Mitsubishi L200. Manual - part 268

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-57

>>M<< SPACER INSTALLATION

AK403504AJ

Rear cover

Spacer

A

B

<V5MB1-J-NEG, JER>

AK503414AJ

Rear cover

<V5MB1-J-ND2, NEZ, PD2>

Spacer

A

B

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 <V5MB1-J-NEG, JER>

0.025 

− 0.150 mm <V5MB1-J-ND2, NEZ, PD2>

>>N<< OIL COVER INSTALLATION

AK403729

AC

Oil hole

Oil cover

In case of <V5MB1-J-NEG, JER> type, install the oil 
cover so that the oil hole shown in the illustration.

>>O<< REAR COVER INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in 

an unbroken, non-excessive quantity.

AKX00172

2 mm
Diameter

AC

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 the sealant to the chain cover.

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

>>P<< SPACER INSTALLATION
Install the previously selected spacer (Refer to 
ADJUSTMENT BEFORE ASSEMBLY).

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-58

>>Q<< COUNTER SHAFT GEAR INSTALLATION

AK503394AB

Notched selection

Input gear

Counter shaft

1. Turn the input gear’s notched selection surface 

toward the counter shaft mounting surface. then 
install the counter shaft.

>>R<< TRANSFER CASE PLATE INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in 

an unbroken, non-excessive quantity.

AK403617AC

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 the sealant to the transfer case plate.

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

CAUTION

The transfer case plate must be installed 

smooth and straight to get a good seal.
3. Install the transfer case plate together with the 

input gear and countershaft. 

>>S<< SPEEDOMETER DRIVEN GEAR SLEEVE 
ASSEMBLY INSTALLATION

AK503942AB

Mating marks

Match the mating marks to the number of teeth.

>>T<< SPRING INSTALLATION

AK403513

Install the spring with its tapered end toward the ball.

>>U<< PLUG INSTALLATION

AK403514AB

Apply the sealant to the threads.

Specified sealant: 3M AAD Part No. 8672 or 
equivalent

NOTE: 

.

The new plug is precoated with sealant, so seal-

ant does not need to be applied.

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-59

>>V<< DETECTION SWITCH INSTALLATION

V

V

V

V

AK801184

A

B

C

D

E

AB

1
2

4

5

3
F

6

Install with care. Do not make mistake when locating 
each switch.

Detection switch name

Connector 
No./Color

A

Center differential lock 
detection switch

1/Brown

B

2WD/4WD detection switch

2/Black

C

Center differential lock 
operation detection switch

4/Blown

D

4WD operation detection switch 5/Black

E

High range/Low range detection 
switch

3/white

F

4LLc operation detection switch 
<V5MB1-J-PD2>

6/white

ADJUSTMENT OF TRANSFER

M1222016700013

SPACER SELECTION FOR ADJUST-
MENT OF COUNTER SHAFT END PLAY

<Measurement using a solder>

CAUTION

• f soft solder is not available, select the spacer 

in accordance with Plastigage method.

• If the spacer appropriate for the standard 

value cannot be selected using soft solder, 
select the spacer in accordance with Plasti-
gage method.

AK403499AB

Solder

1. Put solders (1.0 mm diameter, about 10 mm long) 

in the illustrated positions of the transfer case 
housing.

2. Install the counter shaft into the transfer case.
3. Install the transfer case plate and tighten the bolts 

to the specified torque of 35 

± 6 N⋅m.

4. Remove the transfer case plate and the counter 

shaft, and then take out crushed solders.

5. If the solders have not crushed, use thicker 

solders (1.6 mm diameter, about 10 mm long) and 
repeat steps 2 to 4.

AK305233

6. Measure the thickness of the crushed solder with 

a micrometer and select a spacer that will provide 
the standard value.

Spacer thickness: (T 

− 0) to (T − 0.15)

T: The crushed solder thickness
Standard value: 0 

− 0.15 mm

<Measurement using Plastigage>

AK403499AC

Plastigage

1. Put plastigage (about 10 mm long) in the 

illustrated positions of the transfer case housing.

2. Install the adjusting spacer having the minimum 

thickness.

3. Install the counter shaft into the transfer case.
4. Install the transfer case plate and tighten the bolts 

to the specified torque of 35 

± 6 N⋅m.

5. Remove the transfer case plate and the counter 

shaft, and then take out crushed solders.

6. If the Plastigages have not crushed, replace the 

spacer with a thicker one and repeat steps 3 to 5.

AK402081

Plastigage

Spacer

AB

TRANSFER

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-60

7. Measure the width of the crushed Plastigage at its 

widest part using a scale printed on the Plastigage 
package.

Standard value: 0 

− 0.15 mm

INSPECTION

M1222008900153

4WD DETECTION SWITCH

AK500505AB

4WD operation detection switch

Check for the continuity between the connector ter-
minals.

Switch 
condition

Connector 
terminals

Continuity

Switch end 
pressed

1 

− 2

Conductive

Switch end 
released

1 

− 2

Open

HIGH RANGE/LOW RANGE DETECTION SWITCH

AK500510AB

High range/low range detection 
switch

Check for the continuity between the connector ter-
minals.

Switch 
condition

Connector 
terminals

Continuity

Switch end 
pressed

1 

− 2

Open

Switch end 
released

1 

− 2

Conductive

4LLc OPERATION DETECTION SWITCH

AK503422

Check for the continuity between the connector ter-
minals.

Switch 
condition

Connector 
terminals

Continuity

Switch end 
pressed

1 

− Body earth

Open

Switch end 
released

1 

− Body earth

Conductive

DETECTION SWITCH

AK503422

Check for the continuity between the connector ter-
minals.

Switch 
condition

Connector 
terminals

Continuity

Switch end 
pressed

1 

− Body earth

Open

Switch end 
released

1 

− Body earth

Conductive