Mitsubishi L200. Manual — part 340
AK800442
48
49
50
52
57
51
54
55
56
53
58
59
62
60
61
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
Apply gear oil to
all moving parts
before installation.
35 ± 6 N·m
AC
19 ± 3 N·m
19 ± 3 N·m
46
45
44
47
43
42
Disassembly steps
42. Harness bracket
>>R<<
43. Control housing
>>Q<<
44. Support pin
>>Q<<
45. Return spring
<<
A
>>
>>
K
<<
46. H-L shift rail
47. H-L shift fork
>>
J
<<
48. H-L clutch sleeve
49. Harness bracket
50. Harness bracket
51. Harness bracket
<<A>>
>>
I
<<
52. Chain cover
53. Interlock plunger
54. Wave spring
55. Rear output shaft
56. Needle bearing
57. Needle bearing
58. Center differential case
<<
C
>>
>>
H
<<
59. 2-4WD synchronizer
<<
C
>>
>>
H
<<
60. Chain
<<
C
>>
>>
H
61. Front output shaft
62. Needle bearing
63. E-ring
64. Spring seat
65. Spring
66. 2-4WD shift lug and shift rail
assembly
>>
G
<< 67. Spring pin
68. 2-4WD shift lug
69. Spring retainer
70. Spring
71. 2-4WD shift rail
72. 2-4WD shift fork
73. 2-4WD synchronizer sleeve
74. Spacer
75. Steel ball
>>
F
<<
76. Snap ring
77. Differential lock hub
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-69
Disassembly steps (Continued)
AK503403AG
20 ± 2 N·m
Apply gear oil to
all moving parts
before installation.
80
81
82
83
84
85
86
87
9.0 ± 1.0 N·m
79
78
Disassembly steps
>>
E
78. Snap ring
>>
D
<<
79. H-L clutch hub
80. Low speed gear
81. Needle bearing
82. Rear bearing retainer
83. Transfer drive shaft
84. Oil pool cover
85. Dust seal guard
>>
A
<<
86. Oil seal
87. Transfer case
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-70
DISASSEMBLY SERVICE POINTS
<<A>> H-L SHIFT RAIL REMOVAL
AK503405 AB
2-4WD shift rail
1. Fix the H-L shift rail at the high position.
2. Shift the 2-4WD shift rail at the 4WD position.
NOTE: If the 2-4WD shift rail is at the 2WD posi-
tion, the chain cover cannot be removed because
interlock is actuated.
<<B>> REAR OUTPUT SHAFT / CHAIN / FRONT
OUTPUT SHAFT REMOVAL
AK500492
Remove the rear output shaft, chain and front output
shaft as a set.
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-71
<<C>> 2-4WD SYNCHRONIZER / CHAIN / FRONT
OUTPUT SHAFT REMOVEAL
AK101119
Remove the 2-4WD synchronizer, chain and front
output shaft as a set.
ADJUSTMENT BEFORE REASSEMBLY
Spacer selection for adjustment of countershaft gear
end play. (Refer to adjustment of transfer - spacer
selection for adjustment of countershaft gear end
play
)
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
AK403501 AC
MB990938
MB990931
Transfer case
1. Use special tools to install the oil seal.
• Installer adapter (MB990931)
• Installer bar (MB990938)
2. Apply the specified grease to the lip of oil seal.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
>>B<< SPRING PIN INSTALLATION
AK403503AB
Spring pin
1. Align the 2-4WD shift lug with the 2-4WD shift rail
spring pin hole.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
>>C<< FRONT OUTPUT SHAFT / CHAIN / REAR
OUTPUT SHAFT INSTALLATION
AK500492
1. Engage the chain precisely with the sprocket of
the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch
sleeve. While passing them beside the 2-4WD
shift rail, install the front output shaft, and chain
and rear output shaft.
>>D<< H-L CLUTCH HUB INSTALLATION
AK503408
Installation
direction
Transfer front side
AB
Check that the H-L clutch hub is in the correct direc-
tion for installation.
TRANSFER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-72
>>E<< SNAP RING INSTALLATION
AK500493
1. Install the thickest snap ring that can be fitted in
the snap ring groove of the rear output shaft.
2. Make sure that the H-L clutch hub end play meets
the standard value.
Standard value: 0
− 0.08 mm
(For H-L clutch hub end play)
>>F<< SNAP RING INSTALLATION
AK503398
1. Install the thickest snap ring that can be fitted in
the snap ring groove of the transfer drive shaft.
2. Make sure that the differential lock hub end play
meets the standard value.
Standard value: 0
− 0.08 mm
(For differential lock hub end play)
>>G<< SPRING PIN INSTALLATION
AK503410
1. Align the 2-4WD shift lug with the 2-4WD shift rail
spring pin hole.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
>>H<< 2-4WD SYNCHRONIZER / CHAIN / FRONT
OUTPUT SHAFT INSTALLATION
AK101123
1. Make a white paint mark on the deep groove
portions (three places) of the 2-4WD
synchronizer.
2. Make a white paint mark on the portions (three
places) of the 2-4WD synchronizer sleeve splines.
AK101124
3. Place the chain in tight mesh with the 2-4WD
synchronizer and front output shaft sprockets.
4. With both sprockets spaced the farthest apart,
install them on the transfer case simultaneously.
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