Mitsubishi Montero (2004+). Manual - part 443

2-4 SHIFT RAIL/H-L SHIFT RAIL

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-99

ASSEMBLY SERVICE POINT

.

>>A<< SHIFT RAIL DRIVE GEAR INSTALLATION
Install so that the mating mark of the shift rail drive gear is 
opposite side of the washer.

2-4 SHIFT RAIL/H-L SHIFT RAIL

DISASSEMBLY AND ASSEMBLY

M1233031500021

AKX00241

MARK

WASHER

AB

AKX00265

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

6

7

5

2

1

3

4

AB

DISASSEMBLY STEPS

>>A<<

1.

SPRING PIN

2.

2-4WD SHIFT FORK

3.

SPRING

>>B<<

4.

2-4WD SHIFT RAIL

>>A<<

5.

SPRING PIN

6.

H-L SHIFT FORK

7.

H-L SHIFT RAIL

DISASSEMBLY STEPS 
(Continued)

2-4 SHIFT RAIL/H-L SHIFT RAIL

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-100

ASSEMBLY SERVICE POINTS

.

>>A<< SPRING PIN INSTALLATION
Install the spring pin so that the slit of spring pin faces forward 
of the transfer.

.

>>B<< 2-4WD SHIFT RAIL INSTALLATION
Apply Mitsubishi genuine grease Part number 0101011 or 
equivalent to the contact part between 2-4WD shift rail and 2-4 
WD shift fork, and install.

AKX00266

H - L SHIFT RAIL

2 - 4 SHIFT RAIL

AB

AKX00267

SPECIFICATIONS

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-101

SPECIFICATIONS

TORQUE SPECIFICATION

M1233023100426

Transmission

Transfer

ITEMS

SPECIFICATIONS

Anchor plug

98 

± 15 N⋅m (71 ± 11 ft-lb)

Cable end bracket mounting bolt

48 

± 6 N⋅m (35 ± 4 ft-lb)

Converter housing to transmission case tightening bolts

48 

± 6 N⋅m (35 ± 4 ft-lb)

Detent spring mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Input shaft speed sensor mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Lower valve body cover mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Lower valve body mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Manual control lever mounting nut

22 

± 3 N⋅m (16 ± 2 ft-lb)

Oil filter mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Oil pan mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Oil pump mounting bolt

23 

± 3 N⋅m (17 ± 2 ft-lb)

Output shaft speed sensor mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Output shaft support mounting bolt

23 

± 3 N⋅m (17 ± 2 ft-lb)

Park/neutral position switch mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Reduction brake piston adjust rod

4.9 N

⋅m (43 in-lb)

Reduction brake piston nut 

18 

± 3 N⋅m (13 ± 2 ft-lb)

Separating plate mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Solenoid support mounting bolt

5.9 

± 1 N⋅m (52 ± 9 in-lb)

Transfer to transfer case adapter tightening bolt 

35 

± 6 N⋅m (26 ± 4 ft-lb)

Transmission case to transfer case adapter tightening bolt 

48 

± 6 N⋅m (35 ± 4 ft-lb)

Upper valve body mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Valve body mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

ITEMS

SPECIFICATIONS

2WD switch

35 

± 6 N⋅m (26 ± 4 ft-lb)

2-4WD switch

35 

± 6 N⋅m (26 ± 4 ft-lb)

4H switch

35 

± 6 N⋅m (26 ± 4 ft-lb)

4LL switch

35 

± 6 N⋅m (26 ± 4 ft-lb)

Center differential lock switch

35 

± 6 N⋅m (26 ± 4 ft-lb)

Control housing to transfer case tightening bolt

19 

± 3 N⋅m (13 ± 2 ft-lb)

Output sensor mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Rear cover to chain cover tightening bolt

35 

± 6 N⋅m (26 ± 4 ft-lb)

Sift actuator mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Speedometer sensor mounting bolt

11 

± 1 N⋅m (97 ± 9 in-lb)

Transfer case plate to bearing retainer mounting bolt

20 

± 2 N⋅m (14 ± 1 ft-lb)

SPECIFICATIONS

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-102

GENERAL SPECIFICATIONS

M1233000200455

SERVICE SPECIFICATIONS

M1233000300322

Transmission

Transfer

Transfer case plate to transfer case tightening bolt and nut

35 

± 6 N⋅m (26 ± 4 ft-lb)

Transfer case to bearing retainer mounting bolt

20 

± 2 N⋅m(14 ± 1 ft-lb)

Transfer case to chain cover tightening bolt

35 

± 6 N⋅m (26 ± 4 ft-lb)

ITEMS

SPECIFICATIONS

TRANSMISSION MODEL

V5A51-7-HCB

Applicable engine

3.8L

Transmission type

Electronically controlled 4-speed full-automatic

Torque converter type

3-element with torque converter clutch

Transmission 
gear ratio

1st

3.789

2nd

2.057

3rd

1.421

4th

1.000

5th

0.731

Reverse

3.865

Transfer type

SUPER SELECT 4WD

Transfer gear 
ratio

High

1.000

Low

1.900

ITEMS

STANDARD VALUE

Direct planetary carrier end play mm (in) 

0.25 

− 0.55 (0.0098 − 0.0217)

Underdrive clutch end play mm (in)

1.6 

− 1.8 (0.063 − 0.071)

Input shaft end play mm (in)

0.25 

− 0.81 (0.0098 − 0.0319)

Overdrive clutch end play mm (in)

2.0 

− 2.2 (0.079 − 0.087)

Overdrive clutch return spring retainer end play mm (in)

0 

− 0.09 (0 − 0.004)

Second brake end play mm (in)

1.49 

− 1.95 (0.0587 − 0.0768)

Center support end play mm (in)

0 

− 0.16 (0 − 0.0063)

Brake reaction plate end play mm (in)

0 

− 0.16 (0 − 0.0063)

Reverse clutch end play mm (in)

1.5 

− 1.7 (0.059 − 0.067)

Low/reverse brake end play mm (in)

1.65 

− 2.11 (0.0650 − 0.0831)

Direct clutch end play mm (in) 

1.0 

− 1.2(0.039 − 0.047)

ITEMS

STANDARD VALUE

Countershaft gear end play mm (in)

0 

− 0.15 (0 − 0.006)

H-L clutch hub end play mm (in)

0 

− 0.08 (0 − 0.003)

Differential lock hub end play mm (in) 

0 

− 0.08 (0 − 0.003)

2-4WD clutch hub end play mm (in) 

0 

− 0.08 (0 − 0.003)

Synchronizer outer ring to drive sprocket clearance mm (in)  

 Limit 0.3 (0.01)

Rear output shaft bearing snap ring to chain cover preload mm (in) 

0.12 

− 0.24 (0.005 − 0.009)