Mitsubishi L200. Manual — part 367
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-83
>>T<< REAR COVER INSTALLTION
AK602111AC
Apply the specified sealant to the illustration of the
chain cover.
Specified sealant:
Mitsubishi Part No. MD997740 or equivalent
>>U<< MAIN SHIFT RAIL AND SHIFT ACTUATOR
INSTALLATION
AK602695
50.5mm
Rod
extends
Vew A
A
B
A
AB
1. Contact a 12 voltage power supply across the
terminals of the actuator connector in a polarity
appropriate for causing the actuator motor to
move in the rod extending direction or retracting
direction until the amount of extension of the rod
is as indicated in the drawing.
Terminal A
Terminal B
Rod
movement
Power supply (+) Power supply (-)
Extension
Power supply (-)
Power supply (+) Retraction
AK602112AC
2. Apply the specified grease to the O-ring.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
3. Combine the main shift rail key with actuator key
and insert them in the transfer case.
>>V<< SHIFT RAIL DRIVE GEAR INSTALLATION
AK602113AC
Mark
Tird gear groove
Install the shift rail drive gear with its marked tooth in
mesh with the third gear groove of the each shift rail.
>>W<< TRANSFER CASE COVER INSTALLATION
AK602114AC
Apply specified sealant to the illustrated position of
the transfer case cover.
Specified sealant:
Mitsubishi Part No. MD997740 or equivalent
>>X<< SWITCH INSTALLATION
AK602115 AB
B
A
C
D
E
Install the switches as illustrated.
Mounting
position
Switch name
Tube
color
Connecto
r color
A
2WD/4WD
switch
Blue
Black
B
4LLC switch
Black
Brown
C
2WD switch
Black
Black
D
4H switch
Green
White
E
Center
differential lock
switch
Blue
Brown
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-84
ADJUSTMENT OF TRANSFER
M1233030900071
SPACER SELECTION FOR ADJUST-
MENT OF COUNTERSHAFT GEAR END
PLAY
<Measurement using a solder>
CAUTION
• If soft solder is not available, select the
spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard
value cannot be selected using soft solder,
select the spacer in accordance with Plasti-
gage method.
AK602094AC
Solder
1. Put solders (1.0 mm diameter, about 10 mm long)
in the illustrated positions of the transfer case
housing.
2. Install the countershaft gear into the transfer case.
3. Install the transfer case plate and tighten the bolts
to the specified torque of 35
± 6 N⋅m.
4. Remove the transfer case plate and the
countershaft gear, and then take out crushed
solders.
5. If the solders have not crushed, use thicker
solders (1.6 mm diameter, about 10 mm long) and
repeat steps 2 to 4.
AK602691
6. Measure the thickness of the crushed solder with
a micrometer and select a spacer that will provide
the standard value.
Spacer thickness: (T
− 0) to (T − 0.15)
T: The crushed solder thickness
Standard value: 0
− 0.15 mm
(For counter shaft gear end play)
<Measurement using plastigage>
AK602692
Plastigage
AB
1. Put plastigage (about 10 mm long) in the
illustrated positions of the transfer case housing.
2. Install the adjusting spacer having the minimum
thickness.
3. Install the countershaft gear into the transfer case.
4. Install the transfer case plate and tighten the bolts
to the specified torque of 35
± 6 N⋅m.
5. Remove the transfer case plate and the
countershaft gear, and then take out crushed
solders.
6. If the plastigages have not crushed, replace the
spacer with a thicker one and repeat steps 3 to 5.
AK602693
Plastigage
Spacer
AB
TRANSFER CASE PLATE
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-85
7. Measure the width of the crushed plastigage at its
widest part using a scale printed on the plastigage
package.
Spacer thickness: (T
− 0) to (T − 0.15)
T: The crushed solder thickness
Standard value: 0
− 0.15 mm
(For counter shaft gear end play)
TRANSFER CASE PLATE
DISASSEMBLY AND REASSEMBLY
M1233024200244
AK602116
2
3
4
5
6
19 ± 2 N·m
AC
1
Apply gear oil to
all moving parts
before installation.
Disassembly steps
>>B<<
1.
Seal bolt
2.
Bearing retainer
3.
Transfer input gear
>>A<<
4.
Oil seal
5.
Baffle plate
6.
Transfer case plate
Disassembly steps (Continued)
COUNTERSHAFT GEAR
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
23D-86
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
AK602117
MB990938
MB990933
AC
1. Apply specified grease to the lip of the oil seal.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
2. Use special tools to install the oil seal.
• Handle (MB990938)
• Installer adapter (MB990933)
>>B<< SEAL BOLT INSTALLATION
AK602091AC
Apply the specified sealant to the threads.
Specified sealant:
3M STUD Locking No. 4170 or equivalent
NOTE: The new bolt does not require sealant appli-
cation as it is precoated with sealant.
COUNTERSHAFT GEAR
DISASSEMBLY AND REASSEMBLY
M1233024000284
AK602118
1
2
3
4
5
6
AC
Apply gear oil to
all moving parts
before installation.
Disassembly steps
<<A>>
>>C<<
1.
Ball bearing
>>B<<
2.
Snap ring
>>A<<
3.
Spacer
<<B>>
>>A<<
4.
Roller bearing
<<B>>
>>A<<
5.
Inner race
6.
Counter shaft gear
Disassembly steps (Continued)
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