DISASSEMBLY AND REASSEMBLY

Disassembly steps >>T<< 1. Centre differential lock detection switch >>T<< 2. 2WD/4WD detection switch 3. Gasket >>T<< 4. Centre differential lock operation detection switch >>T<< 5. 4WD operation detection switch >>T<< 6. High range/Low range detection switch 7. Gasket 8. Steel ball >>S<< 9. Plug >>R<< 10. Spring 11. Steel ball >>T<< 12. 4LLc operation detection switch 13. Gasket 14. Plug 15. Gasket 16. Plug 17. Gasket 18. Vehicle speed sensor 19. Key 20. Speedometer clamp >>Q<< 21. Speedometer driven gear sleeve assembly 22. Bracket >>P<< 23. Transfer case plate >>O<< 24. Countershaft gear >>N<< 25. Spacer 26. Sealing cap 27. Needle bearing 28. Connector bracket 29. Harness bracket >>M<< 30. Rear cover 31. Oil cover >>L<< 32. Spacer 33. Dust seal cover >>K<< 34. Oil seal >>J<< 35. Spring pin

Disassembly steps <<A>> >>I<< 36. H-L shift rail 37. H-L shift fork >>H<< 38. H-L clutch sleeve 39. Harness bracket 40. Harness bracket 41. Harness bracket >>G<< 42. Chain cover 43. Interlock plunger 44. Wave spring 45. Rear output shaft 46. Needle bearing 47. Needle bearing 48. Centre differential case <<B>> >>F<< 49. Driver sprocket <<B>> >>F<< 50. Chain <<B>> >>F<< 51. Front output shaft 52. Needle bearing 53. E-ring 54. Spring seat 55. Spring 56. 2-4WD shift lug and shift rail assembly >>E<< 57. Spring pin 58. 2-4WD shift lug 59. Spring seat 60. Spring 61. 2-4WD shift rail 62. 2-4WD shift fork 63. 2-4WD synchroniser sleeve 64. Spacer 65. Steel ball >>D<< 66. Snap ring 67. Differential lock hub

Disassembly steps >>C<< 68. Snap ring >>B<< 69. H-L clutch hub 70. Low speed gear 71. Needle bearing 72. Rear bearing retainer 73. Transfer drive shaft 74. Oil pool cover 75. Dust seal guard >>A<< 76. Oil seal 77. Transfer case

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 2-4WD synchroniser, chain and front output shaft as a set.

ADJUSTMENT BEFORE REASSEMBLY

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

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 axial play meets the standard value. Standard value: 0 - 0.08 mm

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 axial play meets the standard value. Standard value: 0 - 0.08 mm

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 centre of the shift rail shaft.

1.Make a white paint mark on the deep groove portions (three places) of the 2-4WD synchroniser. 2.Make a white paint mark on the portions (three places) of the 2-4WD synchroniser sleeve splines.

3.Place the chain in tight mesh with the 2-4WD synchroniser and front output shaft sprockets. 4.With both sprockets spaced the farthest apart, install them on the transfer case simultaneously.

1. caution Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity. 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. 2.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 centre of the shift rail.

1.Use special tools to install the oil seal. Installer adapter (MB990929) 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: 0.025 - 0.150 mm

1. caution Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity. 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. 2.Apply the sealant to the chain cover. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

1.Turn the input gear’s notched selection surface toward the counter shaft mounting surface. then install the counter shaft.

1. caution Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity. 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. 2.Apply the sealant to the transfer case plate. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent 3. 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 AAD part No.8672 or equivalent note The new plug is precoated 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./Colour A Centre differential lock detection switch 1/Brown B 2WD/4WD detection switch 2/Black C Centre differential lock operation detection switch 4/Blown D 4WD operation detection switch 5/Black E High range/Low range detection switch 3/white F 4LLc operation detection switch 6/white