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Mitsubishi Montero Sport (2004+). Manual - part 393

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-75

Required Special Tools:

• MB990929:Installer Adapter

• MB990938:Handle

AK101102

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

20 ± 2 N·m
14 ± 1 ft-lb

20 ± 2 N·m
14 ± 2 ft-lb

8.8 ± 1 N·m
78 ± 9 in-lb

DISASSEMBLY STEPS

60. OIL POOL COVER
61. SIDE COVER
62. SIDE COVER GASKET

>>D<<

63. SNAP RING

>>C<<

64. H-L CLUTCH HUB
65. LOW SPEED GEAR

66. NEEDLE BEARING

>>B<<

67. REAR BEARING RETAINER
68. TRANSFER DRIVE SHAFT
69. DUST SEAL GUARD

>>A<<

70. OIL SEAL
71. TRANSFER CASE

DISASSEMBLY STEPS

TRANSFER

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23B-76

DISASSEMBLY SERVICE POINT

<<A>>H-L SHIFT RAIL/CHAIN COVER REMOVAL

NOTE: If the 2-4WD shift rail is at the 2WD position, the
chain cover cannot be removed because interlock is actu-
ated.

1. Shift the 2-4WD shift rail at the 4WD position.
2. Remove the chain cover, and then remove the H-L shift rail.

<<B>>REAR OUTPUT SHAFT/CHAIN/FRONT OUTPUT
SHAFT REMOVEAL
Remove the rear output shaft, chain and front output shaft as a
set.

ADJUSTMENT BEFORE ASSEMBLY

SPACER SELECTION FRO ADJUSTMENT OF COUNTER-
SHFT GEAR END PLAY
1. Place pieces of solder [approximately 10 mm (0.4 inch) in

length and 1.6 mm (0.06 inch) in diameter] in the transfer
case housing as shown.

2. Install the countershaft gear into the transfer case.
3. Install the transfer case plate and tighten the bolts.

4. Using a micrometer, measure the thickness of the crushed

solder. Based on the result, select a spacer which adjusts
the end play to the standard value shown below.

Standard value: 0

− 0.15 mm (0 − 0.006 inch)

NOTE: NOTE: If the solder is not crushed, repeat steps 1
and 2 using thicker solder.

AK000329

2-4WD SHIFT RAIL

AK101119

AKX00164

SOLDER

AKX00165

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AUTOMATIC TRANSMISSION OVERHAUL

23B-77

ASSEMBLY SERVICE POINTS

>>A<<OIL SEAL INSTALLATION
1. Use special tools MB990929 and MB990938 to install the oil

seal.

2. Apply Mitsubishi genuine grease Part number 0101011 or

equivalent to the lip of the oil seal.

>>B<< BOLT INSTALLATION
Apply Mitsubishi genuine sealant part number MD997740 or
equivalent to the threads.
NOTE: The new bolt is precoated with sealant, so sealant does
not need to be applied.

>>C<< H-L CLUTCH HUB INSTALLATION
Install the H-L clutch hub in the direction indicated by arrow.

>>D<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the H-L clutch
hub end play to the standard value.

Standard value: 0

− 0.08 mm (0 − 0.003 inch)

AKX00166

MB990938

MB990929

TRANSFER
CASE

AKX00402

AK101120

TRANSMISSION
FRONT SIDE

INSTALLATION
DIRECTION

AK101121

TRANSFER

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AUTOMATIC TRANSMISSION OVERHAUL

23B-78

>>E<< SNAP RING INSTALLATION
Select and install the snap ring which adjusts the differential
lock hub end play to the standard value.

Standard value: 0

− 0.08 mm (0 − 0.003 inch)

>>F<<SPRING PIN INSTALLATION
1. Align the 2-4WD shift lug with the 2-4WD shift rail spring pin

hole.

2. Hammer in the spring valve so that the spring pin slit

matches the center of the shift rail shaft.

>>G<<FRONT OUTPUT SHAFT/CHAIN/REAR OUTPUT
SHAFT INSTALLATION
1. Make a white paint mark on the deep groove portions (three

places) of the 2-4WD synchronizer.

2. Make a white paint mark on the portions (three places) of

the 2-4WD synchronizer sleeve splines.

3. Place the chain in tight mesh with the 2-4WD synchronizer

and front output shaft sprockets.

4. With both sprockets spaced the farthest apart, install them

on the transfer case simultaneously.

AK101122

AK000330

SPRING PIN

2-4WD SHIFT LUG

AK101123

AK101124

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