Mitsubishi L200. Manual — part 365
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-75
TRANSFER
DISASSEMBLY AND REASSEMBLY
M1233006700674
AK602084AC
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
19
20
21
22
23
24
25
26
27
28
35 ± 6 N·m
35 ± 6 N·m
35 ± 6 N·m
35 ± 6 N·m
11 ± 1 N·m
35 ± 6 N·m
35 ± 6 N·m
1
11 ± 1 N·m
11 ± 1 N·m
11 ± 1 N·m
29
30
31
32
17
18
19 ± 3 N·m
Apply gear oil to
all moving parts
before installation.
Removal steps
1.
Vacuum hose
>>X<<
2.
4LLC switch
3.
Gasket
4.
Steel ball
>>X<<
5.
2WD switch
6.
Gasket
7.
Steel ball
>>X<<
8.
Center differential lock switch
9.
Gasket
10. Steel ball
>>X<<
11. 4H switch
12. Gasket
13. Steel ball
>>X<<
14. 2WD/4WD switch
15. Gasket
16. Steel ball
17. Clip
18. Harness bracket
>>W<<
19. Transfer case cover
>>V<<
20. Shift rail drive gear
>>V<<
21. Shift rail drive gear
22. Dust seal guard
23. Dynamic damper
24. Vehicle speed sensor
25. O-ring
26. Rear output sensor
27. O-ring
28. Front output sensor
29. O-ring
>>U<<
30. Shift actuator
31. O-ring
>>U<<
32. Main shaft rail
Removal steps (Continued)
AK602085
33
34
35
36
37
38
39
40
41
42
43
44
46
47
48
49
50
51
52
53
64
65
66
67
68
69
54
55
56
57
58
59
60
61
62
63
35 ± 6 N·m
35 ± 6 N·m
5.0 ± 1.0 N·m
70
71
72
73
AC
45
21 ± 4 N·m
Apply gear oil to
all moving parts
before installation.
Removal steps
>>T<<
33. Rear cover
>>S<<
34. Oil seal
35. Snap ring
36. Sensor rotor
37. Steel ball
>>R<<
38. Oil guide
>>Q<<
39. Spacer
40. Snap ring
>>P<<
41. Snap ring
42. Transmission wiring harness
protector
43. Connector bracket
44. Connector bracket
45. Connector bracket
46. Clip
47. Connector bracket
>>O<<
48. Chain cover
>>N<<
49. Rear output shaft
50. O-ring
51. Needle bearing
52. Snap ring
53. Center differential planetary
carrier
54. Viscous coupling
<<A>>
>>M<<
55. Chain
<<A>>
>>M<<
56. Front output shaft
>>M<<
57. Drive sprocket
58. Needle bearing
59. Synchronizer inner ring
60. Synchronizer inner cone
61. Synchronizer outer ring
62. Synchronizer inner spring
>>K<<
63. Snap ring
>>K<<
64. 2-4WD clutch
<<A>>
>>K<<
65. Sun gear
66. Needle bearing
67. Wave spring
68. 2-4WD clutch sleeve
69. 2-4WD shift fork
70. Spacer
71. Steel ball
>>H<<
72. Snap ring
73. Differential lock hub
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-76
Removal steps (Continued)
AK602086
19 ± 2 N·m
35 ± 6 N·m
35 ± 6 N·m
74
75
76
77
78
80
79
81
82
83
84
85
86
87
88
89
90
91
AC
Apply gear oil to
all moving parts
before installation.
Removal steps
74. Harness bracket
>>G<<
75. Transfer case plate
76. Needle bearing
77. Countershaft gear
>>F<<
78. Spacer
>>E<<
79. H-L shift fork
>>E<<
80. H-L clutch sleeve
>>D<<
81. Snap ring
82. H-L clutch hub
83. Low speed gear
84. Needle bearing
>>C<<
85. Rear bearing retainer
86. Transfer drive shaft
87. Dust seal guard
>>B<<
88. Oil seal
<<B>>
>>A<<
89. Oil pool cover
90. Oil guide
91. Transfer case
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-77
Removal steps (Continued)
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-78
DISASSEMBLY SERVICE POINTS
<<A>> CHAIN / FORNT OUTPUT SHAFT / SUN GEAR REMOVAL
AK602087
Remove the chain, front output shaft and sun gear as
a set from the transfer case.
<<B>> OIL POOL COVER REMOVAL
CAUTION
The oil pool cover normally does not require dis-
assembly. Once it is removed, the transfer case
cannot be reused.
AK602088AC
Unstake the positions shown in the illustration to
remove the oil pool cover.
ADJUSTMENT BEFORE REASSEMBLY
Spacer selection for adjustment of countershaft gear
end play. (Refer to adjustment of transfer - spacer
selection for adjustment of countershaft gear end
play
)
RESASSEMBLY SERVICE POINTS
>>A<< OIL POOL COVER INSTALLATION
AK602089AC
5 mm
1.9 mm
Install the oil pool cover on a new transfer case.
Stake the projecting portions of the transfer so that
the dimensions will be as illustrated.
>>B<< OIL SEAL INSTALLATION
AK602090AC
MB990938
MB990932
1. Use special tools to install the oil seal.
• Handle (MB990938)
• Installer adapter (MB990932)
2. Apply the specified grease to the lip of oil seal.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
>>C<< SEAL BOLT INSTALLATION
AK602091AC
1. Apply the specified sealant to the threads.
Specified sealant:
3M STUD locking No. 4170 or equivalent
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