Mitsubishi Montero Sport (2004+). Manual - part 397

 

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Mitsubishi Montero Sport (2004+). Manual - part 397

 

 

2-4WD SYNCHRONIZER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-91

INSPECTION

M1233014300024

.

SYNCHRONIZERRING AND SYNCHRONIZER CONE
Combine the inner and outer synchronizer rings and cone with 
the drive sprocket and measure the dimension A limit, replace 
them as set.

limit: 0.3 mm (0.12 inch)

AK101275AB

A

DRIVE
SPROCKET

OUTER
SYNCHRONIZER RING

SYNCHRONIZER
CONE

OUTER
SYNCHRONIZER
RING

CENTER DIFFERENTIAL CASE

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-92

CENTER DIFFERENTIAL CASE

DISASSEMBLY AND ASSEMBLY

M1233013900023

ASSEMBLY SERVICE POINTS

.

>>A<<CENTER DIFFERENTIAL INSTALLATION
Pay attention to the position of the dowel pins when reassem-
bling, and make sure that the match marks on the outside cir-
cumference are in alignment.

AK101273

4

5

6

1

2

3

4

3

4

3

4

3

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

69 ± 10 N·m
51 ± 7 ft-lb

AB

DISASSEMBLY STEPS

>>A<<

1.

CENTER DIFFERENTIAL CASE 
FRONT

2.

DOWEL PIN

3.

PINION

4.

THRUST WASHER

5.

PINION SHAFT

6.

CENTER DIFFERENTIAL CASE 
REAR

DISASSEMBLY STEPS (Continued)

AK101274

DOWEL PIN

DOWEL PIN

AB

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-93

REAR OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY

M1233013600066

Required special tools

• MD998801: Bearing Remover

• MD998812: Installer Cap

• MD998814: Installer-200

• MD998823: Installer Adapter

AK101106

1

2

3

4

AB

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

DISASSEMBLY STEPS

>>B<<

1.

SNAP RING

<<A>>

>>A<<

2.

BALL BEARING

3.

VISCOUS COUPLING

4.

REAR OUTPUT SHAFT

DISASSEMBLY STEPS 

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-94

DISASSEMBLY SERVICE POINT

.

<<A>> BALL BEARING REMOVAL
Use special tool MD998917 to remove the ball bearing.

ASSEMBLY SERVICE POINTS

.

>>A<< BALL BEARING INSTALLATION
Use special tools MD998812, MD998814 and MD998824 to 
install the ball bearing.

.

>>B<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in the snap 

ring groove of the rear output shaft.

2. Make sure that the rear output shaft bearing end play meets 

the standard value.

Standard value: 0 

− 0.08 mm (0 − 0.003 inch)

AK101110

MD998801

AB

AK101111

MD998812

MD998814

MD998823

AB

AK101112AB

 

 

 

 

 

 

 

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