Mitsubishi Montero (2004+). Manual — part 427

TRANSMISSION

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23B-35

CAUTION

Make sure thrust bearing number 9 is mounted in the cor-
rect direction.

CAUTION

Measure and record the thickness of the thrust race num-
ber 8 to be assembled.
19.Apply Vaseline or blue petroleum jelly on the thrust race

number 8 being used, and then install it on the rear side of
the center support.

CAUTION

• Install the center support so that the oil holes shown in

the illustration face the lower side of the transmission
case.

• Make sure that the thrust race number 8 attached to the

rear side of the center support does not fall off.

20.Install the center support.

CAUTION

Install the cable bracket together with special tool.
21.Using the Transfer case adapter bolt, install special tool

MB991603.

AKX00072

THRUST
BEARING NO.9

DIRECT
ANNULUS GEAR

AE

AKX00074

THRUST RACE NO.8

AB

AKX00075

AKX00324

MB991603

CABLE END
BRACKET

AC

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23B-36

22.Select the thrust race number 8 with the following

procedure:

(1) Fix a dial gauge to special tool MB991603.
(2) Push the direct planetary carrier,and the direct annulus

gear in alternately, and then measure the end play of
direct planetary carrier.

NOTE: When pushing the direct planetary carrier in, take
care that the center support does not move.
NOTE: When pushing the direct annulus gear in, use the
special tool MB998304.

(3) Reinstall by selecting the thrust race number 8 installed

by the procedure (19) so that the end play of direct
planetary carrier becomes the standard value.

NOTE: Refer to the thickness recorded in step 12.

Standard value: 0.25

− 0.55 mm (0.0098 − 0.0217 inch)

(4) Measure the end play again, and confirm that it is within

the standard value.

NOTE: Carry this step out with special tool MB991603
and dial gauge installed.

23.Using the following steps, select the snap ring for fixing the

center support.

(1) Install the snap ring used for fixing the center support

used.

(2) After pushing the direct planetary carrier,and the center

support in alternately, and then measure the end play of
center support.

NOTE: When pushing the direct planetary carrier in, be
sure to push them in to the point where the center sup-
port touches the snap ring.

(3) Select the snap ring for fixing the center support

installed in step 23 (1) so that the end play of the center
support is at the standard value. Then, reassemble.

Standard value: 0

− 0.16 mm (0 − 0.0063 inch)

(4) Measure the end play again, and confirm that it is within

the standard value.

24.Using the following steps, select the snap ring for adjusting

the brake reaction plate end play and second brake end
play, and the pressure plate for adjusting the low/reverse
brake end play.

AKX00325

MB991603

MD998304

DIRECT
ANNULUS GEAR

AC

DIRECT PLANTARY
CARRIER

AKX00078

THRUST
RACE NO.8

END PLAY

THRUST
BEARING NO.9

AB

AKX00079

SNAP RING

AB

AKX00326

MB991603

CENTER SUPPORT

DIRECT PLANETARY
CARRIER

AC

AKX00081

STANDARD VALUE

CENTER SUPPORT

SNAP RING

LOW/REVERSE
BRAKE PISTON

AB

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23B-37

(1) Install the wave spring onto the low/reverse brake

piston.

(2) Install special tool MB991632 onto the position shown in

the illustration instead of the pressure plate for the
low/reverse brake. Install the brake disc, brake plate
and snap ring.

CAUTION

Pay close attention to the assembly direction of the reac-
tion plate.

(3) Install the reaction plate and snap ring that was used.
(4) Install a dial gauge onto special tool (MD998913) so that

the end contacts the brake reaction plate. Measure the
end play by moving special tool MB991632.

(5) Select the snap ring installed in step 24 (3) so that the

end play is within the standard value. Then, reassemble.

Standard value: 0

− 0.16 mm (0 − 0.0063 inch)

(6) Measure the end play again, and confirm that it is within

the standard value.

CAUTION

Pay close attention to the shape and assembly direction of
the brake plate A installation.

(7) Next, install special tool MB991632 instead of the

pressure plate for the second brake. Install the four
brake discs and three brake plates.

(8) Install the return spring, second brake and snap ring.

AKX00052

AKX00082

MB991632

SNAP RING

AB

AKX00083

MD998913

MB991632

SNAP RING

END PLAY

AB

AKX00084

MB991632

A

SECOND BRAKE

SNAP RING

RETURN
SPRING

AB

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23B-38

(9) Install a dial gauge onto special tool MD998913 so the

end contacts the special tool. Move special tool
MB991632 and measure the moving amount. Select a
pressure plate with a thickness that corresponds to the
measured moving amount from the following table.

Standard value: 1.49

− 1.95 mm (0.0587 − 0.0768 inch)

(10)Remove the snap ring, second brake, return spring and

special tool MB991632 installed in step (8).

(11) Install the pressure plate selected in step (9), and install

the return spring, second brake and snap ring again.

(12) Install a dial gauge onto special tool MD998913 so the

end contacts the special tool. Move special tool
MB991632 and measure the moving amount. Select a
pressure plate with a thickness that corresponds to the
measured moving amount from the following table.

End play standard value (reference)
: 1.65

− 2.11 mm (0.0650 − 0.0831 inch)

AKX00085

MD998913

MB991632

MOVING
AMOUNT

AB

MOVING AMOUNT mm (in)

PRESSURE PLATE

THICKNESS
mm (in)

ID SYMBOL ID SYMBOL

1.2 or more

− less than 1.4 (0.047 or more − less than 0.055) 1.6 (0.063)

F

MR336390

1.4 or more

− less than 1.6 (0.055 or more − less than 0.063) 1.8 (0.071)

E

MR336391

1.6 or more

− less than 1.8 (0.063 or more − less than 0.071) 2.0 (0.079)

D

MR336392

1.8 or more

− less than 2.0 (0.071 or more − less than 0.079) 2.2 (0.087)

C

MR336393

2.0 or more

− less than 2.2 (0.079 or more − less than 0.087) 2.4 (0.094)

B

MR336394

2.2 or more

− less than 2.4 (0.087 or more − less than 0.094) 2.6 (0.102)

A

MR336395

2.4 or more

− less than 2.6 (0.094 or more − less than 0.102) 2.8 (0.110)

0

MR336396

2.6 or more

− less than 2.8 (0.102 or more − less than 0.110) 3.0 (0.118)

1

MR336397

AKX00086

MD998913

MB991632

A

AB

MOVING AMOUNT mm (in)

PRESSURE PLATE

THICKNESS
mm (in)

ID SYMBOL ID SYMBOL

1.5 or more

− less than 1.7 (0.059 or more − less than 0.067) 1.8 (0.071)

E

MD759425

1.7 or more

− less than 1.9 (0.067 or more − less than 0.075) 2.0(0.079)

D

MD759426

1.9 or more

− less than 2.1 (0.075 or more − less than 0.083) 2.2 (0.087)

C

MD759427