DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. 4WD operation detection switch 2. Gasket 3. High range/Low range detection switch 4. Gasket 5. Steel ball >>N<< 6. Plug >>S<< 7. Spring 8. Steel ball >>N<< 9. Plug >>S<< 10. Spring 11. Steel ball >>N<< 12. Plug >>N<< 13. Plug >>N<< 14. Plug 15. 4L operation detection switch 16. Gasket 17. Vehicle speed sensor 18. Speedometer sleeve clamp >>R<< 19. Speedometer driven gear sleeve assembly

Disassembly steps 20. Bracket >>Q<< 21. Transfer case plate >>P<< 22. Counter shaft >>O<< 23. Spacer 24. Sealing cap 25. Needle bearing >>N<< 26. Plug 27. Filler plug 28. Drain plug 29. Connector bracket 30. Harness bracket >>M<< 31. Rear cover >>L<< 32. Oil cover >>K<< 33. Spacer 34. Dust seal cover >>J<< 35. Oil seal >>I<< 36. Spring pin

Disassembly steps <<A>> >>H<< 37. H-L shift rail 38. H-L shift fork >>G<< 39. H-L clutch sleeve 40. Harness bracket 41. Harness bracket 42. Harness bracket >>F<< 43. Chain cover 44. Interlock plunger 45. Wave spring >>E<< 46. Snap ring >>D<< 47. H-L clutch hub 48. Low speed gear 49. Needle bearing <<B>> >>C<< 50. Rear output shaft <<B>> >>C<< 51. Chain <<B>> >>C<< 52. Front output shaft 53. 2-4WD shift fork 54. Snap ring 55. Spring retainer 56. Return spring 57. 2-4WD shift lug and shift rail assembly >>B<< 58. Spring pin 59. 2-4 WD shift lug 60. Spacer 61. 2-4WD shift rail 62. Dust seal guard >>A<< 63. Oil seal 64. 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 rear output shaft, 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

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.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.

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.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 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 (MB990932) 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

Install the oil cover so that the oil hole shown in the illustration.

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 chain cover. Specified sealant: MITSUBISHI MOTORS GENUINE Part No. MD997740 or equivalent

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.

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

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 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 counter shaft.

Match the mating marks to the number of teeth. Transmission model Number of teeth V5MB1-J-PCJH 23 V5MB1-J-JDJH, PDJH, PDMH 24 V5MB1-J-JEJH 25

Install the spring with its tapered end toward the ball.