Mitsubishi L200. Manual - part 368

COUNTERSHAFT GEAR

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-87

DISASSEMBLY SERVICE POINTS

<<A>> BALL BEARING REMOVAL

AK602119 AC

MD998801

Use special tool Bearing remover (MD998801) to 
remove the ball bearing.

<<B>> SPACER / ROLLER BEARING / INNER 
RACE REMOVAL
1. Remove the spacer and bearing.

AK602120 AC

MD998801

MD998368

2. Using special tool, remove the inner race.

• Remover (MD998801)

• Bearing installer (MD998368)

NOTE: The removal sequence of roller bearing 
parts vary depending on the direction that the 
roller bearing was installed, In come cases, the 
inner race, roller bearing and spacer may have to 
be simultaneously removed.

REASSEMBLY SERVICE POINTS

>>A<< INNER RACE / ROLLER BEARING / 
SPACER INSTALLATION

AK602121AC

MD998812

MD998818

1. Use special tools to install the inner race.

• Installer cap (MD998812)

• Installer adapter (38) (MD998818)

2. Install the roller bearing and spacer.

>>B<< SNAP RING INSTALLATION

AK602122

1. Install the thickest snap ring that can be fitted into 

the snap ring groove of the counter shaft gear.

2. Make sure that the counter shaft gear roller 

bearing end play meets the standard value.

Standard value: 0 

− 0.08 mm

(For counter shaft gear bearing end play)

>>C<< BALL BEARING INSTALLATION

AK602123 AC

MD998812

MD998818

1. Use special tools to install the ball bearing.

• Installer cap (MD998812)

• Installer adapter (38) (MD998818)

2-4 SHIFT RAIL/H-L SHIFT RAIL

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-88

2-4 SHIFT RAIL/H-L SHIFT RAIL

DISASSEMBLY AND REASSEMBLY

M1233031500054

AK602124AC

1

2

3

4

5

6

7

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

>>B<<

1.

Spring pin

>>A<<

2.

2-4WD shift fork

3.

Spring

>>A<<

4.

2-4WD shift rail

>>B<<

5.

Spring pin

>>A<<

6.

H-L shift fork

>>A<<

7.

H-L shift rail

REASSEMBLY SERVICE POINTS

>>A<< SHIFT RAIL AND SHIT FORK INSTALLA-
TION

AK602125AC

Apply the specified grease to the outer periphery of 
the shift fork mounting portion of the shift rail and 
then assemble the shift fork and shift rail. 

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>B<< SPRING PIN INSTALLATION

AK603210AC

H-L shift rail

2-4WD shift rail

Install the spring pin with its split toward the forward 
end of the transfer.

TRANSFER DRIVE SHAFT

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-89

TRANSFER DRIVE SHAFT

DISASSEMBLY AND REASSEMBLY

M1233014500095

AK602127

1

2

AC

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

<<A>>

>>A<<

1.

Ball bearing

2.

Transfer drive shaft

DISASSEMBLY SERVICE POINT

<<A>> BALL BEARING REMOVAL

AK602128AC

MD998917

1. Use special tool Bearing remover (MD998917) to 

support the ball bearing.

2. Press the transfer drive shaft with a press and 

remove the ball bearing.

REASSEMBLY SERVICE POINT

>>A<< BALL BEARING INSTALLATION

AK602129AC

MD998812

MD998814

MD998830

MD998198

Use the special tools to install the ball bearing.

• Installer cap (MD998812)

• Installer-200 (MD998814)

• Installer adapter (66) (MD998830)

• Puller (MD998198)

FRONT OUTPUT SHAFT

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-90

FRONT OUTPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1233006100070

AK602130

1

2

3

4

AC

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

<<A>>

>>B<<

1.

Ball bearing

2.

Sensor rotor

<<B>>

>>A<<

3.

Ball bearing

4.

Front output shaft

DISASSEMBLY SERVICE POINTS

<<A>> BALL BEARING REMOVAL

AK602131AC

MD998801

1. Use special tool Bearing remover (MD998801) to 

support the ball bearing.

2. Press the front output shaft with a press and 

remove the ball bearing with sensor rotor.

<<B>> BALL BEARING REMOVAL

AK602132 AC

MD998801

1. Use special tool Bearing remover (MD998801) to 

support the ball bearing.

2. Press the front output shaft with a press and 

remove the ball bearing.