Mitsubishi Montero (2004+). Manual - part 440

TRANSFER CASE PLATE

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-87

INSPECTION

M1233013400084

.

2-4WD, H-L, 4LLC, 2WD, CENTER DIFFERENTIAL LOCK, 
4H  DETECTION SWITCH
Check for the continuity between the connector terminal and 
switch body.

.

LOW RANGE OPERATION DETECTION SWITCH
Check for the continuity between the connector terminal and 
switch body.

TRANSFER CASE PLATE

DISASSEMBLY AND ASSEMBLY

M1233024200062

SWITCH STATE

CONTINUITY

Switch end pressed

No

Switch end released

Yes

SWITCH STATE

CONTINUITY

Switch end pressed

Yes

Switch end released

No

AKX00182

AKX00438

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

4

5

6

1

2

3

20 ± 3 N·m
14 ± 2 ft-lb

AD

DISASSEMBLY STEPS

>>B<<

1.

BOLT

2.

BEARING RETAINER

3.

TRANSFER INPUT GEAR

>>A<<  

4.

OIL SEAL

5.

BAFFLE PLATE

6.

TRANSFER CASE PLATE

DISASSEMBLY STEPS 
(Continued)

TRANSFER CASE PLATE

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-88

Required Special Tools:

• MB990938: Handle

• MB990936: Installer Adapter

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
1. Use special tools MB990938 and MB990936 to install the oil 

seal.

2. Apply Mitsubishi genuine grease part number 0101011 or 

equivalent to the lip of the oil seal.

.

>>B<< BOLT INSTALLATION
Apply Mitsubishi genuine sealant part number MD997740 or 
equivalent to the threads.
NOTE: The new bolt is precoated with sealant, so sealant does 
not need to be applied.

AKX00216

MB990938

MB990936

AB

AKX00402

INPUT GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-89

INPUT GEAR

DISASSEMBLY AND ASSEMBLY

M1233015100078

Required special tools:

• MD998801: Bearing Remover

• MD998812: Installer Cap

• MD998826: Installer Adapter

DISASSEMBLY SERVICE POINT

.

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

AKX00252

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

1

2

3

4

5

6

AB

DISASSEMBLE STEPS

>>B<<

1.

SNAP RING

<<A>>

>>A<<

2.

BALL BEARING

3.

SNAP RING

4.

CONE SPRING

5.

SUB GEAR

6.

TRANSFER INPUT GEAR

DISASSEMBLE STEPS 
(Continued)

AKX00253

MD998801

AB

COUNTERSHAFT GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-90

ASSEMBLY SERVICE POINTS

.

>>A<< BALL BEARING INSTALLATION
Use special tools MD998812 and MD998826 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 transfer input gear.

2. Make sure that the transfer input gear bearing end play 

meets the standard value.

Standard value: 0 

− 0.06 mm (0 − 0.002 inch)

COUNTERSHAFT GEAR

DISASSEMBLY AND ASSEMBLY

M1233024000079

AKX00254

MD998812

MD998826

AB

AKX00255

AKX00256

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

1

2

3

4

5

6

AB