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Disassembly Remove snap ring, 2WD-4WD synchronizer hub and synchronizer spring. Remove outer synchronizer ring, synchronizer cone and inner synchronizer ring. Remove drive sprocket and needle bearing from front drive pinion. Inspect inner and outer synchronizer rings and cone for excessive wear. Install inner and outer synchronizer rings and cone onto drive sprocket. Measure distance between drive sprocket and outer synchronizer. If distance is less than .0118" (.300 mm) replace synchronizer parts as a set. Reassembly Install drive sprocket and needle bearing onto front drive pinion. Apply transfer case gear oil to contacting surfaces of inner and outer synchronizer rings and synchronizer cone. Install inner and outer synchronizer rings and synchronizer cone. Install synchronizer spring, 2WD-4WD synchronizer hub and snap ring to complete assembly. When installing new snap ring, select thickest ring that will fit into groove. Acceptable snap ring clearance is 0-.003" (0-.080 mm). Fig. 8: Exploded View Of 2WD-4WD Synchronizer (Montero) Courtesy of Mitsubishi Motor Sales of America. TRANSFER CASE REASSEMBLY NOTE: ALWAYS replace all gaskets, oil seals, snap rings and spring pins with new parts. Coat both sides of gaskets and bolt threads with sealant. Lubricate all sliding and rotating parts with transfer case gear oil before assembling. Reassembly (Ram-50) |