DISASSEMBLY AND REASSEMBLY

Removal steps >>V<< 1. Shift rail drive gear 2. Dynamic damper <V5M31-E-XCL, ME, MEL, KDL> 3. Tension wire bracket<V5M31-E-SF, SFL> 4. Dust seal guard 5. Vehicle speed sensor 6. O-ring 7. Rear output sensor 8. O-ring 9. Front output sensor 10. O-ring >>U<< 11. Shift actuator 12. O-ring >>U<< 13. Main shaft rail

Removal steps >>T<< 14. Rear cover >>S<< 15. Oil seal 16. Snap ring 17. Sensor rotor 18. Steel ball >>R<< 19. Oil guide >>Q<< 20. Spacer 21. Snap ring >>P<< 22. Snap ring 23. Transmission wiring harness protector 24. Connector bracket <V5M31-E-KDL> 25. Connector bracket 26. Connector bracket >>O<< 27. Chain cover >>N<< 28. Rear output shaft 29. O-ring 30. Needle bearing 31. Snap ring 32. Center differential planetary carrier 33. Viscous coupling <<A>> >>M<< 34. Chain <<A>> >>M<< 35. Front output shaft >>M<< 36. Drive sprocket 37. Needle bearing >>L<< 38. Synchronizer inner ring >>L<< 39. Synchronizer inner cone >>L<< 40. Synchronizer outer ring 41. Synchronizer inner spring >>K<< 42. Snap ring >>K<< 43. 2-4WD clutch hub <<A>> >>K<< 44. Sun gear 45. Needle bearing 46. Wave spring >>J<< 47. 2-4WD clutch sleeve >>J<< 48. 2-4WD shift fork >>I<< 49. Spacer >>I<< 50. Steel ball >>H<< 51. Snap ring 52. Differential lock hub

Removal steps >>G<< 53. Transfer case plate 54. Needle bearing 55. Countershaft gear >>F<< 56. Spacer >>E<< 57. H-L clutch sleeve >>E<< 58. H-L shift fork >>D<< 59. Snap ring 60. H-L clutch hub 61. Low speed gear 62. Needle bearing >>C<< 63. Seal bolt 64. Rear bearing retainer 65. Transfer drive shaft 66. Dust seal guard >>B<< 67. Oil seal <<B>> >>A<< 68. Oil pool cover 69. Oil guide 70. Transfer case

Remove the chain, front output shaft and sun gear as a set from the transfer case.

Unstake the positions shown in the illustration to remove the oil pool cover.

1.Put solders (1.0 mm diameter, about 10 mm long) in the illustrated positions of the transfer case housing. 2.Install the countershaft gear into the transfer case. 3.Install the transfer case plate and tighten the bolts to the specified torque of 35 ± 6 N·m. 4.Remove the transfer case plate and the countershaft gear, and then take out crushed solders. 5.If the solders have not crushed, use thicker solders (1.6 mm diameter, about 10 mm long) and repeat steps 2 to 4.

6.Measure the thickness of the crushed solder with a micrometer and select a spacer that will provide the standard value. Spacer thickness: (T - 0) to (T - 0.15) T: The crushed solder thickness Standard value: 0 - 0.15 mm

1.Put plastigage (about 10 mm long) in the illustrated positions of the transfer case housing. 2.Install the adjusting spacer having the minimum thickness. 3.Install the countershaft gear into the transfer case. 4.Install the transfer case plate and tighten the bolts to the specified torque of 35 ± 6 N·m. 5.Remove the transfer case plate and the countershaft gear, and then take out crushed solders. 6.If the plastigages have not crushed, replace the spacer with a thicker one and repeat steps 3 to 5.

7.Measure the width of the crushed plastigage at its widest part using a scale printed on the plastigage package. Spacer thickness: (T - 0) to (T - 0.15) T: The crushed solder thickness Standard value: 0 - 0.15 mm

Install the oil pool cover on a new transfer case. Stake the projecting portions of the transfer so that the dimensions will be as illustrated.

1.Use special tools to install the oil seal. Installer bar (MB990938) Installer adapter (MB990932) 2.Apply the specified grease to the lip of oil seal. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

1.Apply the specified sealant to the threads. Specified sealant: 3M STUD Locking No. 4170 or equivalent note The new bolt does not require sealant application as it is precoated with sealant.

