Mitsubishi Montero (2004+). Manual — part 443
2-4 SHIFT RAIL/H-L SHIFT RAIL
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-99
ASSEMBLY SERVICE POINT
.
>>A<< SHIFT RAIL DRIVE GEAR INSTALLATION
Install so that the mating mark of the shift rail drive gear is
opposite side of the washer.
2-4 SHIFT RAIL/H-L SHIFT RAIL
DISASSEMBLY AND ASSEMBLY
M1233031500021
AKX00241
MARK
WASHER
AB
AKX00265
APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.
6
7
5
2
1
3
4
AB
DISASSEMBLY STEPS
>>A<<
1.
SPRING PIN
2.
2-4WD SHIFT FORK
3.
SPRING
>>B<<
4.
2-4WD SHIFT RAIL
>>A<<
5.
SPRING PIN
6.
H-L SHIFT FORK
7.
H-L SHIFT RAIL
DISASSEMBLY STEPS
(Continued)
2-4 SHIFT RAIL/H-L SHIFT RAIL
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-100
ASSEMBLY SERVICE POINTS
.
>>A<< SPRING PIN INSTALLATION
Install the spring pin so that the slit of spring pin faces forward
of the transfer.
.
>>B<< 2-4WD SHIFT RAIL INSTALLATION
Apply Mitsubishi genuine grease Part number 0101011 or
equivalent to the contact part between 2-4WD shift rail and 2-4
WD shift fork, and install.
AKX00266
H - L SHIFT RAIL
2 - 4 SHIFT RAIL
AB
AKX00267
SPECIFICATIONS
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-101
SPECIFICATIONS
TORQUE SPECIFICATION
M1233023100426
Transmission
Transfer
ITEMS
SPECIFICATIONS
Anchor plug
98
± 15 N⋅m (71 ± 11 ft-lb)
Cable end bracket mounting bolt
48
± 6 N⋅m (35 ± 4 ft-lb)
Converter housing to transmission case tightening bolts
48
± 6 N⋅m (35 ± 4 ft-lb)
Detent spring mounting bolt
5.9
± 1 N⋅m (52 ± 9 in-lb)
Input shaft speed sensor mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Lower valve body cover mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Lower valve body mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Manual control lever mounting nut
22
± 3 N⋅m (16 ± 2 ft-lb)
Oil filter mounting bolt
5.9
± 1 N⋅m (52 ± 9 in-lb)
Oil pan mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Oil pump mounting bolt
23
± 3 N⋅m (17 ± 2 ft-lb)
Output shaft speed sensor mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Output shaft support mounting bolt
23
± 3 N⋅m (17 ± 2 ft-lb)
Park/neutral position switch mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Reduction brake piston adjust rod
4.9 N
⋅m (43 in-lb)
Reduction brake piston nut
18
± 3 N⋅m (13 ± 2 ft-lb)
Separating plate mounting bolt
5.9
± 1 N⋅m (52 ± 9 in-lb)
Solenoid support mounting bolt
5.9
± 1 N⋅m (52 ± 9 in-lb)
Transfer to transfer case adapter tightening bolt
35
± 6 N⋅m (26 ± 4 ft-lb)
Transmission case to transfer case adapter tightening bolt
48
± 6 N⋅m (35 ± 4 ft-lb)
Upper valve body mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Valve body mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
ITEMS
SPECIFICATIONS
2WD switch
35
± 6 N⋅m (26 ± 4 ft-lb)
2-4WD switch
35
± 6 N⋅m (26 ± 4 ft-lb)
4H switch
35
± 6 N⋅m (26 ± 4 ft-lb)
4LL switch
35
± 6 N⋅m (26 ± 4 ft-lb)
Center differential lock switch
35
± 6 N⋅m (26 ± 4 ft-lb)
Control housing to transfer case tightening bolt
19
± 3 N⋅m (13 ± 2 ft-lb)
Output sensor mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Rear cover to chain cover tightening bolt
35
± 6 N⋅m (26 ± 4 ft-lb)
Sift actuator mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Speedometer sensor mounting bolt
11
± 1 N⋅m (97 ± 9 in-lb)
Transfer case plate to bearing retainer mounting bolt
20
± 2 N⋅m (14 ± 1 ft-lb)
SPECIFICATIONS
TSB Revision
AUTOMATIC TRANSMISSION OVERHAUL
23B-102
GENERAL SPECIFICATIONS
M1233000200455
SERVICE SPECIFICATIONS
M1233000300322
Transmission
Transfer
Transfer case plate to transfer case tightening bolt and nut
35
± 6 N⋅m (26 ± 4 ft-lb)
Transfer case to bearing retainer mounting bolt
20
± 2 N⋅m(14 ± 1 ft-lb)
Transfer case to chain cover tightening bolt
35
± 6 N⋅m (26 ± 4 ft-lb)
ITEMS
SPECIFICATIONS
TRANSMISSION MODEL
V5A51-7-HCB
Applicable engine
3.8L
Transmission type
Electronically controlled 4-speed full-automatic
Torque converter type
3-element with torque converter clutch
Transmission
gear ratio
1st
3.789
2nd
2.057
3rd
1.421
4th
1.000
5th
0.731
Reverse
3.865
Transfer type
SUPER SELECT 4WD
Transfer gear
ratio
High
1.000
Low
1.900
ITEMS
STANDARD VALUE
Direct planetary carrier end play mm (in)
0.25
− 0.55 (0.0098 − 0.0217)
Underdrive clutch end play mm (in)
1.6
− 1.8 (0.063 − 0.071)
Input shaft end play mm (in)
0.25
− 0.81 (0.0098 − 0.0319)
Overdrive clutch end play mm (in)
2.0
− 2.2 (0.079 − 0.087)
Overdrive clutch return spring retainer end play mm (in)
0
− 0.09 (0 − 0.004)
Second brake end play mm (in)
1.49
− 1.95 (0.0587 − 0.0768)
Center support end play mm (in)
0
− 0.16 (0 − 0.0063)
Brake reaction plate end play mm (in)
0
− 0.16 (0 − 0.0063)
Reverse clutch end play mm (in)
1.5
− 1.7 (0.059 − 0.067)
Low/reverse brake end play mm (in)
1.65
− 2.11 (0.0650 − 0.0831)
Direct clutch end play mm (in)
1.0
− 1.2(0.039 − 0.047)
ITEMS
STANDARD VALUE
Countershaft gear end play mm (in)
0
− 0.15 (0 − 0.006)
H-L clutch hub end play mm (in)
0
− 0.08 (0 − 0.003)
Differential lock hub end play mm (in)
0
− 0.08 (0 − 0.003)
2-4WD clutch hub end play mm (in)
0
− 0.08 (0 − 0.003)
Synchronizer outer ring to drive sprocket clearance mm (in)
Limit 0.3 (0.01)
Rear output shaft bearing snap ring to chain cover preload mm (in)
0.12
− 0.24 (0.005 − 0.009)
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