Mitsubishi Montero Sport (2004+). Manual - part 396

COUNTERSHAFT GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-87

COUNTERSHAFT GEAR

DISASSEMBLY AND ASSEMBLY

M1233024000068

Required special tools:

• MD998801: Bearing Remover

• MD998368: Bearing Installer

• MD998812: Installer Cap

• MD998818: Installer Adapter

DISASSEMBLY SERVICE POINTS

.

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

.

AKX00256

APPLY GEAR OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

1

2

3

4

5

6

AB

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

COUNTERSHAFT GEAR

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-88

<<B>>SPACER/ROLLER BEARING/INNER RACE 
REMOVEL
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.

.

>>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.

AKX00258

MD998801

MD998368

AB

AKX00259

MD998812

MD998818

AB

AKX00260

AKX00261

MD998812

MD998818

AB

2-4WD SYNCHRONIZER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-89

2-4WD SYNCHRONIZER

DISASSEMBLY AND ASSEMBLY

M1233014200038

AK101269

4

5

6

1

2

3

7

8

9

APPLY AUTOMATIC
TRANSMISSION FLUID
TO ALL MOVING PARTS
BEFORE INSTALLATION.

AB

DISASSEMBLY STEPS

>>C<<

1.

SNAP RING

2.

2-4WD SYNCHRONIZER HUB

3.

SYNCHRONIZER SPRING

>>B<<

4.

OUTER SYNCHRONIZER RING

5.

SYNCHRONIZER CONE

>>A<<

6.

INNER SYNCHRONIZER RING

7.

DRIVE SPROCKET

8.

NEEDLE BEARING

9.

FRONT SIDE GEAR

DISASSEMBLY STEPS 

2-4WD SYNCHRONIZER

TSB Revision

AUTOMATIC TRANSMISSION OVERHAUL

23B-90

ASSEMBLY SERVICE POINTS

.

>>A<< INNER SYNCHRONIZER RING INSTALLATION
Apply oil the synchronizer ring cone surface before installation.

.

>>B<<OUTER SYNCHRONIZER RING INSTALLATION
Apply oil the synchronizer ring cone surface before installation.

.

>>C<<SNAP RING INSTALLATION
Select and install the snap ring which adjusts the 2-4WD syn-
chronizer hub end play to standard value.

Standard value: 0 

− 0.08 mm (0 − 0.0031 inch)

AK101270

AK101271

AK101272

SNAP RING

AB