Select a proper snap ring so that the end play of the H-L clutch hub will have the standard value, and install the snap ring on the transfer drive shaft. Standard value: 0 - 0.08 mm

Apply the specified grease to the H-L shift fork shaft inserting portion, and install the H-L shift fork and H-L clutch sleeve in combined state in the transfer case. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

Install the previously selected spacer (Refer to ADJUSTMENT BEFORE REASSEMBLY .)

1.Apply the specified grease to the illustrated position of the H-L shift rail inserting portion of the transfer case plate. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

2.face the notched portion of the input gear in the illustrated direction (in the direction of the countershaft gear bearing hole).

3.Apply the specified sealant to the transfer case. Specified sealant: Mitsubishi Part No. MD997740 or equivalent 4. caution If the sub gear does not readily come in mesh with the countershaft gear, rote the transfer drive shaft, etc. to securely engage it. While making sure that the notched portion of the input gear positioned in Step 2 is in alignment with the gear portion of the countershaft, install the transfer case palate.

Select a proper snap ring so that the end play of the differential lock hub will have standard value, and install it on the transfer drive shaft. Standard value: 0 - 0.08 mm

Install the steel ball in the illustrated position of the transfer drive shaft and install the spacer with its oil groove toward the chain cover.

Apply the specified grease to the 2-4WD shift fork shaft inserting position and install the 2-4WD shift fork and 2-4WD clutch sleeve in combined state in the transfer case. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

1.Install the 2-4WD clutch hub on the sun gear. 2.Select the proper snap ring so that the end of play of the 2-4WD clutch hub will have the standard value, and install it on the sun gear. Standard value: 0 - 0.08 mm

1.Combine the synchronizer outer ring, synchronizer cone and synchronizer inner ring, press then against the drive sprocket, and measure the dimension shown in the illustration. Limit: 0.3 mm 2.If the dimension is out of the limit value, replace them with a synchronizer ring set. 3.Apply gear oil to the synchronizer outer ring and synchronizer inner ring.

4.Line up the notched portion of the 2-4WD clutch hub with the projecting portion of the synchronizer ring and install the ring on the 2-4WD clutch hub.

1.Set the chain in mesh with the drive sprocket and front output shaft sprocket and install them in the transfer case.

2.Install the drive sprocket so that its illustrated holes will mach the projecting portions of the synchronizer cone.

Apply the specified grease to the O-ring at the illustrated position and install the output shaft. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

1.Apply the specified grease to the indicated 2-4WD shift rail inserting portion. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent 2.Apply the specified sealant to the illustration of the chain cover. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

1.Install the snap ring in the bearing groove of the rear output shaft. 2.With the rear output shaft pressed against the chain cover, measure the clearance between the chain cover and snap ring. 3.Select a snap ring whose thickness is the dimension of the measured clearance plus the standard value. Standard value: 0.12 - 0.24 mm 4.Remove the snap ring from the bearing groove of the rear output shaft, install the selected snap ring, and reinstall the removed snap ring in the bearing groove of the rear output shaft.

1.With the output shaft pressed toward the chain cover, measure the projection of the bearing from the chain cover.

2.Measure the dimension of the rear cover concave portion at the illustrated position. 3.Subtract the measure value in Step 1 from the measured value in Step 2 to calculate the clearance between the bearing and rear cover. Select a proper spacer so that the clearance will have the standard value. Standard value: 0 - 0.12 mm

Apply specified grease to the lip of the oil seal. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

Use special tools to install the oil seal in the rear cover. Installer bar (MB990938) Installer adapter (MB990932)

Apply the specified sealant to the illustration of the chain cover. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

1.Contact a 12 voltage power supply across the terminals of the actuator connector in a polarity appropriate for causing the actuator motor to move in the rod extending direction or retracting direction until the amount of extension of the rod is as indicated in the drawing Terminal A Terminal B Rod movement Power supply (+) Power supply (-) Extension Power supply (-) Power supply (+) Retraction

2.Apply the specified grease to the O-ring. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent 3.Combine the main shift rail key with actuator key and insert them in the transfer case.

Install the shift rail drive gear with its marked tooth in mesh with the third gear groove of the each shift rail.