Mitsubishi L200. Manual - part 270

2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-65

2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>

DISASSEMBLY AND REASSEMBLY

M1222010900020

AK503423

4

5

6

1

2

3

7

9

9

8

10

AB

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

>>

C

<< 1.

Snap ring

2.

2-4WD Synchronizer hub

3.

2-4WD Synchronizer spring

>>

B

<< 4.

Outer synchronizer ring

5.

Synchronizer cone

>>

A

<< 6.

Inner synchronizer ring

7.

Drive sprocket

8.

Bearing spacer

9.

Needle bearing

10. Front side gear

REASSEMBLY SERVICE POINTS

>>A<< INNER SYNCHRONIZER RING INSTALLA-
TION

AK503426AB

Apply oil the synchronizer ring cone surface before 
installation.

2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-66

>>B<<OUTER SYNCHRONIZER RING 
INSTALLATION

AK503427AB

Apply oil the synchronizer ring cone surface before 
installation.

>>C<<SNAP RING INSTALLATION

AK101272AD

Snap ring

Select and install the snap ring which adjusts the 2-
4WD synchronizer hub end play to standard value.

Standard value: 0 

− 0.08 mm

INSPECTION

M1222011000020

SYNCHRONIZER RING

AK500672AB

CAUTION

When any of the outer ring, inner ring or cone 
has to be replaced, replace them as a set.
1. Check to ensure that the clutch gear tooth surface 

and cone surface are not damaged and broken.

AK503424

2. After applying oil to the taper portion on each 

gear, press and fit the synchronizer ring by hand. 
Confirm the synchronizer ring cannot be rotated.

AK503425

3. Using the thickness gauge, check the clearance 

between the synchronizer ring and the gear.

Limit: 0.3 mm

CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-67

CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>

DISASSEMBLY AND REASSEMBLY

M1222010600041

AK503428

4

5

6

1

2

3

4

3

4

3

4

3

69 ± 10 N·m

AB

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

>>

A

<< 1.

Center differential case A

2.

Dowel pin

3.

Differential pinion

4.

Thrust washer

5.

Pinion shaft

6.

Center differential case B

REASSEMBLY SERVICE POINT

>>A<<CENTER DIFFERENTIAL CASE B INSTAL-
LATION

AK101274AD

Dowel pin

Dowel pin

Pay attention to the position of the dowel pins when 
reassembling, and make sure that the match marks 
on the outside circumference are in alignment.

H-L SHIFT FORK

MANUAL TRANSMISSION OVERHAUL <V5MB1>

22C-68

H-L SHIFT FORK

DISASSEMBLY AND REASSEMBLY

M1222009700022

AK500689AB

1

2

3

6

5

4

9.0 ± 2.0 N·m

Disassembly steps 

>>

A

<<

1.

Return spring plug

2.

Return spring

3.

Return spring

4.

Select plunger

5.

Plunger boss

6.

High & low shift fork

REASSEMBLY SERVICE POINT

>>A<< RETURN SPRING PLUG INSTALLATION

AK500693

Return spring plug

AC

Plunger boss

Apply the sealant to the thread and screw the return 
spring plug to be an even surface between the 
plunger boss end face and the return spring plug.

Specified sealant: 3M STUD Locking No. 
4170 or equivalent