Mitsubishi Montero (2004+). Manual — part 437
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-75
TRANSFER
DISASSEMBLY AND ASSEMBLY
M1233013300139
AKX00205
4
5
6
1
2
3
7
8
9
14
15
16
11
12
13
17
18
19
24
26
21
22
23
27
28
29
10
20
30
11 ± 1 N·m
97 ± 9 in-lb
19 ± 3 N·m
13 ± 2 ft-lb
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
35 ± 6 N·m
26 ± 4 ft-lb
AB
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
11 ± 1 N·m
97 ± 9 in-lb
11 ± 1 N·m
97 ± 9 in-lb
11 ± 1 N·m
97 ± 9 in-lb
25
DISASSEMBLY STEPS
1.
VACUUM HOSE
>>W<<
2.
4LLC DETECTION SWITCH
3.
GASKET
4.
STEEL BALL
>>W<<
5.
2WD DETECTION SWITCH
6.
GASKET
7.
STEEL BALL
>>W<<
8.
CENTER DIFFERENTIAL LOCK
SWITCH
9.
GASKET
10. STEEL BALL
>>W<<
11. 4H DETECTION SWITCH
12. GASKET
13. STEEL BALL
>>W<<
14. 2-4WD DETECTION SWITCH
15. GASKET
16. STEEL BALL
>>V<<
17. TRANSFER CASE COVER
>>U<<
18. SHIFT RAIL DRIVE GEAR
>>U<<
19. SHIFT RAIL DRIVE GEAR
20. DUST SEAL GUARD
DISASSEMBLY STEPS
(Continued)
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-76
21. DYNAMIC DAMPER
22. VEHICLE SPEED SENSOR
23. O-RING
24. REAR OUTPUT SENSOR
25. O-RING
26. FRONT OUTPUT SENSOR
27. O-RING
>>T<<
28. SIFT ACTUATOR
29. O-RING
>>T<<
30. MAIN SHIFT RAIL
DISASSEMBLY STEPS
(Continued)
AKX00206
34
35
36
31
32
33
37
38
39
40
44
45
46
41
42
43
47
48
49
50
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
54
55
56
51
52
53
57
58
59
60
64
65
61
62
63
35 ± 6 N·m
26 ± 4 ft-lb
AB
35 ± 6 N·m
26 ± 4 ft-lb
DISASSEMBLY STEPS
>>S<<
31. REAR COVER
>>R<<
32. OIL SEAL
33. SNAP RING
34. SENSOR ROTOR
35. STEEL BALL
36. OIL GUIDE
>>Q<<
37. SPACER
38. SNAP RING
>>P<<
39. SNAP RING
>>O<<
40. CHAIN COVER
>>N<<
41. REAR OUTPUT SHAFT
42. O-RING
43. BEARING
44. SNAP RING
45. CENTER DIFFERENTIAL
PLANETARY CARRIER
46. VISCOUS COUPLING
DISASSEMBLY STEPS
(Continued)
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-77
Required special tools:
• MB990932: Installer Adapter
• MB990936: Installer Adapter
• MB990938: Handle
<<A>>
>>M<<
47. CHAIN
<<A>>
>>M<<
48. FRONT OUTPUT SHAFT
>>M<<
49. DRIVE SPROCKET
50. BEARING
>>L<<
51. SYNCHRONIZER INNER RING
>>L<<
52. SYNCHRONIZER CONE
>>L<<
53. SYNCHRONIZER OUTER RING
54. SYNCHRONIZER SPRING
65. DIFFERENTIAL LOCK HUB
DISASSEMBLY STEPS
(Continued)
AKX00207
66
67
68
69
70
74
75
76
71
72
73
77
78
79
80
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
20 ± 3 N·m
14 ± 2 ft-lb
81
82
AB
35 ± 6 N·m
26 ± 4 ft-lb
35 ± 6 N·m
26 ± 4 ft-lb
DISASSEMBLY STEPS
>>G<<
66. TRANSFER CASE PLATE
67. BEARING
68. COUNTER SHAFT GEAR
>>F<<
69. SPACER
>>E<<
70. H-L CLUTCH SLEEVE
>>E<<
71. H-L SHIFT FORK
>>D<<
72. SNAP RING
73. H-L CLUTCH HUB
74. LOW SPEED GEAR
75. BEARING
>>C<<
76. REAR BEARING RETAINER
77. TRANSFER DRIVE SHAFT
78. DUST SEAL GUARD
>>B<<
79. OIL SEAL
<<B>>
>>A<<
80. OIL GUIDE
81. OIL GUIDE
82. TRANSFER CASE
DISASSEMBLY STEPS
(Continued)
TRANSFER
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-78
DISASSEMBLY SERVICE POINTS
.
<<A>> CHAIN/FRONT OUTPUT SHAFT/SUN GEAR
REMOVAL
Remove the sun gear, chain and front output shaft as a set.
.
<<B>> OIL GUIDE REMOVAL
CAUTION
Usually no disassembly is necessary for the oil guide.
After removal, the transfer case can not be reused.
Remove the caulking part and disassemble the oil guide.
ASSEMBLY SERVICE POINTS
.
>>A<< OIL GUIDE INSTALLATION
Mount the oil guide on new transfer case, and caulk so that the
dimension of protruded part (4 places) is as shown to fix the oil
guide.
.
AKX00208
AKX00209
AKX00210
5 mm (0.2 in)
AB
2 mm
(0.08 in)
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