Mitsubishi Montero (2002-2004). Manual - part 547

COUNTERSHAFT GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-119

Required special tools:

• MD998801: Bearing Remover

• MD998368: Bearing Installer

• MD998812: Installer Cap

• MD998818: Installer Adapter

DISASSEMBLY SERVICE POINT

.

<<A>> BALL BEARING REMOVAL
Use special tool MD998801 to remove the ball bearing.

.

<<B>> SPACER/ROLLER BEARING/INNER RACE 
REMOVAL
1. Remove the spacer and roller bearing.
2. Use special tools MD998801 and MD998368 to remove the 

inner race.

NOTE: In the case that the installation of the spacer, roller 
bearing, and inner race is in reverse order according to the 
vehicle, then remove the inner race, roller bearing and spacer 
at the same time.

ASSEMBLY SERVICE POINTS

.

>>A<< INNER RACE/ROLLER BEARING/SPACER INSTAL-
LATION
1. Use special tools MD998812 and MD998818 to install the 

inner race.

2. Install the roller bearing and spacer.

.

DISASSEMBLY STEPS

<<A>>

>>C<<

1.

BALL BEARING

>>B<<

2.

SNAP RING

<<B>>

>>A<<

3.

SPACER

<<B>>

>>A<<

4.

ROLLER BEARING

<<B>>

>>A<<

5.

INNER RACE

6.

COUNTER SHAFT GEAR

DISASSEMBLY STEPS 

AKX00257

MD998801

AB

AKX00258

MD998801

MD998368

AB

AKX00259

MD998812

MD998818

AB

COUNTERSHAFT GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-120

>>B<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted into the snap 

ring groove of the counter shaft gear.

2. Make sure that the counter shaft gear roller bearing end play 

meets the standard value.

Standard value: 0 

− 0.08 mm (0 − 0.003 inch)

.

>>C<< BALL BEARING INSTALLATION
Use special tools MD998812 and MD998818 to install the ball 
bearing.

AKX00260

AKX00261

MD998812

MD998818

AB

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-121

REAR OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY

M1233013600022

<PART TIME 4WD>

Required Special Tools:

• MB991013: Special Spanner

• MD998801: Bearing Remover

AK000017

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

4

5

6

1

2

3

7

8

9

14

15

16

11

12

13

17

18

10

255 ± 10 N·m
188 ± 7 ft-lb

AB

19

20

21

22

23

24

25

DISASSEMBLY STEPS

>>F<<

1.

SNAP RING

<<A>>

>>E<<

2.

CLUTCH HUB

3.

LOW SPEED GEAR

4.

NEEDLE BEARING

5.

SNAP RING

6.

ROTOR

7.

STEEL BALL

<<B>>

>>D<<

8.

JAM NUT

<<C>>

>>C<<

9.

BALL BEARING

10. SPACER
11. SPROCKET SPACER
12. STEEL BALL
13. DRIVE SPROCKET

14. NEEDLE BEARING
15. SPROCKET SLEEVE
16. STEEL BALL
17. SYNCHRONIZER INNER RING
18. SYNCHRONIZER CONE
19. SYNCHRONIZER OUTER RING
20. SYNCHRONIZER SPRING
21. CLUTCH SLEEVE

<<D>>

>>B<<

22. CLUTCH HUB

<<D>>

23. STOPPER PLATE

<<D>>

>>A<<

24. BALL BEARING
25. REAR OUTPUT SHAFT

DISASSEMBLY STEPS 

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-122

• MD998812: Installer Cap

• MD998813: Installer-100

• MD998814: Installer-200

• MD998820: Installer Adapter (42)

• MD998821: Installer Adapter (44)

• MD998829: Installer Adapter (60)

DISASSEMBLY SERVICE POINTS

.

<<A>> CLUTCH HUB REMOVAL
1. Use special tool MD998801 to support the low speed gear.
2. Use a press to push at the front end of the rear output shaft 

and then remove the hub and gear.
NOTE: The clutch hub may fit loosely on the shaft, so that 
removal is possible without using a press.

.

<<B>> JAM NUT REMOVAL
1. Remove the staked nut from the shaft.
2. Hold the drive sprocket in a soft-jaw vise.
3. Shift the clutch sleeve to the drive sprocket side.

4. Use special tool MB991013 to remove the jam nut.

.

<<C>> RADIAL BALL BEARING REMOVAL
1. Use special tool MD998801 to support the ball bearing.
2. Use a press to push at a rear end of the rear output shaft, 

and then remove the radial ball bearing.
NOTE: The bearing may fit loosely on the shaft, so that 
removal is possible without using a press.

.

AKX00414

MD998801

AB

AKX00415

AKX00416

MB991013

AB

AKX00417

MD998801

AB