Mitsubishi L200. Manual - part 341

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-73

>>I<< CHAIN COVER INSTALLATION

CAUTION

• Completely degrease the FIPG-applied sur-

face 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.

•

AK403508AB

2 mm Diameter

Make sure the starting point and the ending 
point are about the middle between the bolts.

1. Apply sealant to the chain cover, and then install 

the chain cover.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

>>J<< H-L CLUTCH SLEEVE INSTALLATION

AK500678AB

Identification groove

Installation
direction

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

>>K<< H-L SHIFT RAIL INSTALLATION

AK503411AB

H-L shift rail

Interlock plunger

H-L shift rail

2-4WD 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.

>>L<< 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.

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-74

>>M<< OIL SEAL INSTALLATION

AK403510 AC

MB990938

MB990932

<Easy select 4WD>

AK403510AH

MB990938

MB990929

<Super select 4WD>

1. Use special tools to install the oil seal.

• Installer adapter (MB990932) <Easy select 

4WD>

• Installer adapter (MB990929) <Super select 

4WD>

• Installer bar (MB990938)

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

Specified lubricant:
 Mitsubishi Part No. 0101011 or equivalent

>>N<< SPACER INSTALLATION

AK403504AE

Rear cover

Spacer

A

B

<Easy select 4WD>

AK503414AE

Rear cover

Spacer

A

B

<Super select 4WD>

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 <Easy select 4WD>

• 0.025 − 0.150 mm <Super select 4WD>

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-75

(For rear output shaft bearing to rear cover 
clearance)

>>O<< OIL COVER INSTALLATION

AK403729

AC

Oil hole

Oil cover

Install the oil cover so that the oil hole shown in the 
illustration.

>>P<< REAR COVER INSTALLATION

CAUTION

• Completely degrease the FIPG-applied sur-

face 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.

•

AKX00172

2 mm
Diameter

AC

Make sure the starting point and the ending 
point are about the middle between the bolts.

Apply the sealant to the chain cover.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

>>Q<< RETURN SPRING / SUPPORT PIN 
INSTALLATION

AK403511AB

Return spring

1. Insert the bent section of the return spring into the 

control housing as shown.

CAUTION

• Completely degrease the FIPG-applied sur-

face 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.

•

AK403517

AB

Make sure the starting point and the ending 
point are about the middle between the bolts.

2. Apply the sealant to the support pin section and 

apply the adhesive to the threads.

Specified sealant:
 3M

™ ATD Part No. 8672 or equivalent

Specified adhesive:
 Mitsubishi Part No. MB160450 or equivalent

3. Insert the support pin and install the nut.

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V4A5>

23C-76

>>R<< CONTROL HOUSING INSTALLATION

CAUTION

• Completely degrease the FIPG-applied sur-

face 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.

•

AK000033

2 mm 
Diameter

AD

Make sure the starting point and the ending 
point are about the middle between the bolts.

Apply the sealant to the control housing.

Specified sealant:
 Mitsubishi Part No. 997740 or equivalent

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

>>T<< 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.

>>U<< TRANSFER CASE PLATE INSTALLATION

CAUTION

• Completely degrease the FIPG-applied sur-

face 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.

•

AK403617AC

2 mm Diameter

Make sure the starting point and the ending 
point are about the middle between the bolts.

1. Apply the sealant to the transfer case plate.

Specified sealant:
 Mitsubishi Part No. MD997740 or equivalent

CAUTION

The transfer case plate must be installed smooth 
and straight to get a good seal.
2. Install the transfer case plate together with the 

input gear and countershaft. 

>>V<< SPEEDOMETER DRIVEN GEAR SLEEVE 
ASSEMBLY INSTALLATION

AK201067AD

Mating marks

Match the mating marks to the number of teeth.