Mitsubishi L200. Manual - part 367

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-83

>>T<< REAR COVER INSTALLTION

AK602111AC

Apply the specified sealant to the illustration of the 
chain cover.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

>>U<< MAIN SHIFT RAIL AND SHIFT ACTUATOR 
INSTALLATION

AK602695

50.5mm

Rod
extends

Vew A

A

B

A

AB

1. Contact a 12 voltage power supply across the 

terminals of the actuator connector in a polarity 
appropriate for causing the actuator motor to 
move in the rod extending direction or retracting 
direction until the amount of extension of the rod 
is as indicated in the drawing.

Terminal A

Terminal B

Rod 
movement

Power supply (+) Power supply (-)

Extension

Power supply (-)

Power supply (+) Retraction

AK602112AC

2. Apply the specified grease to the O-ring.

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

3. Combine the main shift rail key with actuator key 

and insert them in the transfer case.

>>V<< SHIFT RAIL DRIVE GEAR INSTALLATION

AK602113AC

Mark

Tird gear groove

Install the shift rail drive gear with its marked tooth in 
mesh with the third gear groove of the each shift rail.

>>W<< TRANSFER CASE COVER INSTALLATION

AK602114AC

Apply specified sealant to the illustrated position of 
the transfer case cover.

Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

>>X<< SWITCH INSTALLATION

AK602115 AB

B

A

C

D

E

Install the switches as illustrated.

Mounting 
position

Switch name

Tube 
color

Connecto
r color

A

2WD/4WD 
switch

Blue

Black

B

4LLC switch

Black

Brown

C

2WD switch

Black

Black

D

4H switch

Green

White

E

Center 
differential lock 
switch

Blue

Brown

TRANSFER

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-84

ADJUSTMENT OF TRANSFER

M1233030900071

SPACER SELECTION FOR ADJUST-
MENT OF COUNTERSHAFT GEAR END 
PLAY

<Measurement using a solder>

CAUTION

• If 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.

AK602094AC

Solder

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

in the illustrated positions of the transfer case 
housing.

2. Install the countershaft gear 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 

countershaft gear, 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.

AK602691

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

(For counter shaft gear end play)

<Measurement using plastigage>

AK602692

Plastigage

AB

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 countershaft gear 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 

countershaft gear, 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.

AK602693

Plastigage

Spacer

AB

TRANSFER CASE PLATE

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-85

7. Measure the width of the crushed plastigage at its 

widest part using a scale printed on the plastigage 
package.

Spacer thickness: (T 

− 0) to (T − 0.15)

T: The crushed solder thickness
Standard value: 0 

− 0.15 mm

(For counter shaft gear end play)

TRANSFER CASE PLATE

DISASSEMBLY AND REASSEMBLY

M1233024200244

AK602116

2

3

4

5

6

19 ± 2 N·m

AC

1

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

>>B<<

1.

Seal bolt

2.

Bearing retainer

3.

Transfer input gear

>>A<<

4.

Oil seal

5.

Baffle plate

6.

Transfer case plate

Disassembly steps (Continued)

COUNTERSHAFT GEAR

AUTOMATIC TRANSMISSION OVERHAUL <V5A5>

23D-86

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

AK602117

MB990938

MB990933

AC

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

Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent

2. Use special tools to install the oil seal.

• Handle (MB990938)

• Installer adapter (MB990933)

>>B<< SEAL BOLT INSTALLATION

AK602091AC

Apply the specified sealant to the threads.

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

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

COUNTERSHAFT GEAR

DISASSEMBLY AND REASSEMBLY

M1233024000284

AK602118

1

2

3

4

5

6

AC

Apply gear oil to
all moving parts
before installation.

Disassembly steps 

<<A>>

>>C<<

1.

Ball bearing

>>B<<

2.

Snap ring

>>A<<

3.

Spacer

<<B>>

>>A<<

4.

Roller bearing

<<B>>

>>A<<

5.

Inner race

6.

Counter shaft gear

Disassembly steps (Continued)