DISASSEMBLY AND REASSEMBLY



Disassembly steps


1.
 Plug


2.
 Spring


3.
 Ball


4.
 Plug <Super selector 4WD>


5.
 Spring <Super selector 4WD>


6.
 Ball <Super selector 4WD>


7.
 Filler plug


8.
 Drain plug

<Easy select 4WD>

Disassembly steps
<<A>>
 >>G<<
 9.
 Self-locking nut
<<B>>
10.
 Companion flange (front)
<<A>>
 >>G<<
 11.
 Self-locking nut
<<B>>
12.
 Companion flange (rear)


13.
 Transfer chain case

>>F<<
 14.
 Transfer chain case cover (rear)

>>E<<
 15.
 Transfer chain case cover (front)


16.
 Oil separator


17.
 Oil ring


18.
 Oil pump assembly


19.
 Oil pump gear


20.
 Oil pool cover


21.
 Snap ring


22.
 Input gear assembly


23.
 Snap ring


24.
 Planetary ring gear


25.
 Gearshift link pin


26.
 Gearshift link plug


27.
 Gearshift link spring


28.
 Gearshift link ball


29.
 Snap ring


30.
 Gearshift fork 2


31.
 Snap ring


32.
 Gearshift fork 1
<<C>>
33.
 Chain/Front output shaft assembly


34.
 Chain


35.
 Front output shaft assembly


36.
 Rear output shaft assembly


37.
 Snap ring


38.
 Stopper


39.
 Gearshift rail


40.
 Snap ring


41.
 Transfer actuator


42.
 Magnet

>>D<<
 43.
 Transfer case oil seal (front)

>>D<<
 44.
 Transfer case oil seal (rear)

>>C<<
 45.
 Oil seal

>>B<<
 46.
 Front output shaft oil seal

>>B<<
 47.
 Rear output shaft oil seal

>>A<<
 48.
 Transfer case pin

<Super select 4WD>

Disassembly steps
<<A>>
 >>G<<
 49.
 Self-locking nut
<<B>>
50.
 Companion flange (front)
<<A>>
 >>G<<
 51.
 Self-locking nut
<<B>>
52.
 Companion flange (rear)


53.
 Transfer chain case

>>F<<
 54.
 Transfer chain case cover (rear)

>>E<<
 55.
 Transfer chain case cover (front)


56.
 Oil separator


57.
 Oil ring


58.
 Oil pump assembly


59.
 Oil pump gear


60.
 Oil pool cover


61.
 Snap ring


62.
 Input gear assembly


63.
 Snap ring


64.
 Planetary ring gear


65.
 Gearshift link pin


66.
 Gearshift fork 2


67.
 Gearshift stopper


68.
 Snap ring


69.
 Gearshift fork 1


70.
 Snap ring


71.
 Gearshift stopper
<<C>>
72.
 Chain/Front output shaft assembly


73.
 Chain


74.
 Front output shaft assembly


75.
 Rear output shaft assembly


76.
 Stopper


77.
 Gearshift rail


78.
 Snap ring


79.
 Transfer actuator


80.
 Magnet

>>D<<
 81.
 Transfer case oil seal (front)

>>D<<
 82.
 Transfer case oil seal (rear)

>>C<<
 83.
 Oil seal

>>B<<
 84.
 Front output shaft oil seal

>>B<<
 85.
 Rear output shaft oil seal

>>A<<
 86.
 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.