Mitsubishi L200. Manual — part 268

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-57

>>M<< SPACER INSTALLATION

AK403504AJ

Rear cover

Spacer

A

B

<V5MB1-J-NEG, JER>

AK503414AJ

Rear cover

<V5MB1-J-ND2, NEZ, PD2>

Spacer

A

B

1. Measure projection A of the rear output shaft

bearing and depth B of the second stage of the
rear cover.

2. Subtract A from B and let the answer be C. Select

a spacer so that the subtracted value will be the
standard value shown below.

Standard value:

0

− 0.1 mm <V5MB1-J-NEG, JER>

0.025

− 0.150 mm <V5MB1-J-ND2, NEZ, PD2>

>>N<< OIL COVER INSTALLATION

AK403729

AC

Oil hole

Oil cover

In case of <V5MB1-J-NEG, JER> type, install the oil
cover so that the oil hole shown in the illustration.

>>O<< REAR COVER INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in

an unbroken, non-excessive quantity.

AKX00172

2 mm
Diameter

AC

1. Completely degrease the FIPG-applied surface 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.

2. Apply the sealant to the chain cover.

Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent

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

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MANUAL TRANSMISSION OVERHAUL <V5MB1>

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>>Q<< COUNTER SHAFT GEAR INSTALLATION

AK503394AB

Notched selection

Input gear

Counter shaft

1. Turn the input gear’s notched selection surface

toward the counter shaft mounting surface. then
install the counter shaft.

>>R<< TRANSFER CASE PLATE INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in

an unbroken, non-excessive quantity.

AK403617AC

2 mm Diameter

1. Completely degrease the FIPG-applied surface 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.

2. Apply the sealant to the transfer case plate.

Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent

CAUTION

The transfer case plate must be installed

smooth and straight to get a good seal.
3. Install the transfer case plate together with the

input gear and countershaft.

>>S<< SPEEDOMETER DRIVEN GEAR SLEEVE
ASSEMBLY INSTALLATION

AK503942AB

Mating marks

Match the mating marks to the number of teeth.

>>T<< SPRING INSTALLATION

AK403513

Install the spring with its tapered end toward the ball.

>>U<< PLUG INSTALLATION

AK403514AB

Apply the sealant to the threads.

Specified sealant: 3M AAD Part No. 8672 or
equivalent

NOTE:

.

The new plug is precoated with sealant, so seal-

ant does not need to be applied.

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MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-59

>>V<< DETECTION SWITCH INSTALLATION

V

V

V

V

AK801184

A

B

C

D

E

AB

1
2

4

5

3
F

6

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 5/Black

E

High range/Low range detection
switch

3/white

F

4LLc operation detection switch
<V5MB1-J-PD2>

6/white

ADJUSTMENT OF TRANSFER

M1222016700013

SPACER SELECTION FOR ADJUST-
MENT OF COUNTER SHAFT END PLAY

<Measurement using a solder>

CAUTION

• f 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 counter shaft 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 counter

shaft, 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

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

<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 counter shaft 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 counter

shaft, 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

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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

INSPECTION

M1222008900153

4WD DETECTION SWITCH

AK500505AB

4WD operation detection switch

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 RANGE/LOW RANGE DETECTION SWITCH

AK500510AB

High range/low range detection
switch

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

4LLc OPERATION 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

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