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Home >> Mitsubishi Truck >> 2001 >> Montero Sport LS 4WD V6-3.0L SOHC >> Repair and Diagnosis >> Transmission and Drivetrain >> Transfer Case >> Service and Repair >> Disassembly and Assembly

Disassembly and Assembly












DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINT
<> 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 actuated.





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

<> REAR OUTPUT SHAFT/CHAIN/FRONT OUTPUT SHAFT REMOVAL





Remove the rear output shaft, chain and front output shaft as a set.

ADJUSTMENT BEFORE ASSEMBLY SPACER SELECTION FOR ADJUSTMENT OF COUNTERSHAFT 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:
Standard value: 0 - 0.15 mm (0 - 0.006 inch)

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

REASSEMBLY 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<< FRONT OUTPUT SHAFT/CHAIN/REAR OUTPUT SHAFT INSTALLATION





1. Engage the chain precisely with the sprocket of the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch sleeve. While passing them beside the 2-4WD shift rail, install the front output shaft, and chain and rear output shaft.

>>C<< 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.

>>D<< INTERLOCK PLUNGER/CHAIN COVER INSTALLATION





1. Insert the interlock plunger into a position where it does not interfere with 2-4WD shift rail.

CAUTION: Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity.

2. Apply sealant Mitsubishi genuine sealant Part number MD997740 or equivalent to the chain cover, and then install the chain cover.

>>E<< H-L SHIFT RAIL/SPRING PIN INSTALLATION





1. Insert the H-L shift rail from the H-L shift rail hole, paying attention to the direction of the shift rail.
2. Align the spring pin holes on the shift rail with the shift fork. Then tap in the spring pin so that the slit of the spring pin is facing the shaft center of the shift rail.

>>F<< 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 oil seal.

>>G<< OIL COVER INSTALLATION





Install the oil cover so that the oil hole shown in the illustration.

>>H<< SPACER INSTALLATION





1. Measure projection A of the rear output shaft bearing and depth B of the second stage of the rear cover.
2. Subtract A from B and let the answer be C. Select a spacer so that the subtracted value will be the standard value shown.
Standard value: 0 - 0.1 mm (0 - 0.004 inch)

>>I<< REAR COVER INSTALLATION

CAUTION: Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity.





Apply sealant Mitsubishi genuine sealant Part number MD997740 or equivalent to the chain cover.

>>J<< RETURN SPRING/SUPPORT PIN INSTALLATION





1. Insert the bent section of the return spring into the control housing as shown.





2. Apply sealant 3M[tm] ADD Part number 8672 or equivalent to the support pin section as shown, and Mitsubishi genuine adhesive Part number MB160450 or equivalent to the threads.
3. Insert the support pin and install the nut.

>>K<< CONTROL HOUSING INSTALLATION

CAUTION: Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity.





Apply sealant Mitsubishi genuine sealant Part number MD997740 or equivalent to the control housing.

>>L<< H-L SHIFT RAIL PLUG INSTALLATION





Apply sealant 3M ADD Part number 8672 or equivalent to the threads.

NOTE: The new plug is precoated with sealant, so sealant does not need to be applied.

>>M<< PLUG INSTALLATION





Apply sealant 3M[tm] ADD Part number 8672 or equivalent to the threads.

NOTE: The new plug is precoated with sealant, so sealant does not need to be applied.

>>N<< SPACER INSTALLATION
Install the previously selected spacer (see ADJUSTMENT BEFORE ASSEMBLY).

>>O<< TRANSFER CASE PLATE INSTALLATION





1. Face the notched section of the input gears in the direction shown in the illustration.

CAUTION: Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity.





2. Apply Mitsubishi genuine sealant Part number MD997740 or equivalent to the transfer case plate.

CAUTION: The transfer case plate must be installed smooth and straight to get a good seal.

3. Install the transfer case plate together with the input gear. Slide the input gear tooth aligned in Step 1 along the tooth space of the countershaft gear.

>>P<< SPEEDOMETER GEAR INSTALLATION





Match the mating marks to the number of teeth.

>>O<< SPRING INSTALLATION





Install the spring with its tapered end toward the ball.

INSPECTION
2-4WD AND H-L DETECTION SWITCH








Check for the continuity between the connector terminal and switch body

LOW SWITCH





Check for the continuity between the connector terminal and switch body


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