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)