Mitsubishi Montero (1991+). Manual - part 290

         2) Remove 2 seal plugs. Remove 2 poppet springs and steel

balls. Shift transfer case to "4WD" and pull high-low shift rail out,

in rear cover direction. Remove interlock plunger. Remove pulse

generator (if equipped), front output shaft cover and pulse rotor (if

equipped). Remove snap ring from rear bearing on output shaft. Remove

chain cover, oil guide and side cover. Remove countershaft locking

plate. Remove countershaft.

         3) Remove countergear, 2 thrust washers, 2 needle bearings

and spacer through side cover opening. Remove snap ring, spring

retainers and spring from 2WD-4WD shift rail. Remove front output

shaft, rear output shaft and chain as assembly.

         4) Remove 2WD-4WD shift fork and distance piece. Drive out

2WD-4WD shift rail spring pin. Remove 2WD-4WD shift rail and lug.

Remove high-low shift fork and high-low synchronizer sleeve. Remove

needle bearing and snap ring from input gear. Remove input gear

assembly.

         5) If either control shaft or input gear oil seals are to be

replaced, drive out roll pin from transmission control change shifter.

Separate transfer case from adapter. See Fig. 3.

         Disassembly (Montero)

         1) Remove dynamic damper, 5 detection switches and 3 steel

balls. Remove poppet plug, spring and steel ball. Remove speedometer

gear assembly. Remove output shaft rear cover, spacers, dust seal

guard and oil seals. Front output shaft cover, wave spring and spacer

(if equipped).

         2) Remove high-low shift rail plug and high-low shift fork

spring pin. Shift transfer case to "4WD". Remove rear cover and high-

low shift rail. Remove interlock plunger. Remove rear output shaft

(viscous coupling) assembly and center differential assembly. Remove

2WD-4WD synchronizer assembly, chain and front output shaft from

transmission as a unit. With White paint make match marks in grooves

of 2WD-4WD synchronizer in 3 places. With White paint make match marks

on spline projections of 2WD-4WD synchronizer sleeve in 3 places.

Refer to match marks during reassembly.

         3) Remove snap ring, spring seat, spring, 2WD-4WD shift fork

and 2WD-4WD synchronizer sleeve. Remove differential lock hub, oil dam

cover and bearing retainer. Remove side cover and gasket. Remove

transfer counter gear shaft, transfer counter gear, thrust washer,

needle bearings and spacer. Remove transfer drive shaft assembly.

Remove high-low shift fork assembly and clutch sleeve. Remove transfer

input gear assembly.

         4) Remove 2WD-4WD shift lug spring pin, spring, spring

retainer 2WD-4WD shift lug and shift rail. Remove input gear oil seal,

baffle plate, dust seal guard and front output shaft oil seal. See

Fig. 4.

         COMPONENT DISASSEMBLY & REASSEMBLY

         OUTPUT SHAFT ASSEMBLY (MONTERO)

         Disassembly & Reassembly (Rear Shaft)

         Remove snap ring and press ball bearing off without putting

pressure on vicious coupling. Remove viscous coupling. To install,

reverse removal procedure. When installing new snap ring, select

thickest ring that will fit into groove. Acceptable clearance is 0-.

003" (0-.08 mm).

         Disassembly & Reassembly (Front Shaft)

         Remove front bearing. Remove rear bearing. To install reverse

removal procedure.

         OUTPUT SHAFT ASSEMBLY (RAM-50)

         Disassembly

         1) Remove snap ring from rear of output shaft. Remove high-

low synchronizer hub by hand or when low speed gear is pressed off.

Remove bearing spacer and needle bearing. Remove staking from lock nut

on rear output shaft. See Fig. 5. Remove lock nut. Remove ball bearing

from below lock nut. Remove sprocket spacer and steel ball.

         2) Remove drive sprocket, 2 needle bearings, sprocket sleeve

and steel ball. Remove 2WD-4WD synchronizer sleeve, hub, stopper plate

and ball bearing.

         Reassembly

         1) Press ball bearing and stopper plate on front output

shaft, pushing against inner race. After fitting, ensure bearing

rotates smoothly. Install 2WD-4WD synchronizer hub and sleeve. Ensure

hub and sleeve face correct direction. Install steel ball (for

sprocket sleeve positioning) on rear output shaft. Install sprocket

sleeve.

         2) Install 2 needle bearings on outer circumference of

sprocket sleeve. Install drive sprocket. Install steel ball and

sprocket spacer. Install ball bearing (press may not be needed as

bearing may be loose). Check for smooth rotation.

         3) Tighten sprocket retaining lock nut to specification. See

the TORQUE SPECIFICATIONS table. Stake lock nut with punch. After lock

nut is tightened, ensure drive sprocket rotates smoothly. Install

needle bearing, thrust washer and low speed gear on rear of rear

output shaft.

         4) Install needle bearing, thrust washer and low speed gear

on rear output shaft. Mount high-low synchronizer hub. Ensure hub

faces correct direction.

         5) Mount high-low synchronizer hub snap ring on front end of

rear output shaft. Selective fit snap rings are available in 5

thicknesses. Use thickest snap ring that will fit into output shaft

groove. Acceptable clearance is 0-.003" (0-.08 mm). See  Fig. 5.

Fig. 5:  Exploded View Of Output Shaft Assembly (Ram-50)

Courtesy of Mitsubishi Motor Sales of America.

         TRANSFER DRIVE SHAFT (MONTERO)

         Disassembly & Reassembly

         Remove snap ring, high-low synchronizer hub and low speed

gear. Remove bearing spacer, needle bearing and ball bearing. To

assemble, reverse disassembly procedure. Use thickest snap ring that

will fit into output shaft groove. Acceptable clearance is 0-.003" (0-

.08 mm). See Fig. 4.

         INPUT SHAFT ASSEMBLY (RAM-50)

         Disassembly & Reassembly

         1) Remove snap ring from input shaft. Support bearing in

press. Press input shaft out to remove bearing.

         2) On manual transmission models, remove spacer and snap ring

from below bearing. Remove cone spring and sub gear. See  Fig. 6. For

reassembly, reverse disassembly procedures.

         3) Press bearing into input shaft, pushing against inner

race. After fitting, ensure bearing rotates smoothly. Fit snap ring

over front end of input shaft. Snap rings are available in selective

thicknesses. Select thickest snap ring that will fit in groove.

Fig. 6:  Exploded View Of Input Shaft Assembly (Ram-50 - Manual

Shown, Automatic Similar)

Courtesy of Mitsubishi Motor Sales of America.

         CENTER DIFFERENTIAL CASE (MONTERO)

         Disassembly & Reassembly

         Separate center differential case front from rear case.

Remove pinion shaft, pinions, thrust washers and dowel pins. Inspect

for excessive wear and replace parts as needed. Align dowel pins and

match marks on outer case circumferences. Assemble front and rear

center differential cases. See the TORQUE SPECIFICATIONS table. Also,

see Fig. 7.

Fig. 7:  Exploded View Of Center Differential (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         2WD-4WD SYNCHRONIZER (MONTERO)