Mitsubishi Montero (2002-2004). Manual - part 541

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-95

TRANSFER

DISASSEMBLY AND ASSEMBLY

M1233013300021

 <PART TIME 4WD>

AK201404AB

35 ± 6 N·m
26 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

34 ± 5 N·m
25 ± 4 ft-lb

34 ± 5 N·m
25 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

18 ± 3 N·m
13 ± 2 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

16

1

2

3

4

5

6

7
8

9

10

11

12

13

14

15

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

DISASSEMBLY STEPS

1.

2-4WD DETECTION SWITCH

2.

GASKET

3.

H-L DETECTION SWITCH

4.

GASKET

5.

STEEL BALL

>>K<<

6.

PLUG

>>N<<

7.

SPRING

8.

STEEL BALL

>>K<<

9.

PLUG

>>N<<

10. SPRING
11. STEEL BALL

>>K<<

12. PLUG

>>K<<

13. PLUG
14. DUST SEAL GUARD
15. DYNAMIC DAMPER
16. VEHICLE SPEED SENSOR

DISASSEMBLY STEPS 

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-96

AK201405

18 ± 3 N·m
13 ± 2 ft-lb

32 ± 2 N·m
24 ± 1 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

32 ± 2 N·m
24 ± 1 ft-lb

17

18

19

20

21

22

23

24

25

26

27

28

29

AB

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

DISASSEMBLY STEPS

>>M<<

17. TRANSFER CASE PLATE
18. NEEDLE BEARING
19. COUNTERSHAFT GEAR

>>L<<

20. SPACER

>>K<<

21. PLUG

>>J<<

22. H-L SHIFT RAIL PLUG
23. LOW SWITCH

24. GASKET

>>I<<

25. CONTROL HOUSING

>>H<<

26. REAR COVER

>>G<<

27. SPACER

>>F<<

28. OIL SEAL

>>E<<

29. SPRING PIN (H-L SHIFT FORK)

DISASSEMBLY STEPS 

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-97

Required Special Tools:

• MB990929: Installer Adapter

• MB990938: Handle

AK000016

34

35

36

33

32

31

37

38

39

40

44

45

46

41

42

47

48

30

43

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

AB

35 ± 6 N·m
26 ± 4 ft-lb

39

DISASSEMBLY STEPS

<<A>>

>>E<<

30. H-L SHIFT RAIL

<<A>>

>>D<<

31. CHAIN COVER
32. H-L SHIFT FORK
33. H-L CLUTCH SLEEVE

>>D<<

34. INTERLOCK PLUNGER

>>C<<

35. SPRING PIN
36. 2-4WD SHIFT LUG
37. DISTANCE PIECE
38. E-CLIP
39. SPRING SEAT

40. SPRING
41. 2-4WD SHIFT RAIL
42. 2-4WD SHIFT FORK

<<B>>

>>B<<

43. REAR OUTPUT SHAFT

<<B>>

>>B<<

44. CHAIN

<<B>>

>>B<<

45. FRONT OUTPUT SHAFT
47. DUST SEAL GUARD

>>A<<

48. OIL SEAL
49. TRANSFER CASE

DISASSEMBLY STEPS 

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-98

DISASSEMBLY SERVICE POINT

.

<<A>> H-L SHIFT RAIL/CHAIN COVER REMOVAL

NOTE:  If the 2-4WD shift rail is at the 2WD position, the 
chain cover cannot be removed because interlock is actu-
ated.

1. Shift the 2-4WD shift rail at the 4WD position.
2. Remove the chain cover, and then remove the H-L shift rail.

.

<<B>> REAR OUTPUT SHAFT/CHAIN/FRONT OUTPUT 
SHAFT REMOVAL
Remove the rear output shaft, chain and front output shaft as a 
set.

ADJUSTMENT BEFORE ASSEMBLY

.

SPACER SELECTION FRO ADJUSTMENT OF COUNTER-
SHFT GEAR END PLAY
1. Place pieces of solder [approximately 10 mm (0.4 inch) in 

length and 1.6 mm (0.06 inch) in diameter] in the transfer 
case housing as shown.

2. Install the countershaft gear into the transfer case.
3. Install the transfer case plate and tighten the bolts.

4. Using a micrometer, measure the thickness of the crushed 

solder. Based on the result, select a spacer which adjusts 
the end play to the standard value shown below:

Standard value: 0 

− 0.15 mm (0 − 0.006 inch)

NOTE:  If the solder is not crushed, repeat steps 1 and 2 
using thicker solder.

AKX00162

2-4WD SHIFT RAIL

AB

AKX00163

AKX00164

SOLDER

AB

AKX00165