Mitsubishi Montero (2002-2004). Manual - part 550

TRANSFER DRIVE SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-131

DISASSEMBLY SERVICE POINT

.

<<A>> BALL BEARING REMOVAL
Use special tool MD9988917 to remove the ball bearing.

ASSEMBLY SERVICE POINTS

.

>>A<< INNER RACE/ROLLER BEARING/SPACER INSTAL-
LATION
Use special tools MD998812, MD998814, MD998830 and 
MD998192 to install the inner race.

AKX00263

MD998917

AB

AKX00264

MD998812

MD998814

MD998830

MD998192

AB

SHIFTRAIL DRIVE GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-132

SHIFTRAIL DRIVE GEAR

DISASSEMBLY AND ASSEMBLY

M1233030500017

<SUPER SELECT 4WD>

ASSEMBLY SERVICE POINT

.

>>A<< SHIFT RAIL DRIVE GEAR INSTALLATION
Install so that the mating mark of the shift rail drive gear is 
opposite side of the washer.

AKX00240

1

2

3

4

5

6

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

AB

DISASSEMBLY STEPS

1.

SNAP RING

>>A<<

2.

SHIFT RAIL DRIVE GEAR

3.

BEARING

4.

SHIFT RAIL DRIVE GEAR SHAFT

5.

WASHER

6.

SNAP RING

DISASSEMBLY STEPS 

AKX00241

MARK

WASHER

AB

2-4 SHIFT RAIL/H-L SHIFT RAIL

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-133

2-4 SHIFT RAIL/H-L SHIFT RAIL

DISASSEMBLY AND ASSEMBLY

M1233031500010

<SUPER SELECT 4WD>

ASSEMBLY SERVICE POINTS

.

>>A<< SPRING PIN INSTALLATION
Install the spring pin so that the slit of spring pin faces forward 
of the transfer.

.

AKX00265

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

6

7

5

2

1

3

4

AB

DISASSEMBLY STEPS

>>A<<

1.

SPRING PIN

2.

2-4WD SHIFT FORK

3.

SPRING

>>B<<

4.

2-4WD SHIFT RAIL

>>A<<

5.

SPRING PIN

6.

H-L SHIFT FORK

7.

H-L SHIFT RAIL

DISASSEMBLY STEPS 

AKX00266

H - L SHIFT RAIL

2 - 4 SHIFT RAIL

AB

SPECIFICATIONS

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-134

>>B<< 2-4WD SHIFT RAIL INSTALLATION
Apply Mitsubishi genuine grease Part number 0101011 or 
equivalent to the contact part between 2-4WD shift rail and 2-4 
WD shift fork, and install.

SPECIFICATIONS

TORQUE SPECIFICATION

M1233023100028

Transmission

AKX00267

ITEM

SPECIFICATION

Anchor plug <V5A51>

98 

± 15 N⋅m (71 ± 11 ft-lb)

Cable end bracket mounting bolt

48 

± 6 N⋅m (35 ± 4 ft-lb)

Converter housing to transmission case tightening bolts

48 

± 6 N⋅m (35 ± 4 ft-lb)

Detent spring mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Input shaft speed sensor mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Lower valve body cover mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Lower valve body mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Manual control lever mounting nut

22 

± 3 N⋅m (16 ± 2 ft-lb)

Oil filter mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Oil pan mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Oil pump mounting bolt

23 

± 3 N⋅m (17 ± 2 ft-lb)

Output shaft speed sensor mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Output shaft support mounting bolt

23 

± 3 N⋅m (17 ± 2 ft-lb)

Park/neutral position switch mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Reduction brake piston adjust rod <V5A51>

4.9 N

⋅m (43 in-lb)

Reduction brake piston nut <V5A51>

18 

± 3 N⋅m (13 ± 2 ft-lb)

Separating plate mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Solenoid support mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Transfer to transfer case adapter tightening bolt 

35 

± 6 N⋅m (26 ± 4 ft-lb)

Transmission case to transfer case adapter tightening bolt 

48 

± 6 N⋅m (35 ± 4 ft-lb)

Upper valve body mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Valve body mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)