Disassembly

Fig. 1 Exploded view of Mitsubishi transfer case. 87 Raider:

1. Remove four wheel drive lamp switches and steel balls.
2. Remove speedometer sleeve clamp, then the speedometer sleeve assembly. Note which mark on sleeve is aligned with mark on extension housing.
3. Remove rear cover attaching bolts, then the rear cover, gasket and wave spring.
4. Remove front cover, gasket, wave spring and spacer.
5. Using 3/16 inch punch, drive out spring pin from Hi-Lo shift fork.
6. Remove two seal plugs, poppet springs and balls.
7. Remove Hi-Lo shift rail and interlock plunger.
8. On 1988-92 models, remove pulse generator, then pulse generator rotor cover and gasket.

Fig. 2 Exploded view of Mitsubishi transfer case. 1988-92 models:

9. Remove spacer and wave spring from rotor cover, then remove pulse rotor.
10. On all models, remove snap ring from rear bearing of rear output shaft.
11. Remove chain cover, oil guide and side cover.
12. Remove countershaft locking plate, then the countershaft.
13. Remove counter gear, two thrust washers, two needle bearings and spacer through side cover opening.
14. Remove snap ring from 2WD-4WD shift rail, then the two spring retainers and spring from shift rail.
15. Remove front output shaft, rear output shaft and chain as an assembly from transfer case.
16. Remove 2WD-4WD shift rail.
17. Remove Hi-Lo shift fork and clutch sleeve.
18. Remove needle bearing from input gear.
19. Remove snap ring, then the input gear assembly.

Fig. 3 Rear output shaft:

20. Remove snap ring from front end of rear output shaft, then the Hi-Lo clutch hub, low speed gear, thrust washer and needle bearing.
21. Raise detent of rear output shaft locknut and remove.
22. Using suitable puller, remove ball bearing from rear of output shaft.
23. Remove sprocket spacer and steel balls.
24. Remove drive sprocket, two needle bearings, sprocket sleeve and steel ball.
25. Remove 2WD-4WD clutch sleeve, hub, and stop plate, then, using suitable puller, remove ball bearing.
26. Remove snap ring from input gear, then remove bearing using suitable press.
27. Using suitable puller, remove two bearings from front output shaft.
28. To replace control shaft oil seal or input gear oil seal press fitted in front of case, drive out lockpin from transmission control shaft change shifter and separate transfer case from adapter.