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Mitsubishi Montero (2002-2004). Manual - part 530

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23B-51

27.Remove the two output shaft support mounting bolts.

<V4A51>

28.Using the two removed bolts, install special tool MB991603

to the specified torque. <V5A51>

CAUTION

Install the cable bracket together with special tool.
29.Using the Transfer case adapter bolt, install special tool

MB991603.

30.Select the thrust race number 8 with the following

procedure:

(1) Fix a dial gauge to special tool MB991603.
(2) Push the output shaft <V4A51> or direct planetary carrier

<V5A51>,and the output flange <V4A51> or direct
annulus gear <V5A51> in alternately, and then measure
the end play of output shaft <V4A51> or direct planetary
carrier <V5A51>.
NOTE: When pushing the output shaft <V4A51> or direct
planetary carrier <V5A51> in, take care that the center
support does not move.
NOTE: When pushing the output flange <V4A51> or
direct annulus gear <V5A51> in, use the special tool
MB998304.

(3) Reinstall by selecting the thrust race number 8 installed

by the procedure (25) so that the end play of output
shaft<V4A51> or direct planetary carrier <V5A51>
becomes the standard value.
NOTE: Refer to the thickness recorded in step 13.

Standard value: 0.25

− 0.55 mm (0.0098 − 0.0217 inch)

(4) Measure the end play again, and confirm that it is within

the standard value.
NOTE: Carry this step out with special tool MB991603
and dial gauge installed.

AKX00076

MB991603

<V4A51>

AKX00324

MB991603

CABLE END
BRACKET

<V5A51>

AKX00077

MD998304

OUTPUT FLANGE

OUTPUT SHAFUT

MB991603

<V4A51>

AKX00325

MB991603

MD998304

DIRECT
ANNULUS GEAR

<V5A51>

DIRECT PLANTARY
CARRIER

AKX00078

THRUST
RACE NO.8

END PLAY

THRUST
BEARING NO.9

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23B-52

31.Using the following steps, select the snap ring for fixing the

center support.

(1) Install the snap ring used for fixing the center support

used.

(2) After pushing the output shaft <V4A51> or direct

planetary carrier <V5A51>,and the center support in
alternately, and then measure the end play of center
support.
NOTE: When pushing the output shaft <V4A51> or direct
planetary carrier <V5A51> in, be sure to push them in to
the point where the center support touches the snap ring.

(3) Select the snap ring for fixing the center support installed

in step 31 (1) so that the end play of the center support is
at the standard value. Then, reassemble.

Standard value: 0

− 0.16 mm (0 − 0.0063 inch)

(4) Measure the end play again, and confirm that it is within

the standard value.

32.Using the following steps, select the snap ring for adjusting

the brake reaction plate end play and second brake end
play, and the pressure plate for adjusting the low/reverse
brake end play.

AKX00079

SNAP RING

AKX00080

CENTER SUPPORT

OUTPUT SHAFT

MB991603

<V4A51>

AKX00326

MB991603

CENTER SUPPORT

DIRECT PLANETARY
CARRIER

<V5A51>

AKX00081

STANDARD VALUE

CENTER SUPPORT

SNAP RING

LOW/REVERSE
BRAKE PISTON

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23B-53

(1) Install the wave spring onto the low/reverse brake piston.

(2) Install special tool MB991632 onto the position shown in

the illustration instead of the pressure plate for the low/
reverse brake. Install the brake disc, brake plate and
snap ring.

CAUTION

Pay close attention to the assembly direction of the reac-
tion plate.

(3) Install the reaction plate and snap ring that was used.
(4) Install a dial gauge onto special tool (MD998913) so that

the end contacts the brake reaction plate. Measure the
end play by moving special tool MB991632.

(5) Select the snap ring installed in step 32 (3) so that the

end play is within the standard value. Then, reassemble.

Standard value: 0

− 0.16 mm (0 − 0.0063 inch)

(6) Measure the end play again, and confirm that it is within

the standard value.

CAUTION

Pay close attention to the shape and assembly direction of
the brake plate A installation.

(7) Next, install special tool MB991632 instead of the

pressure plate for the second brake. Install the four brake
discs and three brake plates.

(8) Install the return spring, second brake and snap ring.

AKX00052

AKX00082

MB991632

SNAP RING

AKX00083

MD998913

MB991632

SNAP RING

END PLAY

AKX00084

MB991632

SECOND BRAKE

SNAP RING

RETURN
SPRING

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23B-54

(9) Install a dial gauge onto special tool MD998913 so the

end contacts the special tool. Move special tool
MB991632 and measure the moving amount. Select a
pressure plate with a thickness that corresponds to the
measured moving amount from the following table.

Standard value: 1.49

− 1.95 mm (0.0587 − 0.0768 inch)

(10)Remove the snap ring, second brake, return spring and

special tool MB991632 installed in step (8).

(11)Install the pressure plate selected in step (9), and install

the return spring, second brake and snap ring again.

(12)Install a dial gauge onto special tool MD998913 so the

End play standard value (reference)
: 1.65

− 2.11 mm (0.0650 − 0.0831 inch)

AKX00085

MD998913

MB991632

MOVING
AMOUNT

MOVING AMOUNT mm (in)

PRESSURE PLATE

THICKNESS
mm (in)

ID SYMBOL ID SYMBOL

1.2 or more

− less than 1.4 (0.047 or more − less than 0.055) 1.6 (0.063)

MR336390

1.4 or more

− less than 1.6 (0.055 or more − less than 0.063) 1.8 (0.071)

MR336391

1.6 or more

− less than 1.8 (0.063 or more − less than 0.071) 2.0 (0.079)

MR336392

1.8 or more

− less than 2.0 (0.071 or more − less than 0.079) 2.2 (0.087)

MR336393

2.0 or more

− less than 2.2 (0.079 or more − less than 0.087) 2.4 (0.094)

MR336394

2.2 or more

− less than 2.4 (0.087 or more − less than 0.094) 2.6 (0.102)

MR336395

2.4 or more

− less than 2.6 (0.094 or more − less than 0.102) 2.8 (0.110)

MR336396

2.6 or more

− less than 2.8 (0.102 or more − less than 0.110) 3.0 (0.118)

MR336397

AKX00086

MD998913

MB991632

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