Mitsubishi Montero (2004+). Manual - part 437

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-75

TRANSFER

DISASSEMBLY AND ASSEMBLY

M1233013300139

AKX00205

4

5

6

1

2

3

7

8

9

14

15
16

11

12

13

17

18

19

24

26

21

22

23

27

28

29

10

20

30

11 ± 1 N·m
97 ± 9 in-lb

19 ± 3 N·m
13 ± 2 ft-lb

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

35 ± 6 N·m
26 ± 4 ft-lb

AB

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

35 ± 6 N·m
26 ± 4 ft-lb

11 ± 1 N·m
97 ± 9 in-lb

11 ± 1 N·m
97 ± 9 in-lb

11 ± 1 N·m
97 ± 9 in-lb

25

DISASSEMBLY STEPS

1.

VACUUM HOSE

>>W<<

2.

4LLC DETECTION SWITCH

3.

GASKET

4.

STEEL BALL

>>W<<

5.

2WD DETECTION SWITCH

6.

GASKET

7.

STEEL BALL

>>W<<

8.

CENTER DIFFERENTIAL LOCK 
SWITCH

9.

GASKET

10. STEEL BALL

>>W<<

11. 4H DETECTION SWITCH
12. GASKET
13. STEEL BALL

>>W<<

14. 2-4WD DETECTION SWITCH
15. GASKET
16. STEEL BALL

>>V<<

17. TRANSFER CASE COVER

>>U<<

18. SHIFT RAIL DRIVE GEAR

>>U<<

19. SHIFT RAIL DRIVE GEAR
20. DUST SEAL GUARD

DISASSEMBLY STEPS 
(Continued)

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-76

21. DYNAMIC DAMPER
22. VEHICLE SPEED SENSOR
23. O-RING
24. REAR OUTPUT SENSOR
25. O-RING
26. FRONT OUTPUT SENSOR
27. O-RING

>>T<<

28. SIFT ACTUATOR
29. O-RING

>>T<<

30. MAIN SHIFT RAIL

DISASSEMBLY STEPS 
(Continued)

AKX00206

34

35

36

31

32

33

37

38

39

40

44

45

46

41

42

43

47

48

49

50

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

54

55

56

51

52

53

57

58

59

60

64

65

61

62

63

35 ± 6 N·m
26 ± 4 ft-lb

AB

35 ± 6 N·m
26 ± 4 ft-lb

DISASSEMBLY STEPS

>>S<<

31. REAR COVER

>>R<<

32. OIL SEAL
33. SNAP RING
34. SENSOR ROTOR
35. STEEL BALL
36. OIL GUIDE

>>Q<<

37. SPACER
38. SNAP RING

>>P<<

39. SNAP RING

>>O<<

40. CHAIN COVER

>>N<<

41. REAR OUTPUT SHAFT
42. O-RING
43. BEARING
44. SNAP RING
45. CENTER DIFFERENTIAL 

PLANETARY CARRIER

46. VISCOUS COUPLING

DISASSEMBLY STEPS 
(Continued)

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-77

Required special tools:

• MB990932: Installer Adapter

• MB990936: Installer Adapter

• MB990938: Handle

<<A>>

>>M<<

47. CHAIN

<<A>>

>>M<<

48. FRONT OUTPUT SHAFT

>>M<<

49. DRIVE SPROCKET
50. BEARING

>>L<<

51. SYNCHRONIZER INNER RING

>>L<<

52. SYNCHRONIZER CONE

>>L<<

53. SYNCHRONIZER OUTER RING
54. SYNCHRONIZER SPRING
65.  DIFFERENTIAL LOCK HUB

DISASSEMBLY STEPS 
(Continued)

AKX00207

66

67

68

69

70

74

75

76

71

72

73

77

78

79

80

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

20 ± 3 N·m
14 ± 2 ft-lb

81

82

AB

35 ± 6 N·m
26 ± 4 ft-lb

35 ± 6 N·m
26 ± 4 ft-lb

DISASSEMBLY STEPS

>>G<<

66. TRANSFER CASE PLATE
67. BEARING
68. COUNTER SHAFT GEAR

>>F<<

69. SPACER

>>E<<

70. H-L CLUTCH SLEEVE

>>E<<

71.  H-L SHIFT FORK

>>D<<

72. SNAP RING
73. H-L CLUTCH HUB
74. LOW SPEED GEAR

75. BEARING

>>C<<

76. REAR BEARING RETAINER
77. TRANSFER DRIVE SHAFT
78. DUST SEAL GUARD

>>B<<

79. OIL SEAL

<<B>>

>>A<<

80. OIL GUIDE
81. OIL GUIDE
82. TRANSFER CASE

DISASSEMBLY STEPS 
(Continued)

TRANSFER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-78

DISASSEMBLY SERVICE POINTS

.

<<A>> CHAIN/FRONT OUTPUT SHAFT/SUN GEAR 
REMOVAL
Remove the sun gear, chain and front output shaft as a set.

.

<<B>> OIL GUIDE REMOVAL

CAUTION

Usually no disassembly is necessary for the oil guide. 
After removal, the transfer case can not be reused.
Remove the caulking part and disassemble the oil guide.

ASSEMBLY SERVICE POINTS

.

>>A<< OIL GUIDE INSTALLATION
Mount the oil guide on new transfer case, and caulk so that the 
dimension of protruded part (4 places) is as shown to fix the oil 
guide.

.

AKX00208

AKX00209

AKX00210

5 mm (0.2 in)

AB

2 mm

(0.08 in)