Mitsubishi L200. Manual — part 366

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-79

NOTE: The new bolt does not require sealant appli-
cation as it is precoated with sealant.

>>D<< SNAP RING INSTALLATION

AK602092

1. Select a proper snap ring so that the end play of

the H-L clutch hub will have the standard value,
and install the snap ring on the transfer drive
shaft.

Standard value: 0

− 0.08 mm

(For H-L clutch hub end play)

>>E<< H-L SHIFT FORK AND H-L CLUTCH
SLEEVE INSTALLATION

AK602093AC

H-L shift fork

1. Apply the specified grease to the H-L shift fork

shaft inserting portion, and install the H-L shift fork
and H-L clutch sleeve in combined state in the
transfer case.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>F<< SPACER INSTALLATION
Install the previously selected spacer (Refer to
ADJUSTMENT BEFORE REASSEMBLY.)

>>G<< TRANSFER CASE PLATE INSTALLATION

AK602095AC

1. Apply the specified grease to the illustrated

position of the H-L shift rail inserting portion of the
transfer case plate.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

AK602096AC

2. Face the notched portion of the input gear in the

illustrated direction (in the direction of the
countershaft gear bearing hole).

AK602097AC

3. Apply the specified sealant to the transfer case.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-80

CAUTION

If the sub gear does not readily come in mesh
with the countershaft gear, rote the transfer drive
shaft, etc. to securely engage it.
4. While making sure that the notched portion of the

input gear positioned in Step 2 is in alignment with
the gear portion of the countershaft, install the
transfer case palate.

>>H<< SNAP RING INSTALLATION

AK602098

Select a proper snap ring so that the end play of the
differential lock hub will have standard value, and
install it on the transfer drive shaft.

Standard value: 0

− 0.08 mm

(For differential lock hub end play)

>>I<< STEEL BALL AND SPACER INSTALLATION

AK602099AC

Steel ball

Install the steel ball in the illustrated position of the
transfer drive shaft and install the spacer with its oil
groove toward the chain cover.

>>J<< 2-4WD SHIFT FORK AND 2-4WD CLUTCH
SLEEVE INSTALLATION

AK602100AC

Apply the specified grease to the 2-4WD shift fork
shaft inserting position and install the 2-4WD shift
fork and 2-4WD clutch sleeve in combined state in
the transfer case.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>K<< SUN GEAR / 2-4WD CLUTCH HUB / SNAP
RING INSTALLATION

AK602101

1. Install the 2-4WD clutch hub on the sun gear.
2. Select the proper snap ring so that the end of play

of the 2-4WD clutch hub will have the standard
value, and install it on the sun gear.

Standard value: 0

− 0.08 mm

(For 2-4WD clutch hub end play)

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-81

>>L<< SYNCHRONIZER OUTER RING /
SYNCHRONIZER CONE / SYNCHRONIZER INNER
RING INSTALLATION

AK602102

1. Combine the synchronizer outer ring,

synchronizer cone and synchronizer inner ring,
press then against the drive sprocket, and
measure the dimension shown in the illustration.

Limit: 0.3 mm
(For clearance between synchronizer outer
ring and drive sprocket)

2. If the dimension is out of the limit value, replace

them with a synchronizer ring set.

3. Apply gear oil to the synchronizer outer ring and

synchronizer inner ring.

AK602103AC

4. Line up the notched portion of the 2-4WD clutch

hub with the projecting portion of the synchronizer
ring and install the ring on the 2-4WD clutch hub.

>>M<< DRIVE SPROCKET / FRONT OUTPUT
SHAFT / CHAIN INSTALLATION

AK602087

1. Set the chain in mesh with the drive sprocket and

front output shaft sprocket and install them in the
transfer case.

AK602104AC

2. Install the drive sprocket so that its illustrated

holes will mach the projecting portions of the
synchronizer cone.

>>N<< REAR OUTPUT SHAFT INSTALLATION

AK602105 AC

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>O<< CHAIN COVER INSTALLATION

AK602106 AC

1. Apply the specified grease to the indicated 2-4WD

shift rail inserting portion.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

2. Apply the specified sealant to the illustration of the

chain cover.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-82

>>P<< SNAP RING INSTALLATION

AK602107

1. Install the snap ring in the bearing groove of the

rear output shaft.

2. With the rear output shaft pressed against the

chain cover, measure the clearance between the
chain cover and snap ring.

3. Select a snap ring whose thickness is the

dimension of the measured clearance plus the
standard value.

Standard value: 0.12

− 0.24 mm

(For rear output shaft preload)

4. Remove the snap ring from the bearing groove of

the rear output shaft, install the selected snap
ring, and reinstall the removed snap ring in the
bearing groove of the rear output shaft.

>>Q<< SAPCER INSTALLTION

CAUTION

Measure the projection with the snap ring
installed.

AK602108

Projection

AC

1. With the output shaft pressed toward the chain

cover, measure the projection of the bearing from
the chain cover.

AK602109AC

Concave
pprtion

2. Measure the dimension of the rear cover concave

portion at the illustrated position.

Standard value: 0

− 0.12 mm

(For rear output shaft end play)

>>R<< OIL GUIDE INSTALLATION

AK602694

Oil guide

AB

Apply specified grease to the lip of the oil seal.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>S<< OIL SEAL INSTALLATION

AK602110AC

MB990938

MB990932

Use special tools to install the oil seal in the rear
cover.

• Installer adapter (MB990932)

• Handle (MB990938)