DISASSEMBLY AND REASSEMBLY

Removal steps 1. Vacuum hose >>X<< 2. 4LLC operation detection switch 3. Gasket 4. Steel ball >>X<< 5. 2WD detection switch 6. Gasket 7. Steel ball >>X<< 8. Center differential lock detection switch 9. Gasket 10. Steel ball >>X<< 11. 4H detection switch 12. Gasket 13. Steel ball >>X<< 14. 2WD/4WD detection switch 15. Gasket 16. Steel ball 17. Clip 18. Harness bracket >>W<< 19. Transfer case cover >>V<< 20. Shift rail drive gear >>V<< 21. Shift rail drive gear 22. Dust seal guard 23. Dynamic damper 24. Vehicle speed sensor 25. O-ring 26. Rear output sensor 27. O-ring 28. Front output sensor 29. O-ring >>U<< 30. Shift actuator 31. O-ring >>U<< 32. Main shaft rail

Removal steps >>T<< 33. Rear cover >>S<< 34. Oil seal 35. Snap ring 36. Sensor rotor 37. Steel ball >>R<< 38. Oil guide >>Q<< 39. Spacer 40. Snap ring >>P<< 41. Snap ring 42. Transmission wiring harness protector 43. Connector bracket 44. Connector bracket 45. Connector bracket 46. Clip 47. Connector bracket >>O<< 48. Chain cover >>N<< 49. Rear output shaft 50. O-ring 51. Needle bearing 52. Snap ring 53. Center differential planetary carrier 54. Viscous coupling <<A>> >>M<< 55. Chain <<A>> >>M<< 56. Front output shaft >>M<< 57. Drive sprocket 58. Needle bearing >>L<< 59. Synchronizer inner ring >>L<< 60. Synchronizer inner cone >>L<< 61. Synchronizer outer ring 62. Synchronizer inner spring >>K<< 63. Snap ring >>K<< 64. 2-4WD clutch <<A>> >>K<< 65. Sun gear 66. Needle bearing 67. Wave spring >>J<< 68. 2-4WD clutch sleeve >>J<< 69. 2-4WD shift fork >>I<< 70. Spacer >>I<< 71. Steel ball >>H<< 72. Snap ring 73. Differential lock hub

Removal steps 74. Harness bracket >>G<< 75. Transfer case plate 76. Needle bearing 77. Countershaft gear >>F<< 78. Spacer >>E<< 79. H-L shift fork >>E<< 80. H-L clutch sleeve >>D<< 81. Snap ring 82. H-L clutch hub 83. Low speed gear 84. Needle bearing >>C<< 85. Rear bearing retainer 86. Transfer drive shaft 87. Dust seal guard >>B<< 88. Oil seal <<B>> >>A<< 89. Oil pool cover 90. Oil guide 91. 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. Handle (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.

1.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

1.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.

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. 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 adapter (MB990932) Handle (MB990938)

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.

Apply specified sealant to the illustrated position of the control housing. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

Install the switches as illustrated. Mounting Position Switch Name Tube color Connector color A 2WD/4WD detection switch Blue Black B 4LLC operation detection switch Black Brown C 2WD detection switch Black Black D 4H detection switch Green White E Center differential lock detection switch Blue Brown