Mitsubishi Montero (1991+). Manual - part 289

Fig. 1:  4WD Indicator Control Unit Testing (Montero)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2:  Detection Switch Testing Locations (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         REMOVAL & INSTALLATION

         Removal

         1) Remove negative battery cable. Remove transfer case skid

plate (if equipped). Scribe alignment marks and remove both drive

shafts. Drain oil from transfer case. Disconnect wiring harness from

back-up light switch, all 4WD switches and any other electrical

connectors (if equipped).

         2) Disconnect speedometer cable from drive. Unclip cable from

case. Place transfer case shifter in "2H" position and transmission in

Neutral. Remove 6 bolts holding control lever assembly. Remove control

lever assembly and gasket.

         3) Remove select plunger bore plug at right side of case.

Remove select spring and plunger. Remove change shifter spring pin.

Remove change shifter. Remove transfer case mount. Remove 4 bolts and

2 nuts holding transfer case to adapter. Remove transfer case from

vehicle.

         Installation

         1) Position transmission shifter in Neutral and transfer case

lever in "2H" position. Install neutral return plungers and springs in

holes on top of adapter. Tighten plug until it is flush with adapter

surface. Cover plug threads with sealant.

         2) Coat inside of change shifter with grease. Ensure change

shifter pin protrudes 1/8" above change shifter when installed. Mount

detent plunger spring and install plug (if equipped). To complete

installation, reverse removal procedure. Fill transfer case with API

GL-4 or higher 75W-90 or 75W-85W gear oil.

Fig. 3:  Exploded View Of Transfer Case (Ram-50)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4:  Exploded View Of Transfer Case (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         TRANSFER CASE DISASSEMBLY

         Disassembly (Ram-50)

         1) Remove both 4WD indicator switches and steel balls. Remove

speedometer gear assembly. Remove output shaft cover, gasket, wave

spring and spacer. See Fig. 3. Remove rear cover, rear cover gasket

and spacer from chain cover. Drive roll pin out of high-low shift

fork.