Mitsubishi Montero (1991+). Manual - part 292

4WD shift rail snap ring.

         6) Assemble front output shaft assembly, chain and 2WD-4WD

synchronizer assembly. Align match marks made during disassembly. Link

chain tightly onto 2WD-4WD synchronizer and front output shaft

sprockets. Install both sprockets and chain to transfer case at same

time, while keeping them as far apart as possible.

         7) Install center differential case assembly, rear output

shaft assembly needle bearings and rear output shaft assembly. Install

interlock plunger so it does not interfere with 2WD-4WD shift rail.

Evenly apply sealant to chain cover and install chain cover.

         8) Install high-low shift rail through high-low shift rail

hole into shift fork. Align spring pin holes in high-low shift rail

and shift fork. Tap in spring pin so slit is facing shift rail shaft

center. Install and tighten high-low shift rail plug to specification.

See TORQUE SPECIFICATIONS.

         9) Before installing front output shaft cover, measure

protrusion "A" of front output shaft rear bearing and recess "B" of

cover and calculate clearance. See Fig. 11. If clearance is greater

than .079" (2.00 mm), select and install spacer to bring clearance

within specification. If clearance is less than .079" (2.00 mm), use

wave spring alone. Apply sealant to both sides of gasket and install

gasket and cover. Apply Locking Adhesive (3M 4170 Stud Lock) to bolts

and tighten to specification. See TORQUE SPECIFICATIONS.

Fig. 11:  Measuring Rear Output Shaft Bearing Clearance (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         10) Install rear output shaft ball bearing snap ring. Measure

clearance between chain cover and snap ring. Add .0008-.0039" (.02-.10

mm) to clearance measured and install spacer of similar thickness.

Install rear output shaft oil seal (apply grease to lip of seal).

Install rear cover oil seal (apply grease to lip of seal).

         11) Before installing rear cover, snap ring and spacer

thicknesses must be determined. Measure protrusion of rear output

shaft bearing. Measure inset of both stages of cover. Subtract inset

recess from rear bearing protrusion. Select a snap ring which adjusts

difference between inset recess and rear bearing protrusion, and

spacer thickness to 0-.004" (0-0.10 mm). Evenly apply sealant to rear

cover and install cover. Tighten bolts to specification. Refer to the

TORQUE SPECIFICATIONS table.

         12) Install speedometer gear, ensuring mating marks match

according to number of gear teeth. Install speedometer gear sleeve

clamp and tighten bolt to specification. See  Fig. 10.

         13) Apply sealant to poppet plug threads. Install poppet

steel balls, springs and poppet plugs and tighten to specification.

Install detection switches, steel balls and gaskets. See  Fig. 12.

Install dynamic damper and tighten bolts to specification.

Fig. 12:  Installation Of Detection Switches (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

Application                                   Ft. Lbs. (N.m)

Adapter-To-Transfer Bearing Retainer  .........  ( 1) 14 (19)

Case Nuts & Bolts  ..........................  22-31 (30-42)

Center Differential Case Bolts  ...................  48 (65)

Chain Cover Bolt  ...........................  22-31 (30-42)

Detection Switch  .............................  ( 1) 27 (36)

Drain Plug  .................................  22-26 (30-35)

Dynamic Damper  ...................................  52 (70)

High-Low Shift Rail Plug  .....................  ( 1) 24 (33)

Interlock Plunger Plug  .................  ( 1) 22-26 (30-35)

Lock Plate Bolts  ...........................  11-16 (15-22)

Oil Dam Cover  ................................  ( 1) 14 (19)

Oil Filler Plug  ............................  22-26 (30-35)

Output Shaft Cover Bolt  ....................  11-16 (15-22)

Poppet Plug  ..................................  ( 1) 27 (36)

Pulse Rotor Bolt  .......................  ( 2) 11-16 (15-22)

Rear Cover Bolt  ............................  11-16 (15-22)

Rear Output Shaft Lock Nut  ...............  74-96 (100-130)

Seal Plug  ..............................  ( 2) 22-31 (30-42)

Speedometer Sleeve Clamp Bolt  ..............  11-16 (15-22)

4WD Indicator Light Switch  ...................  ( 2) 22 (33)

                                              INCH Lbs. (N.m)

Pulse Generator Bolt  ..................  ( 2) 89-106 (10-12)

Side Cover Bolt  .............................  71-89 (8-10)

(1) - Montero.

(2) - Ram-50.

         WIRING DIAGRAMS

Fig. 13:  Rear Differential Lock Circuit (Montero)