DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. 4WD operation detection switch 2. Gasket 3. High range/Low range detection switch 4. Gasket 5. Steel ball 6. Poppet spring plug >>O<< 7. Spring 8. Steel ball 9. Poppet spring plug >>O<< 10. Spring 11. Steel ball 12. Seal plug 13. Poppet spring plug 14. Plug 15. Vehicle speed sensor 16. Speedometer sleeve clamp >>N<< 17. Speedometer driven gear sleeve assembly

Disassembly steps 18. Side cover 19. Side cover gasket 20. Poppet spring plug 21. Connector bracket 22. Harness bracket >>M<< 23. Rear cover >>L<< 24. Spacer 25. Snap ring 26. Dust seal cover >>K<< 27. Oil seal >>J<< 28. Spring pin

Disassembly steps <<A>> >>J<< 29. H-L shift rail 30. Harness bracket 31. Harness bracket 32. Harness bracket >>I<< 33. Chain cover >>I<< 34. Interlock plunger 35. Wave spring 36. Lock plate <<B>> 37. Counter gear shaft 38. O-ring >>H<< 39. Counter gear >>G<< 40. Thrust washer >>G<< 41. Thrust washer 42. Needle bearing 43. Bearing spacer 44. Snap ring 45. Spring retainer 46 Return spring >>F<< 47. Spring pin 48. 2-4 WD shift rail 49. Distance piece 50. 2-4 WD shift lug <<C>> >>E<< 51. Rear output shaft <<C>> >>E<< 52. Chain <<C>> >>E<< 53. Front output shaft 54. 2-4 WD shift fork 55. H-L shift fork 56. H-L shift sleeve 57. Needle bearing

Disassembly steps >>D<< 58. Snap ring 59. Input gear >>C<< 60. Oil seal 61. Baffle plate 62. Dust seal guide >>B<< 63. Oil seal >>A<< 64. Oil seal 65. 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.

1.Remove the counter gear shaft toward the transmission case side.

Remove the rear output shaft, chain and front output shaft as a set.

ADJUSTMENT BEFORE REASSEMBLY

1.Using a socket wrench, 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

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.Use special tools to install the oil seal. Installer adapter (MB990934) 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.Install the thickest snap ring that can be fitted in the snap ring groove of the input gear. 2.Make sure that the input gear axial play meets the standard value. Standard value: 0 - 0.06 mm

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.

Driven in the spring pin in such a way that its slit is oriented as shown.

Install the thrust washer in such a way that the tab will fit into the case groove.

Insert the counter gear from the transmission case side, while taking into the account the lock plate groove position.

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.Insert the interlock plunger into a position where it does not interfere the 2-4WD shift rail. caution Squeeze the sealant out evenly to apply it in an unbroken, non-excessive quantity. 3.Apply sealant to the chain cover, and then install the chain cover. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

1.Insert the H-L shift rail from the H-L shift rail plug, while taking into account its direction. 2.Line up the shift rail and shift fork spring pin holes and install the spring pin so that the slit of the spring pin will face the axial 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 - 0.1 mm

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

2.Match the mating marks to the number of teeth. Transmission model Number of teeth V5M21-J-QDR 24 V5M21-J-QFR 26 V5M21-J-GGR 27

Install the spring with its tapered end toward the ball.