|
1.Fix the H-L shift rail at the high position.
2.Shift the 2-4WD shift rail at the 4WD position.
| note |
If the 2-4WD shift rail is at the 2WD position, the chain cover cannot be removed because
interlock is actuated.
|
|
|
Remove the rear output shaft, chain and front output shaft as a set.
|
|
Remove the 2-4WD synchronizer, chain and front output shaft as a set.
|
|
|
Spacer selection for adjustment of countershaft gear end play. (Refer to adjustment of
transfer - spacer selection for adjustment of countershaft gear end play  )
|
|
1.Use special tools to install the oil seal.
- Installer adapter (MB990931)
- Installer bar (MB990938)
2.Apply the specified grease to the lip of oil seal.
Specified lubricant:
MITSUBISHI MOTORS GENUINE Part No. 0101011 or equivalent
|
|
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.
|
|
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.
|
|
Check that the H-L clutch hub is in the correct direction for 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 H-L clutch hub end play meets the standard value.
Standard value: 0 - 0.08 mm
(For H-L clutch hub end play)
|
|
1.Install the thickest snap ring that can be fitted in the snap ring groove of the transfer
drive shaft.
2.Make sure that the differential lock hub end play meets the standard value.
Standard value: 0 - 0.08 mm
(For differential lock hub end play)
|
|
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.
|
|
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.
|
|
1.
| caution |
- Completely degrease the FIPG-applied surface
so that water and oil including the old sealant cannot adhere to the surface coated with the
sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the
bolts.
|
Apply sealant to the chain cover, and then install the chain cover.
Specified sealant:
MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent
|
|
Check that the H-L clutch sleeve is in the correct direction for installation.
|
|
1.Tilt the transfer case with the 2-4WD shift rail downward as shown in the illustration.
2.Move the 2-4WD shift rail in the direction of the arrow fully.
3.After making sure that the plunger is not exposed out of the H-L shift rail hole in
the transfer case, install the H-L shift rail.
|
|
1.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.
|
|
1.Use special tools to install the oil seal.
- Installer adapter (MB990932) <Easy select 4WD>
- Installer adapter (MB990929) <Super select 4WD>
- Installer bar (MB990938)
2.Apply the specified grease to the lip of oil seal.
Specified lubricant:
MITSUBISHI MOTORS GENUINE Part No. 0101011 or equivalent
|
|
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 below.
Standard value:
- 0 - 0.1 mm <Easy select 4WD>
- 0.025 - 0.150 mm <Super select 4WD>
(For rear output shaft bearing to rear cover clearance)
|
|
Install the oil cover so that the oil hole shown in the illustration.
|
|
Apply the sealant to the chain cover.
Specified sealant:
MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent
|
|
1.Insert the bent section of the return spring into the control housing as shown.
|
|
2.
| caution |
- Completely degrease the FIPG-applied surface
so that water and oil including the old sealant cannot adhere to the surface coated with the
sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the
bolts.
|
Apply the sealant to the support pin section and apply the adhesive to the threads.
Specified sealant:
3M™ ATD Part No. 8672 or equivalent
Specified adhesive:
MITSUBISHI MOTORS GENUINE Part No. MB160450 or equivalent
3.Insert the support pin and install the nut.
|
|
Apply the sealant to the control housing.
Specified sealant:
MITSUBISHI MOTORS GENUINE Part No. 997740 or equivalent
|
|
|
Install the previously selected spacer (Refer to ADJUSTMENT BEFORE ASSEMBLY).
|
|
1.Turn the input gear’s notched selection surface toward the counter shaft mounting
surface. then install the counter shaft.
|
|
1.
| caution |
- Completely degrease the FIPG-applied surface
so that water and oil including the old sealant cannot adhere to the surface coated with the
sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the
bolts.
|
Apply the sealant to the transfer case plate.
Specified sealant:
MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent
2.
| caution |
The transfer case plate must be installed smooth and straight
to get a good seal.
|
Install the transfer case plate together with the input gear and countershaft.
|
|
Match the mating marks to the number of teeth.
|
|
Install the spring with its tapered end toward the ball.
|
|
Apply the sealant to the threads.
Specified sealant:
3M™ ATD Part No. 8672 or equivalent
| note |
The new plug is percolated with sealant, so sealant does not need to be applied.
|
|
|
Install with care. Do not make mistake when locating each switch.
Detection switch name
|
Connector No. / Color
|
A
|
Center differential lock detection switch
|
1 / Brown
|
B
|
2WD/4WD detection switch
|
2 / Black
|
C
|
Center differential lock operation detection switch
|
4 / Blown
|
D
|
4WD operation detection switch
|
6 / Black
|
E
|
High/low detection switch
|
3 / white
|
F
|
4LLc detection switch
|
5 / White
|
|
