Mitsubishi L200. Manual - part 366

 

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Mitsubishi L200. Manual - part 366

 

 

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-79

NOTE: The new bolt does not require sealant appli-
cation as it is precoated with sealant.

>>D<< SNAP RING INSTALLATION

AK602092

1. Select a proper snap ring so that the end play of 

the H-L clutch hub will have the standard value, 
and install the snap ring on the transfer drive 
shaft.

Standard value: 0 

 0.08 mm

(For H-L clutch hub end play)

>>E<< H-L SHIFT FORK AND H-L CLUTCH 
SLEEVE INSTALLATION

AK602093AC

H-L shift fork

1. Apply the specified grease to the H-L shift fork 

shaft inserting portion, and install the H-L shift fork 
and H-L clutch sleeve in combined state in the 
transfer case.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

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

>>G<< TRANSFER CASE PLATE INSTALLATION

AK602095AC

1. Apply the specified grease to the illustrated 

position of the H-L shift rail inserting portion of the 
transfer case plate.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

AK602096AC

2. Face the notched portion of the input gear in the 

illustrated direction (in the direction of the 
countershaft gear bearing hole).

AK602097AC

3. Apply the specified sealant to the transfer case.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-80

CAUTION

If the sub gear does not readily come in mesh 
with the countershaft gear, rote the transfer drive 
shaft, etc. to securely engage it.
4. While making sure that the notched portion of the 

input gear positioned in Step 2 is in alignment with 
the gear portion of the countershaft, install the 
transfer case palate.

>>H<< SNAP RING INSTALLATION

AK602098

Select a proper snap ring so that the end play of the 
differential lock hub will have standard value, and 
install it on the transfer drive shaft.

Standard value: 0 

 0.08 mm

(For differential lock hub end play)

>>I<< STEEL BALL AND SPACER INSTALLATION

AK602099AC

Steel ball

Install the steel ball in the illustrated position of the 
transfer drive shaft and install the spacer with its oil 
groove toward the chain cover.

>>J<< 2-4WD SHIFT FORK AND 2-4WD CLUTCH 
SLEEVE INSTALLATION

AK602100AC

Apply the specified grease to the 2-4WD shift fork 
shaft inserting position and install the 2-4WD shift 
fork and 2-4WD clutch sleeve in combined state in 
the transfer case.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>K<< SUN GEAR / 2-4WD CLUTCH HUB / SNAP 
RING INSTALLATION

AK602101

1. Install the 2-4WD clutch hub on the sun gear.
2. Select the proper snap ring so that the end of play 

of the 2-4WD clutch hub will have the standard 
value, and install it on the sun gear.

Standard value: 0 

 0.08 mm

(For 2-4WD clutch hub end play)

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-81

>>L<< SYNCHRONIZER OUTER RING / 
SYNCHRONIZER CONE / SYNCHRONIZER INNER 
RING INSTALLATION

AK602102

1. Combine the synchronizer outer ring, 

synchronizer cone and synchronizer inner ring, 
press then against the drive sprocket, and 
measure the dimension shown in the illustration.

Limit: 0.3 mm
(For clearance between synchronizer outer 
ring and drive sprocket)

2. If the dimension is out of the limit value, replace 

them with a synchronizer ring set.

3. Apply gear oil to the synchronizer outer ring and 

synchronizer inner ring.

AK602103AC

4. Line up the notched portion of the 2-4WD clutch 

hub with the projecting portion of the synchronizer 
ring and install the ring on the 2-4WD clutch hub.

>>M<< DRIVE SPROCKET / FRONT OUTPUT 
SHAFT / CHAIN INSTALLATION

AK602087

1. Set the chain in mesh with the drive sprocket and 

front output shaft sprocket and install them in the 
transfer case.

AK602104AC

2. Install the drive sprocket so that its illustrated 

holes will mach the projecting portions of the 
synchronizer cone.

>>N<< REAR OUTPUT SHAFT INSTALLATION

AK602105 AC

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>O<< CHAIN COVER INSTALLATION

AK602106 AC

1. Apply the specified grease to the indicated 2-4WD 

shift rail inserting portion.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

2. Apply the specified sealant to the illustration of the 

chain cover.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-82

>>P<< SNAP RING INSTALLATION

AK602107

1. Install the snap ring in the bearing groove of the 

rear output shaft.

2. With the rear output shaft pressed against the 

chain cover, measure the clearance between the 
chain cover and snap ring.

3. Select a snap ring whose thickness is the 

dimension of the measured clearance plus the 
standard value.

Standard value: 0.12 

 0.24 mm

(For rear output shaft preload)

4. Remove the snap ring from the bearing groove of 

the rear output shaft, install the selected snap 
ring, and reinstall the removed snap ring in the 
bearing groove of the rear output shaft.

>>Q<< SAPCER INSTALLTION

CAUTION

Measure the projection with the snap ring 
installed.

AK602108

Projection

AC

1. With the output shaft pressed toward the chain 

cover, measure the projection of the bearing from 
the chain cover.

AK602109AC

Concave
pprtion

2. Measure the dimension of the rear cover concave 

portion at the illustrated position.

Standard value: 0 

 0.12 mm

(For rear output shaft end play)

>>R<< OIL GUIDE INSTALLATION

AK602694

Oil guide

AB

Apply specified grease to the lip of the oil seal.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

>>S<< OIL SEAL INSTALLATION

AK602110AC

MB990938

MB990932

Use special tools to install the oil seal in the rear 
cover.

• Installer adapter (MB990932)

• Handle (MB990938)

 

 

 

 

 

 

 

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