
(2) - Ram-50.
WIRING DIAGRAMS
Fig. 13: Rear Differential Lock Circuit (Montero)
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