Mitsubishi L200. Manual — part 344
2-4WD SYNCHRONIZER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-85
2-4WD SYNCHRONIZER
DISASSEMBLY AND REASSEMBLY
M1233014200072
AK503423
4
5
6
1
2
3
7
9
9
8
10
AB
Apply gear oil to
all moving parts
before installation.
Disassembly steps
>>
C
<< 1.
Snap ring
2.
2-4WD Synchronizer hub
3.
2-4WD Synchronizer spring
>>
B
<< 4.
Outer synchronizer ring
5.
Synchronizer cone
>>
A
<< 6.
Inner synchronizer ring
7.
Drive sprocket
8.
Bearing spacer
9.
Needle bearing
10. Front side gear
REASSEMBLY SERVICE POINTS
>>A<< INNER SYNCHRONIZER RING INSTALLA-
TION
AK503426AB
Apply oil the synchronizer ring cone surface before
installation.
2-4WD SYNCHRONIZER
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-86
>>B<< OUTER SYNCHRONIZER RING
INSTALLATION
AK503427AB
Apply oil the synchronizer ring cone surface before
installation.
>>C<< SNAP RING INSTALLATION
AK101272AD
Snap ring
Select and install the snap ring which adjusts the 2-
4WD synchronizer hub end play to standard value.
Standard value: 0
− 0.08 mm
(For 2-4WD synchronizer hub end play)
INSPECTION
M1233014300057
SYNCHRONIZER RING
AK500672AB
CAUTION
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
1. Check to ensure that the clutch gear tooth surface
and cone surface are not damaged and broken.
AK503424
2. After applying oil to the taper portion on each
gear, press and fit the synchronizer ring by hand.
Confirm the synchronizer ring cannot be rotated.
AK503425
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
Limit: 0.3 mm
(For synchronizer ring clearance)
CENTRE DIFFERENTIAL CASE
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-87
CENTRE DIFFERENTIAL CASE
DISASSEMBLY AND REASSEMBLY
M1233013900056
AK503428
4
5
6
1
2
3
4
3
4
3
4
3
69 ± 10 N·m
AB
Apply gear oil to
all moving parts
before installation.
Disassembly steps
>>
A
<< 1.
Center differential case B
2.
Dowel pin
3.
Differential pinion
4.
Thrust washer
5.
Pinion shaft
6.
Center differential case B
REASSEMBLY SERVICE POINT
>>A<< CENTER DIFFERENTIAL CASE B INSTAL-
LATION
AK101274AD
Dowel pin
Dowel pin
Pay attention to the position of the dowel pins when
reassembling, and make sure that the match marks
on the outside circumference are in alignment.
REAR OUTPUT SHAFT
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
23C-88
REAR OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1233013600141
<Easy select 4WD>
AK500645AB
1
2
3
4
5
10
11
12
7
8
9
13
14
6
255 ± 10 N·m
15
16
17
18
Apply gear oil to
all moving parts
before installation.
Disassembly steps
<<
A
>>
>>
F
1.
Lock nut
<<
B
>>
>>
E
2.
Ball bearing
3.
Oil guide
4.
Sprocket spacer
5.
Steel ball
6.
Drive sprocket
7.
Needle bearing
8.
Sprocket sleeve
9.
Steel ball
10. Synchronizer inner ring
11. Synchronizer cone
12. Synchronizer outer ring
13. Synchronizer spring
>>
D
14. Clutch sleeve
<<
C
>>
>>
C
15. Clutch hub
<<
C
>>
>>
A
16. Stopper plate
<<
C
>>
>>
A
17. Ball bearing
18. Rear output shaft
Disassembly steps (Continued)
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