Mitsubishi L200. Manual — part 267
AK503403AJ
20 ± 2 N·m
Apply gear oil to
all moving parts
before installation.
66
67
68
69
70
71
72
73
74
9.0 ± 1.0 N·m
75
Disassembly steps
>>
D
<<
66. Snap ring
>>
C
<<
67. H-L clutch hub
68. Low speed gear
69. Needle bearing
70. Rear bearing retainer
71. Transfer drive shaft
72. Oil pool cover
73. Dust seal guard
>>
A
<<
74. Oil seal
75. Transfer case
TRANSFER
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-53
DISASSEMBLY SERVICE POINTS
<<A>> H-L SHIFT RAIL REMOVAL
AK503405 AB
2-4WD shift rail
1. Fix the H-L shift rail at the high position.
2. Shift the 2-4WD shift rail at the 4WD position.
NOTE: If the 2-4WD shift rail is at the 2WD posi-
tion, the chain cover cannot be removed because
interlock is actuated.
<<B>> REAR OUTPUT SHAFT / CHAIN/FRONT
OUTPUT SHAFT REMOVAL
AK500492
Remove the rear output shaft, chain and front output
shaft as a set.
TRANSFER
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-54
<<C>> 2-4WD SYNCHRONIZER / CHAIN/FRONT
OUTPUT SHAFT REMOVAL
AK101119
Remove the 2-4WD synchronizer, chain and front
output shaft as a set.
ADJUSTMENT BEFORE REASSEMBLY
Spacer selection for adjustment of counter shaft end
play. (Refer to ADJUSTMENT OF TRANSFER -
SPACER SELECTION FOR ADJUSTMENT OF
COUNTER SHAFT END PLAY
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
AK403501 AC
MB990938
MB990931
Transfer case
1. Use special tools to install the oil seal.
• Installer adapter (MB990931)
• Installer bar (MB990938)
2. Apply the specified grease to the lip of oil seal.
Specified lubricant: Mitsubishi Part No.
0101011 or equivalent
>>B<< FRONT OUTPUT SHAFT / CHAIN / REAR
OUTPUT SHAFT INSTALLATION
AK500492
1. Engage the chain precisely with the sprocket of
the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch
sleeve. While passing them beside the 2-4WD
shift rail, install the front output shaft, and chain
and rear output shaft.
>>C<< H-L CLUTCH HUB INSTALLATION
AK503408
Installation
direction
Transfer front side
AB
Check that the H-L clutch hub is in the correct direc-
tion for installation.
>>D<< SNAP RING INSTALLATION
AK500493
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 H-L clutch hub end play meets
the standard value.
Standard value: 0
− 0.08 mm
TRANSFER
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-55
>>E<< SNAP RING INSTALLATION
AK503398
1. Install the thickest snap ring that can be fitted in
the snap ring groove of the transfer drive shaft.
2. Make sure that the differential lock hub end play
meets the standard value.
Standard value: 0
− 0.08 mm
>>F<< SPRING PIN INSTALLATION
AK503410
1. Align the e2-4WD shift lug with the 2-4WD shift
rail spring pin hole.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
>>G<< 2-4WD SYNCHRONIZER/CHAIN/FRONT
OUTPUT SHAFT INSTALLATION
AK101123
1. Make a white paint mark on the deep groove
portions (three places) of the 2-4WD
synchronizer.
2. Make a white paint mark on the portions (three
places) of the 2-4WD synchronizer sleeve splines.
AK101124
3. Place the chain in tight mesh with the 2-4WD
synchronizer and front output shaft sprockets.
4. With both sprockets spaced the farthest apart,
install them on the transfer case simultaneously.
>>H<< CHAIN COVER INSTALLATION
CAUTION
Squeeze the sealant out evenly to apply it in
an unbroken, non-excessive quantity.
AK403508AB
2 mm Diameter
1. Completely degrease the FIPG-applied surface so
that water and oil including the old sealant cannot
adhere to the surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply sealant to the chain cover, and then install
the chain cover.
Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent
>>I<< H-L CLUTCH SLEEVE INSTALLATION
AK500678AB
Identification groove
Installation
direction
TRANSFER
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-56
Check that the H-L clutch sleeve is in the correct
direction for installation.
>>J<< H-L SHIFT RAIL INSTALLATION
AK503411AB
H-L shift rail
Interlock plunger
H-L shift rail
2-4WD shift rail
2-4WD shift rail
1. Tilt the transfer case with the 2-4WD shift rail
downward as shown in the illustration.
2. Move the 2-4WD shift rail in the direction of the
arrow fully.
3. After making sure that the plunger is not exposed
out of the H-L shift rail hole in the transfer case,
install the H-L shift rail.
>>K<< SPRING PIN INSTALLATION
AK503412
1. Align the spring pin holes on the shift rail with the
shift fork. Then tap in the spring pin so that the slit
of the spring pin is facing the shaft center of the
shift rail.
>>L<< OIL SEAL INSTALLATION
AK403510AQ
MB990938
MB990932
<V5MB1-J-NEG, JER>
AK403510AR
MB990938
MB990929
<V5MB1-J-ND2, NEZ, PD2>
1. Use special tools to install the oil seal.
• Installer adapter (MB990932) <V5MB1-J-NEG,
JER>
• Installer adapter (MB990929) <V5MB1-J-ND2,
NEZ, PD2>
• Installer bar (MB990938)
2. Apply the specified grease to the lip of oil seal.
Specified lubricant: Mitsubishi Part No.
0101011 or equivalent
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