Mitsubishi L200. Manual — part 345

REAR OUTPUT SHAFT

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-89

<Super select 4WD>

AK101106

1

2

3

4

AC

Apply gear oil to
all moving parts
before installation.

Disassembly steps

>>

B

<<

1.

Snap ring

<<

B

>>

>>

A

<<

2.

Ball bearing

3.

Viscous coupling

4.

Rear output shaft

DISASSEMBLY SERVICE POINTS

<<A>> LOCK NUT REMOVAL

AK403516

1. Remove the lock nut from the shaft.

AK500495

MB991013

AB

2. Hold the drive sprocket in a soft-jaw vise.
3. Shift the clutch sleeve to the drive sprocket side.
4. Use special tool Power steering lock nut special

spanner (MB991013) to remove the lock nut.

REAR OUTPUT SHAFT

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-90

<<B>> BALL BEARING REMOVAL

AK403518 AC

MD998801

<Easy select 4WD>

AK101110AG

MD998917

<Super select 4WD>

1. Use special tool to support the ball bearing.

• Bearing remover (MD998801) <Easy select

4WD>

• Bearing remover (MD998817) <Super select

4WD>

2. Use a press to push at a rear end of the rear

output shaft, and then remove the radial ball
bearing.
NOTE: The bearing may fit loosely on the shaft,
so that removal is possible without using a press.

<<C>> CLUTCH HUB / STOPPER PLATE / BALL
BEARING REMOVAL

AK403520

MD998801

2-4WD clutch hub

Ball bearing

AB

1. Place special tool Bearing remover (MD998801)

so that the load is applied at the bearing.

2. Use a press to push at the rear end of the rear

output shaft, and then remove the clutch hub and
ball bearing.

NOTE: The clutch hub may fit loosely on the
shaft, so that removal is possible without using a
press.

REASSEMBLY SERVICE POINTS

>>A<< BALL BEARING / STOPPER PLATE
INSTALLATION

AK403521AD

MD998812

MD998814

MD998813

MD998829

MD998801

Ball bearing

<Easy select 4WD>

AK101111

MD998812

MD998814

MD998823

AD

<Super select 4WD>

1. Fit the ball bearing and stopper plate onto the rear

output shaft.

2. Use special tools to press in the ball bearing.

• Bearing remover (MD998801) <Easy select

4WD>

• Installer cap (MD998812)

• Installer-100 (MD998813) <Easy select 4WD>

• Installer-200 (MD998814)

• Installer adapter (MD998823) <Super select

4WD>

• Installer adapter (MD998829) <Easy select

4WD>

>>B<< SNAP RING INSTALLATION

AK101112

REAR OUTPUT SHAFT

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-91

1. Install the thickest snap ring that can be fitted in

the snap ring groove of the rear output shaft.

2. Make sure that the rear output shaft bearing end

play meets the standard value.

Standard value: 0

− 0.08 mm

(For rear output shaft end play)

>>C<< CLUTCH HUB INSTALLATION

AK500686AB

MD998812

MD998801

MD998813

MD998814

MD998821

2-4WD clutch hub

Installation
direction

1. Confirm the clutch hub installation direction, and

fit onto the rear output shaft.

2. Use special tools press in the clutch hub.

• Bearing remover (MD998801)

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer-200 (MD998814)

• Installer adapter (MD998821)

NOTE: The clutch hub may fit loosely on the shaft,
so that installation is possible without using a
press.

>>D<< CLUTCH SLEEVE INSTALLTION

AK500685

Installation
direction

AB

Check that the clutch sleeve is in the correct direc-
tion for installation.

>>E<< BALL BEARING INSTALLATION

AK403526AD

MD998812

MD998814

MD998821

MD998801

Ball bearing

1. Use special tools to install the radial ball bearing.

• Bearing remover (MD998801)

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (MD998821)

NOTE: The ball bearing may be fitted loosely on
the shaft, so that installation is possible without
using a press

>>F<< LOCK NUT INSTALLTION

AK500495

MB991013

AB

1. Hold the drive sprocket in a soft-jaws vise.
2. Shift the clutch sleeve to the drive sprocket side.
3. Using special tool Power steering lock nut special

spanner (MB991013) tighten the lock nut to the
specified torque 255

± 10 N⋅m.

AK403516

4. Stake the two places of the lock nut as shown in

illustration.

FRONT OUTPUT SHAFT

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-92

INSPECTION

M1233013700052

SYNCHRONIZER OUTER RING/SYN-
CHRONIZER CONE/SYNCHRONIZER
INNER RING INSTALLATION

AK403556

1. Push the synchronizer outer ring, synchronizer

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

Limit: 0.3mm
(For synchronizer ring clearance)

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

synchronizer ring set.

FRONT OUTPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1233006100081

AK700646

Apply gear oil to
all moving parts
before installation.

1

2

3

AB

Disassembly steps

<<

A

>>

>>

B

<<

1.

Ball bearing

<<

A

>>

>>

A

<<

2.

Ball bearing

3.

Front output shaft

Disassembly steps (Continued)