Mitsubishi L200. Manual — part 342
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-77
>>W<< SPRING INSTALLATION
AK403513
Install the spring with its tapered end toward the ball.
>>X<< PLUG INSTALLATION
CAUTION
• Completely degrease the FIPG-applied sur-
face 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.
•
AK403514AB
Make sure the starting point and the ending
point are about the middle between the bolts.
Apply the sealant to the threads.
Specified sealant:
3M
™ ATD Part No. 8672 or equivalent
NOTE: The new plug is percolated with sealant, so
sealant does not need to be applied.
>>Y<< DETECTION SWITCH INSTALLATION
AK503496
A
B
C
D
E
F
AB
4
6
3
5
1
2
Install with care. Do not make mistake when locating
each switch.
Detection switch name
Connector
No. / Color
A
Center differential lock
detection switch
1 / Brown
B
2WD/4WD detection switch
2 / Black
C
Center differential lock
operation detection switch
4 / Blown
D
4WD operation detection switch 6 / Black
E
High/low detection switch
3 / white
F
4LLc detection switch
5 / White
ADJUSTMENT OF TRANSFER
M1233030900060
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.
AK403499AB
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.
AK305233
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-78
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 countershaft gear end play)
<Measurement using Plastigage>
AK403499AC
Plastigage
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.
AK402081
Plastigage
Spacer
AB
7. Measure the width of the crushed Plastigage at its
widest part using a scale printed on the Plastigage
package.
Standard value: 0
− 0.15 mm
(For countershaft gear end play)
INSPECTION
M1233013400114
<Easy select 4WD>
4WD OPERATION DETECTION SWITCH
AK500505
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− 2
Conductive
Switch end
released
1
− 2
Open
HIGH/LOW DETECTION SWITCH
AK500510
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-79
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− 2
Open
Switch end
released
1
− 2
Conductive
LOW DETECTION SWITCH
AK500511
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− 2
Open
Switch end
released
1
− 2
Conductive
<Super select 4WD>
CENTER DIFFERENTIAL LOCK DETECTION
SWITCH, 2WD/4WD DETECTION SWITCH,
CENTER DIFFERENTIAL LOCK OPERATION
DETECTION SWITCH, 4WD OPERATION DETEC-
TION SWITCH, HIGH/LOW DETECTION SWITCH
AK503422
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− Body earth
Open
Switch end
released
1
− Body earth
Conductive
4LLc DETECTION SWITCH
AK503422
Check for the continuity between the connector ter-
minals.
Switch
condition
Connector
terminals
Continuity
Switch end
pressed
1
− Body earth
Conductive
Switch end
released
1
− Body earth
Open
TRANSFER CASE PLATE
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-80
TRANSFER CASE PLATE
DISASSEMBLY AND REASSEMBLY
M1233024200222
AK700641
Apply automatic
transmission fluid
to all moving parts
before installation.
4
5
6
1
2
AB
19 ± 3 N·m
3
Disassembly steps
>>
B
<< 1.
Bolt
2.
Bearing retainer
3.
Transfer input gear
>>
A
<< 4.
Oil seal
5.
Baffle plate
6.
Transfer case plate
REASSEMBLY SERVICE POINT
>>A<< OIL SEAL INSTALLATION
1. Use socket wrench to install the oil seal.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
AKX00216
MB990938
MB990933
AD
2. Use special tools to install the oil seal.
• Installer bar (MB990938)
• Installer adapter (MB990933)
>>B<< BOLT INSTALLATION
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