DISASSEMBLY AND REASSEMBLY



Disassembly steps


1.
 Plug


2.
 Spring


3.
 Pin


4.
 Plug


5.
 Spring


6.
 Ball


7.
 Filler plug


8.
 Drain plug


9.
 Gasket




Disassembly steps
<<A>>
 >>G<<
 1.
 Self-locking nut
<<B>>
2.
 Companion flange (front)
<<A>>
 >>G<<
 3.
 Self-locking nut
<<B>>
4.
 Companion flange (rear)


5.
 Transfer chain case

>>F<<
 6.
 Transfer chain case cover (rear)

>>E<<
 7.
 Transfer chain case cover (front)


8.
 Oil separator


9.
 Oil ring


10.
 Oil pump assembly


11.
 Oil pump gear


12.
 Oil pool cover


13.
 Snap ring


14.
 Input gear assembly


15.
 Snap ring


16.
 Planetary ring gear


17.
 Gearshift link pin


18.
 Gearshift fork 2


19.
 Gearshift stopper


20.
 Snap ring


21.
 Gearshift fork 1


22.
 Snap ring


23.
 Gearshift stopper
<<C>>
24.
 Chain/Front output shaft assembly


25.
 Chain


26.
 Front output shaft assembly


27.
 Rear output shaft assembly


28.
 Stopper


29.
 Gearshift rail


30.
 Snap ring


31.
 Transfer actuator


32.
 O-ring


33.
 Magnet

>>D<<
 34.
 Transfer case oil seal (front)

>>D<<
 35.
 Transfer case oil seal (rear)

>>C<<
 36.
 Oil seal

>>B<<
 37.
 Front output shaft oil seal

>>B<<
 38.
 Rear output shaft oil seal

>>A<<
 39.
 Transfer case pin

DISASSEMBLY SERVICE POINTS

<<A>> SELF-LOCKING NUT REMOVAL

Use special tool front hub & flange yoke holder (MB990767) to hold the companion flange, and then remove the companion flange self-locking nut.
Releasing torque:

  • Above 60 N·m (Front)
  • Above 78 N·m (Rear)

<<B>> COMPANION FLANGE (FRONT)/COMPANION FLANGE (REAR) REMOVAL

Use special tools to remove the companion flange.

  • Side brg puller cup (MB990811)
  • Axle shaft puller (MB990926)

<<C>> CHAIN/FRONT OUTPUT SHAFT ASSEMBLY REMOVAL

Expand the shown snap ring to remove the chain and the front output shaft assembly as a set.

REASSEMBLY SERVICE POINTS

>>A<< TRANSFER CASE PIN INSTALLATION
1.Install the transfer case pin on a transfer chain case cover (rear).

2.Insert the transfer case pin into the transfer chain case cover (rear) until the shown dimension is satisfied.

>>B<< REAR OUTPUT SHAFT OIL SEAL/FRONT OUTPUT SHAFT OIL SEAL INSTALLATION

1.Use special tools to install the oil seal.

  • Installer bar (MB990938)
  • Installer adaptor (MB990926)
2.Apply the specified grease to the lip of oil seal.
Specified lubricant: MITSUBISHI MOTORS GENUINE Part No. 0101011 or equivalent

>>C<< OIL SEAL INSTALLATION

1.Use special tool, Base (MB990643), install the oil seal.
2.Apply the specified grease to the lip of oil seal.
Specified lubricant: MITSUBISHI MOTORS GENUINE Part No. 0101011 or equivalent

>>D<< TRANSFER CASE OIL SEAL (REAR)/TRANSFER CASE OIL SEAL (FRONT) INSTALLATION

1.Use special tool, Remover base (MB991523), install the oil seal.
2.Apply the specified grease to the lip of oil seal.
Specified lubricant: MITSUBISHI MOTORS GENUINE Part No. 0101011 or equivalent

>>E<< TRANSFER CHAIN CASE COVER (FRONT) INSTALLATION

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

>>F<< TRANSFER CHAIN CASE COVER (REAR) INSTALLATION

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

>>G<< SELF-LOCKING NUT INSTALLATION
1.Tighten the self-locking nut to specified torque.
Specified torque:

  • 118 ± 19 N·m (Front)
  • 128 ± 25 N·m (Rear)

2.
caution
  • Do not damage other parts.
  • Do not apply the excessive load to shaft.
Caulk into the overall front or rear output shaft grove.
3.Make sure of firmly caulking self-locking nut on the groove, after caulking.