Mitsubishi Montero (2002-2004). Manual - part 542

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-99

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
1. Use special tools MB990929 and MB990938 to install the oil 

seal.

2. Apply MITSUBISHI genuine grease Part number 0101011 or 

equivalent to the lip of the oil seal.

.

>>B<< FRONT OUTPUT SHAFT/CHAIN/REAR OUTPUT 
SHAFT INSTALLATION
1. Engage the chain precisely with the sprocket of the rear 

output shaft and the front output shaft.

2. Install the 2-4WD shift fork on the 2-4WD clutch sleeve. 

While passing them beside the 2-4WD shift rail, install the 
front output shaft, and chain and rear output shaft.

.

>>C<< SPRING PIN INSTALLATION
1. Align the 2-4WD shift lug with the 2-4WD shift rail spring pin 

hole.

2. Hammer in the spring valve so that the spring pin slit 

matches the center of the shift rail shaft.

.

>>D<< INTERLOCK PLUNGER/CHAIN COVER 
INSTALLATION
1. Insert the interlock plunger into a position where it does not 

interfere with 2-4WD shift rail.

CAUTION

Squeeze the sealant out evenly to apply it in an unbroken, 
non-excessive quantity.
2. Apply sealant MITSUBISHI genuine sealant Part number 

MD997740 or equivalent to the chain cover, and then install 
the chain cover.

.

AKX00166

MB990938

MB990929

TRANSFER
CASE

AB

AKX00163

AKX00167

2-4WD
SHIFT LUG

SPRING PIN

AB

TRANSFER

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AUTOMATIC TRANSMISSION OVERHAUL

23B-100

>>E<< H-L SHIFT RAIL/SPRING PIN INSTALLATION
1. Insert the H-L shift rail from the H-L shift rail hole, paying 

attention to the direction of the shift rail.

2. Align the spring pin holes on the shift rail with the shift fork. 

Then tap in the spring pin so that the slit of the spring pin is 
facing the shaft center of the shift rail.

.

>>F<< OIL SEAL INSTALLATION
1. Use special tools MB990929 and MB990938 to install the oil 

seal.

2. Apply MITSUBISHI genuine grease Part number 0101011 or 

equivalent to the lip of oil seal.

.

>>G<< SPACER INSTALLATION
1. Measure projection A of the rear output shaft bearing and 

depth B of the second stage of the rear cover.

2. Subtract A from B and let the answer be C. Select a spacer 

so that the subtracted value will be the standard value 
shown below.

Standard value: 0 

− 0.08 mm (0 − 0.003 inch)

.

AKX00169

SLIT

H-L
SHIFT
RAIL

AB

AKX00170

MB990938

MB990929

AB

AKX00171

A

B

REAR COVER

SPACER

AB

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23B-101

>>H<< REAR COVER INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in an unbroken, 
non-excessive quantity.
Apply sealant Mitsubishi genuine sealant Part number 
MD997740 or equivalent to the chain cover.

.

>>I<< CONTROL HOUSING INSTALLATION

CAUTION

Squeeze the sealant out evenly to apply it in an unbroken, 
non-excessive quantity.
Apply sealant Mitsubishi genuine sealant Part number 
MD997740 or equivalent to the control housing.

.

>>J<< H-L SHIFT RAIL PLUG INSTALLATION
Apply sealant 3M

ä ADD Part number 8672 or equivalent to the 

threads.
NOTE: The new plug is precoated with sealant, so sealant 
does not need to be applied.

.

>>K<< PLUG INSTALLATION
Apply sealant 3M

ä ADD Part number 8672 or equivalent to the 

threads.
NOTE: The new plug is precoated with sealant, so sealant 
does not need to be applied.

.

AKX00172

2 mm(0.1 in)
DIAMETER

AB

AK000033

2 mm (0.1 in)
DIAMETER

AC

AKX00176

AKX00177

TRANSFER

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23B-102

>>L<< SPACER INSTALLATION
Install the previously selected spacer (see ADJUSTMENT 
BEFORE ASSEMBLY).

.

>>M<< TRANSFER CASE PLATE INSTALLATION
1. Face the notched section of the input gears in the direction 

shown in the illustration.

CAUTION

Squeeze the sealant out evenly to apply it in an unbroken, 
non-excessive quantity.
2. Apply MITSUBISHI genuine sealant Part number 

MD997740 or equivalent to the transfer case plate.

CAUTION

The transfer case plate must be installed smooth and 
straight to get a good seal.
3. Install the transfer case plate together with the input gear. 

Slide the input gear tooth aligned in Step 1 along the tooth 
space of the countershaft gear.

.

>>N<< SPRING INSTALLATION
Install the spring with its tapered end toward the ball.

AKX00178

NOTCHED
SECTION

COUNTER
SHAFT

AB

AKX00179

2 mm(0.1 in)
DIAMETER

AB

AKX00181