Mitsubishi Montero (2002-2004). Manual - part 548

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-123

<<D>> CLUTCH HUB REMOVAL
1. Place special tool MD998801 so that the load is applied at 

the bearing.

2. Use a press to push at the rear end of the rear output shaft, 

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

ASSEMBLY SERVICE POINTS

.

>>A<< BALL BEARING/STOPPER PLATE INSTALLATION
1. Use special tool MD998801 to the rear output shaft.
2. After installing the ball bearing, fit the stopper plate onto the 

rear output shaft.

3. Use special tools MD998812, MD998813, MD998814 and 

MD998829 to press in the ball bearing.

.

>>B<< CLUTCH HUB INSTALLATION
1. Use special tool MD998801 to the rear output shaft.
2. Confirm the clutch hub installation direction, and fit onto the 

rear output shaft.

3. Use special tools MD998812, MD998813, MD998814 and 

MD998821 to press in the clutch hub.
NOTE: The clutch hub may fit loosely on the shaft, so that 
installation is possible without using a press.

.

>>C<< BALL BEARING INSTALLATION
1. Use special tool MD998801 to support the rear output shaft.
2. Use special tools MD998812, MD998814 and MD998819 to 

install the radial ball bearing.
NOTE: The ball bearing may be fitted loosely on the shaft, 
so that installation is possible without using a press.

.

AKX00418

MD998801

AB

AKX00419

MD998801

MD998814

MD998812

MD998829

MD998813

AB

AKX00420

MD998812

MD998813

MD998814

MD998821

MD998801

2-4WD
CLUTCH HUB

INSTALLATION
DIRECTION

AB

AK000034AB

MD998812

MD998814

MD998820

BALL
BEARING

MD998801

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-124

>>D<< JAM NUT INSTALLATION
1. Hold the drive sprocket in a soft-jaws vise.
2. Shift the clutch sleeve to the drive sprocket side.
3. Using special tool MB991013, tighten the jam nut to the 

specified torque.

4. Stake the two places of the jam nut as shown in illustration.

.

>>E<< CLUTCH HUB INSTALLATION
1. Use special tool MD998801 to support the drive sprocket.
2. Confirm the clutch hub installation direction, and fit onto the 

rear output shaft.

3. Use special tools MD998812 and MD998821 to press in the 

clutch hub.

.

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

ring groove of the rear output shaft.

2. Make sure that the clutch hub end play meets the standard 

value.

Standard value: 0 

− 0.08 mm (0 − 0.003 inch)

AKX00416

MB991013

AB

AKX00422

AKX00423

INSTALLATION

DIRECTION

MD998812

MD998821

MD998801

H-L CLUTCH

HUB

DRIVE

SPROCKET

AB

AKX00424

CLUTCH HUB

END PLAY

SNAP RING

AB

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-125

DISASSEMBLY AND ASSEMBLY

M1233013600033

<SUPER SELECT 4WD>

Required special tools

• MD998812: Installer Cap

• MD998814: Installer-200

• MD998824: Installer Adapter

• MD998917: Bearing Remover

DISASSEMBLY SERVICE POINT

.

<<A>> BALL BEARING REMOVAL
Use special tool MD998917 to remove the ball bearing.

AKX00242

1

2

3

4

5

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

AB

DISASSEMBLY STEPS

>>C<<

1.

SNAP RING

2.

ANNULUS GEAR

>>B<<

3.

SNAP RING

<<A>>

>>A<<

4.

BALL BEARING

5.

REAR OUTPUT SHAFT

DISASSEMBLY STEPS 

AKX00243

MD998917

AB

REAR OUTPUT SHAFT

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-126

ASSEMBLY SERVICE POINTS

.

>>A<< BALL BEARING INSTALLATION
Use special tools MD998812, MD998814 and MD998824 to 
install the ball bearing.

.

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

ring groove of the rear output shaft.

2. Make sure that the rear output shaft bearing end play meets 

the standard value.

Standard value: 0 

− 0.08 mm (0 − 0.003 inch)

.

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

ring groove of the annulus gear.

2. Make sure that the annulus gear end play meets the 

standard value.

Standard value: 0 

− 0.08 mm (0 − 0.003 inch)

AKX00244

MD998812

MD998814

MD998824

AB

AKX00245

AKX00246