Mitsubishi L200. Manual — part 270
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-65
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
DISASSEMBLY AND REASSEMBLY
M1222010900020
AK503423
4
5
6
1
2
3
7
9
9
8
10
AB
Apply gear oil to
all moving parts
before installation.
Disassembly steps
>>
C
<< 1.
Snap ring
2.
2-4WD Synchronizer hub
3.
2-4WD Synchronizer spring
>>
B
<< 4.
Outer synchronizer ring
5.
Synchronizer cone
>>
A
<< 6.
Inner synchronizer ring
7.
Drive sprocket
8.
Bearing spacer
9.
Needle bearing
10. Front side gear
REASSEMBLY SERVICE POINTS
>>A<< INNER SYNCHRONIZER RING INSTALLA-
TION
AK503426AB
Apply oil the synchronizer ring cone surface before
installation.
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-66
>>B<<OUTER SYNCHRONIZER RING
INSTALLATION
AK503427AB
Apply oil the synchronizer ring cone surface before
installation.
>>C<<SNAP RING INSTALLATION
AK101272AD
Snap ring
Select and install the snap ring which adjusts the 2-
4WD synchronizer hub end play to standard value.
Standard value: 0
− 0.08 mm
INSPECTION
M1222011000020
SYNCHRONIZER RING
AK500672AB
CAUTION
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
1. Check to ensure that the clutch gear tooth surface
and cone surface are not damaged and broken.
AK503424
2. After applying oil to the taper portion on each
gear, press and fit the synchronizer ring by hand.
Confirm the synchronizer ring cannot be rotated.
AK503425
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
Limit: 0.3 mm
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-67
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
DISASSEMBLY AND REASSEMBLY
M1222010600041
AK503428
4
5
6
1
2
3
4
3
4
3
4
3
69 ± 10 N·m
AB
Apply gear oil to
all moving parts
before installation.
Disassembly steps
>>
A
<< 1.
Center differential case A
2.
Dowel pin
3.
Differential pinion
4.
Thrust washer
5.
Pinion shaft
6.
Center differential case B
REASSEMBLY SERVICE POINT
>>A<<CENTER DIFFERENTIAL CASE B INSTAL-
LATION
AK101274AD
Dowel pin
Dowel pin
Pay attention to the position of the dowel pins when
reassembling, and make sure that the match marks
on the outside circumference are in alignment.
H-L SHIFT FORK
MANUAL TRANSMISSION OVERHAUL <V5MB1>
22C-68
H-L SHIFT FORK
DISASSEMBLY AND REASSEMBLY
M1222009700022
AK500689AB
1
2
3
6
5
4
9.0 ± 2.0 N·m
Disassembly steps
>>
A
<<
1.
Return spring plug
2.
Return spring
3.
Return spring
4.
Select plunger
5.
Plunger boss
6.
High & low shift fork
REASSEMBLY SERVICE POINT
>>A<< RETURN SPRING PLUG INSTALLATION
AK500693
Return spring plug
AC
Plunger boss
Apply the sealant to the thread and screw the return
spring plug to be an even surface between the
plunger boss end face and the return spring plug.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
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