Mitsubishi Montero (1991+). Manual - part 291

         Disassembly

         Remove snap ring, 2WD-4WD synchronizer hub and synchronizer

spring. Remove outer synchronizer ring, synchronizer cone and inner

synchronizer ring. Remove drive sprocket and needle bearing from front

drive pinion. Inspect inner and outer synchronizer rings and cone for

excessive wear. Install inner and outer synchronizer rings and cone

onto drive sprocket. Measure distance between drive sprocket and outer

synchronizer. If distance is less than .0118" (.300 mm) replace

synchronizer parts as a set.

         Reassembly

         Install drive sprocket and needle bearing onto front drive

pinion. Apply transfer case gear oil to contacting surfaces of inner

and outer synchronizer rings and synchronizer cone. Install inner and

outer synchronizer rings and synchronizer cone. Install synchronizer

spring, 2WD-4WD synchronizer hub and snap ring to complete assembly.

When installing new snap ring, select thickest ring that will fit into

groove. Acceptable snap ring clearance is 0-.003" (0-.080 mm).

Fig. 8:  Exploded View Of 2WD-4WD Synchronizer (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         TRANSFER CASE REASSEMBLY

NOTE:    ALWAYS replace all gaskets, oil seals, snap rings and spring

         pins with new parts. Coat both sides of gaskets and bolt

         threads with sealant. Lubricate all sliding and rotating

         parts with transfer case gear oil before assembling.

         Reassembly (Ram-50)

         1) Install input gear and front output shaft oil seals into

transfer case housing. Pack grease between lips of seals and press

seal circumference uniformly.

         2) Install input gear assembly in transfer case. See  Figs. 3

and 6. Input gear assembly snap ring is available in selective

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

groove. Allowed snap ring clearance is 0-.0024" (0-.060 mm).

         3) Insert needle bearing onto rear output shaft assembly.

Install high-low synchronizer sleeve and shift fork. Install 2WD-4WD

shift fork. Engage chain securely on front and rear output shaft

sprockets. Assemble 2WD-4WD synchronizer sleeve with 2WD-4WD shift

fork. Install assembly over 2WD-4WD shift rail. Install front and rear

output shafts with chain as an assembly.

         4) Install 2WD-4WD shift lug, distance piece, 2WD-4WD shift

rail and spring pin. Ensure slit in spring pin is in line with 2WD-4WD

shift rail. Install 2 spring retainers with spring on 2WD-4WD shift

rail. Install snap ring to end of 2WD-4WD shift rail. See  Fig. 3.

         5) Insert 2 needle bearings and spacer into countergear.

Install one thrust washer at each end of countergear. Ensure tab on

thrust washers fits into groove of transfer case. Install countergear

shaft assembly with "O" ring.

         6) Install side cover and gasket. Install oil guide. Apply

sealant to both sides of gasket and install gasket and chain cover.

Ensure oil guide end fits into chain cover opening. Fit snap ring into

groove of rear bearing on rear output shaft. Tighten bolts to

specification. See TORQUE SPECIFICATIONS.

         7) Install interlock plunger. Shift 2WD-4WD shift rail to 4WD

position. Install high-low shift rail through high-low shift fork in

case. Install 2 poppet balls and springs. Install seal plugs. When

installing poppet springs, smaller end must be toward ball.

         8) On models with pulse generator, install pulse rotor, wave

spring and spacer. Measure protrusion "A" of front output shaft rear

bearing and recess "B" of cover and calculate clearance. See  Fig. 9.

If clearance is greater than .079" (2.0 mm), select and install spacer

to bring clearance within specification. If clearance is less than .

079" (2.0 mm), use wave spring alone. Apply sealant to both sides of

gasket and install gasket and cover. Install pulse generator (if

equipped).

         9) On all models, align high-low shift fork and shift rail

spring holes and drive in roll pin with punch. Roll pin should be

installed with slit on center line of shift rail. Install wave spring

on rear of rear output shaft bearing. Apply sealant to both sides of

rear cover gasket. Install gasket and cover.

         10) Check output shaft end play. Measure protrusion "A" of

rear output shaft rear bearing and recess "B" of cover and calculate

clearance. Ensure end play is 0-.004" (0-.10 mm). Apply sealant to

both sides of gasket and install gasket and cover. See  Fig. 9.

         11) Install speedometer sleeve assembly in rear cover. Align

match mark on speedometer sleeve assembly in rear cover. See  Fig. 10.

Align match mark on speedometer sleeve with mark on case according to

number of teeth on speedometer driven gear. Install speedometer driven

gear sleeve clamp and tighten bolt to specification. Install both 4WD

indicator light switches with steel balls. See  TORQUE SPECIFICATIONS.

Fig. 9:  Measuring Rear Output Shaft Bearing Clearance (Ram-50)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10:  Aligning Speedometer Sleeve

Courtesy of Mitsubishi Motor Sales of America.

         Reassembly (Montero)

         1) Install input gear and front output shaft oil seals into

transfer case housing. Install transfer input gear assembly baffle

plate and input gear seal. Pack grease between lips of seals and press

seal circumference uniformly.

         2) Install 2WD-4WD shift lug into transfer case. Install

spring retainer and spring to shift rail and install into shift lug.

Press on shift rail to align spring pin holes in shift rail and shift

lug. While holding shift rail, tap spring pin into place with slit

facing center of shift rail.

         3) Install transfer input gear assembly and snap ring. Select

thickest snap ring that will fit into groove. Allowed snap ring

clearance is 0-.0024" (0-.060 mm). Insert needle bearing onto transfer

drive shaft assembly. Install high-low synchronizer sleeve and shift

fork assembly. Install transfer drive shaft assembly.

         4) Install transfer countergear shaft thrust washers, needle

bearings, bearing spacer and transfer countergear. Install one thrust

washer at each end of transfer countergear. Ensure tab on thrust

washers fits into groove of transfer case. Install counter gear shaft

from transmission case side so lock plate groove is aligned with lock

plate. Install lock plate. Install side cover and gasket.

         5) Install bearing retainer. If reusing bearing retainer

bolts, apply Locking Adhesive (3M 4170 Stud Lock) to threads. Install

oil dam cover. Install differential lock hub, snap ring, steel ball

and sleeve. Select thickest snap ring that will fit into groove.

Allowed snap ring clearance is 0-.003" (0-.08 mm). Install 2WD-4WD

synchronizer sleeve, 2WD-4WD shift fork, spring, spring seat and 2WD-