Mitsubishi L200. Manual - part 340

AK800442

48

49

50 

52

57

51

54

55

56

53

58

59

62

60

61

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

Apply gear oil to
all moving parts
before installation.

35 ± 6 N·m

AC

19 ± 3 N·m

19 ± 3 N·m

46

45

44

47

43

42

Disassembly steps 

42. Harness bracket

>>R<<

43. Control housing

>>Q<<

44. Support pin

>>Q<<

45. Return spring

<<

A

>>

>>

K

<<

46. H-L shift rail
47. H-L shift fork

>>

J

<<

48. H-L clutch sleeve
49. Harness bracket
50. Harness bracket
51. Harness bracket

<<A>>

>>

I

<<

52. Chain cover
53. Interlock plunger
54. Wave spring
55. Rear output shaft
56. Needle bearing
57. Needle bearing
58. Center differential case

<<

C

>>

>>

H

<<

59. 2-4WD synchronizer

<<

C

>>

>>

H

<<

60. Chain

<<

C

>>

>>

H

<<

61. Front output shaft
62. Needle bearing
63. E-ring
64. Spring seat
65. Spring
66. 2-4WD shift lug and shift rail 

assembly

>>

G

<< 67. Spring pin

68. 2-4WD shift lug
69. Spring retainer
70. Spring
71. 2-4WD shift rail
72. 2-4WD shift fork
73. 2-4WD synchronizer sleeve
74. Spacer
75. Steel ball

>>

F

<<

76. Snap ring
77. Differential lock hub

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-69

Disassembly steps (Continued)

AK503403AG

20 ± 2 N·m

Apply gear oil to
all moving parts
before installation.

80

81

82

83

84

85

86

87

9.0 ± 1.0 N·m

79

78

Disassembly steps 

>>

E

<<

78. Snap ring

>>

D

<<

79. H-L clutch hub
80. Low speed gear
81. Needle bearing
82. Rear bearing retainer
83. Transfer drive shaft
84. Oil pool cover
85. Dust seal guard

>>

A

<<

86. Oil seal
87. Transfer case

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-70

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

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-71

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

AK101119

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

ADJUSTMENT BEFORE REASSEMBLY

Spacer selection for adjustment of countershaft gear 
end play. (Refer to adjustment of transfer - spacer 
selection for adjustment of countershaft gear end 
play 

P.23C-77

)

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<< SPRING PIN INSTALLATION

AK403503AB

Spring pin

1. Align the 2-4WD 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.

>>C<< 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.

>>D<< H-L CLUTCH HUB INSTALLATION

AK503408

Installation
direction

Transfer front side

AB

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

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-72

>>E<< 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

(For H-L clutch hub end play)

>>F<< 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

(For differential lock hub end play)

>>G<< SPRING PIN INSTALLATION

AK503410

1. Align the 2-4WD 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.

>>H<< 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.