Mitsubishi L200. Manual - part 267

AK503403AJ

20 ± 2 N·m

Apply gear oil to
all moving parts
before installation.

9.0 ± 1.0 N·m

Disassembly steps

66. Snap ring

67. H-L clutch hub
68. Low speed gear
69. Needle bearing
70. Rear bearing retainer
71. Transfer drive shaft
72. Oil pool cover
73. Dust seal guard

74. Oil seal
75. Transfer case

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-53

DISASSEMBLY SERVICE POINTS

<<A>> H-L SHIFT RAIL REMOVAL

AK503405 AB

2-4WD shift rail

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 posi-
tion, the chain cover cannot be removed because
interlock is actuated.

<<B>> REAR OUTPUT SHAFT / CHAIN/FRONT
OUTPUT SHAFT REMOVAL

AK500492

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

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-54

<<C>> 2-4WD SYNCHRONIZER / CHAIN/FRONT
OUTPUT SHAFT REMOVAL

AK101119

Remove the 2-4WD synchronizer, chain and front
output shaft as a set.

ADJUSTMENT BEFORE REASSEMBLY

Spacer selection for adjustment of counter shaft end
play. (Refer to ADJUSTMENT OF TRANSFER -
SPACER SELECTION FOR ADJUSTMENT OF
COUNTER SHAFT END PLAY

P.22C-59

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

AK403501 AC

MB990938

MB990931

Transfer case

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 Part No.
0101011 or equivalent

>>B<< FRONT OUTPUT SHAFT / CHAIN / REAR
OUTPUT SHAFT INSTALLATION

AK500492

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.

>>C<< H-L CLUTCH HUB INSTALLATION

AK503408

Installation
direction

Transfer front side

Check that the H-L clutch hub is in the correct direc-
tion for installation.

>>D<< SNAP RING INSTALLATION

AK500493

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 end play meets

the standard value.

Standard value: 0

− 0.08 mm

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-55

>>E<< SNAP RING INSTALLATION

AK503398

1. Install the thickest snap ring that can be fitted in

the snap ring groove of the transfer drive shaft.

2. Make sure that the differential lock hub end play

meets the standard value.

Standard value: 0

− 0.08 mm

>>F<< SPRING PIN INSTALLATION

AK503410

1. Align the e2-4WD 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 center of the shift rail shaft.

>>G<< 2-4WD SYNCHRONIZER/CHAIN/FRONT
OUTPUT SHAFT INSTALLATION

AK101123

1. Make a white paint mark on the deep groove

portions (three places) of the 2-4WD
synchronizer.

2. Make a white paint mark on the portions (three

places) of the 2-4WD synchronizer sleeve splines.

AK101124

3. Place the chain in tight mesh with the 2-4WD

synchronizer and front output shaft sprockets.

4. With both sprockets spaced the farthest apart,

install them on the transfer case simultaneously.

>>H<< CHAIN COVER INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in

an unbroken, non-excessive quantity.

AK403508AB

2 mm Diameter

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. Apply sealant to the chain cover, and then install

the chain cover.

Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent

>>I<< H-L CLUTCH SLEEVE INSTALLATION

AK500678AB

Identification groove

Installation
direction

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-56

Check that the H-L clutch sleeve is in the correct
direction for installation.

>>J<< H-L SHIFT RAIL INSTALLATION

AK503411AB

H-L shift rail

Interlock plunger

H-L shift rail

2-4WD shift rail

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.

>>K<< SPRING PIN INSTALLATION

AK503412

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 center of the
shift rail.

>>L<< OIL SEAL INSTALLATION

AK403510AQ

MB990938

MB990932

<V5MB1-J-NEG, JER>

AK403510AR

MB990938

MB990929

<V5MB1-J-ND2, NEZ, PD2>

1. Use special tools to install the oil seal.

• Installer adapter (MB990932) <V5MB1-J-NEG,

JER>

• Installer adapter (MB990929) <V5MB1-J-ND2,

NEZ, PD2>

• Installer bar (MB990938)

2. Apply the specified grease to the lip of oil seal.

Specified lubricant: Mitsubishi Part No.
0101011 or equivalent

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