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1. SPECIFICATIONS
TRANSMISSION MODEL TABLE - MODEL 2000
Transmission models Vehicle model Engine model
Intentionally blank
SEALANTS
TRANSMISSION
Item Specified sealant
Transfer case adapter (transmission side) MITSUBISHI genuine sealant part No. MR166584 or
equivalent
TRANSFER <V4A51>
Item Specified sealant
Bearing retainer mounting bolt MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Control housing (Part time 4WD) MITSUBISHI genuine sealant part No. MD997740 or
equivalent
H-L shift rail plug (Part time 4WD) 3MTM AAD part No. 8672 or equivalent
Plug (Part time 4WD) 3MTM AAD part No. 8672 or equivalent
Support pin insertion (Part time 4WD) 3MTM AAD part No. 8672 or equivalent
Support pin thread (Part time 4WD) MITSUBISHI genuine adhesive part No. MD160450 or
equivalent
Transfer case cover (Super select 4WD II) MITSUBISHI genuine sealant part No. MD997740 or
equivalent
Sealing cap (Super select 4WD II) 3MTM AAD part No. 8672 or equivalent
TRM1615
2
11 Nm
1
13 11 Nm
11 Nm
22 Nm
15
<Up to DEC. 2000>
14
12
11 Nm
11 Nm
11
11 Nm
9 10
8
5.9 Nm 5.9 Nm
7 Apply automatic
transmission fluid to
all moving parts
before installation.
11 Nm
40
39
23 Nm
38
47 Nm
45 50
49
43 48
46 47
Apply automatic
44 transmission fluid to
41 all moving parts
before installation.
42
1.8 MR276706
2.0 MR276707
2.2 MR276708
2.4 MR276709
Bearing retainer
Caution
Bearing retainer D Take care not to mistake the thrust bearing
Thrust mounting direction.
bearing No.13
4. Install new seal rings (two large pieces and two small
pieces) onto the output shaft.
Seal ring (small)
5. Insert the output shaft into the output shaft support.
Caution
D Take care not to mistake the thrust bearing No.2
mounting direction.
39. Using the special tool, set a dial gauge as shown in the
MD998316 illustration. Measure the end play of the input shaft, and
replace the thrust race installed in step 36 with a suitable
one so that the end play may meet the standard value.
Then, reassemble.
Standard value: 0.25 – 0.81 mm
40. Measure the end play again, and confirm that it is within
the standard value.
Detent
lever
44. Install two new O-rings to the manual control shaft, and
assemble onto the transmission case together with the
detent lever and parking roller rod.
O-rings
49. Install the oil strainer and two new oil seals. Install the
Oil seals
oil seals so that the notched section is oriented as shown
in the illustration.
Caution
D Take care to the installation direction of the oil
seal.
Oil strainer
O-ring
52. Install the valve body while inserting the manual valve
pin into the detent lever groove.
Manual
valve pin
Detent lever
<Up to DEC. 2000> <From JAN. 2001> 53. Install the oil temperature sensor.
Bolt Length mm
D
A 25
E
B B 30
C 40
C
D 45
D
D E 55
A D C
E Mitsubishi Motors Corporation Aug. 2002 PWEE8920-M Revised
23D-7-32 R4A51, V4A51 – Transmission
O-ring
35 Nm 34 Nm
3
34 Nm 9
10 4 35 Nm
11 35 Nm 5
1
6
12
2 7 13
8
14
15
18 Nm
Disassembly steps
1. 2-4WD detection switch "LA 9. Plug
2. Gasket "PA 10. Spring
3. H-L detection switch 11. Steel ball
4. Gasket "LA 12. Plug
5. Steel ball "LA 13. Plug
"LA 6. Plug 14. Speedometer sleeve clamp
"PA 7. Spring "OA 15. Speedometer gear
8. Steel ball
35 Nm 34 Nm
3
34 Nm 9
10 4 35 Nm
11 35 Nm 5
1
6
12
2 7 13
8
14
15
18 Nm
Disassembly steps
1. 2-4WD detection switch "LA 9. Plug
2. Gasket "PA 10. Spring
3. H-L detection switch 11. Steel ball
4. Gasket "LA 12. Plug
5. Steel ball "LA 13. Plug
"LA 6. Plug 14. Speedometer sleeve clamp
"PA 7. Spring "OA 15. Speedometer gear
8. Steel ball
21 Nm
18 Nm 32
33
35 Nm
26 25 29
35 Nm
28
27
35 Nm
22
23
34
30
31
24
21
17 20
16
35 Nm
32 Nm
35 Nm
35 Nm
Disassembly steps
"NA 16. Transfer case plate "JA 26. Control housing
17. Needle bearing "IA 27. Support pin
18. Countershaft gear "IA 28. Return spring
"MA 19. Spacer "HA 29. Rear cover
"LA 20. Plug "QA 30. Oil cover
"KA 21. H-L shift rail plug "GA 31. Spacer
22. Low switch 32. Dust seal guard
23. Gasket "FA 33. Oil seal
24. Dynamic damper "EA 34. Spring pin (H-L shift fork)
25. Harness bracket
45
44
47
44 43
35 Nm
46
40
39
49
42 35
48
41
8.8 Nm
51
36
52
50
37
Apply gear oil to all
moving parts before
55 installation.
38 54
53
Disassembly steps
AA" "EA 35. H-L shift rail 46. 2-4WD shift rail
AA" "DA 36. Chain cover 47. 2-4WD shift fork
37. H-L shift fork AB" "BA 48. Rear output shaft
38. H-L clutch sleeve AB" "BA 49. Chain
"DA 39. Interlock plunger AB" "BA 50. Front output shaft
"CA 40. Spring pin 51. Side cover
41. 2-4WD shift lug 52. Side cover gasket
42. Distance piece 53. Dust seal guard
43. E-clip "AA 54. Oil seal
44. Spring seat 55. Transfer case
45. Spring
34 Nm
3 4 15
35 Nm
35 Nm 5
9 14
6
10 12
7 35 Nm
1 11
8
34 Nm
13
2
18 Nm
16 35 Nm
Disassembly steps
1. 4WD switch "PA 10. Spring
2. Gasket 11. Steel ball
3. Transfer switch "LA 12. Plug
4. Gasket "LA 13. Plug
5. Steel ball 14. Dynamic damper
"LA 6. Plug 15. Dust seal guard
"PA 7. Spring 16. Vehicle speed sensor
8. Steel ball 17. Under guard
"LA 9. Plug
35 Nm
18 Nm
24 29
27
25
26
30
35 Nm
28 23
18 22
35 Nm 32 Nm
19 35 Nm
20
35 Nm
Disassembly steps
"NA 18. Transfer case plate 25. Gasket
19. Needle bearing "JA 26. Control housing
20. Countershaft gear "HA 27. Rear cover
"MA 21. Spacer "GA 28. Spacer
"LA 22. Plug "FA 29. Oil seal
"KA 23. H-L shift rail plug "EA 30. Spring pin (H-L shift fork)
24. Low switch
41
40
39
43
42
38
40
44 35 Nm
36 35
31 45
37
33
32
46
Disassembly steps
AA" "EA 31. H-L shift rail 41. Spring
AA" "DA 32. Chain cover 42. 2-4WD shift rail
33. H-L shift fork 43. 2-4WD shift fork
34. H-L clutch sleeve AB" "BA 44. Rear output shaft
"DA 35. Interlock plunger AB" "BA 45. Chain
"CA 36. Spring pin AB" "BA 46. Front output shaft
37. 2-4WD shift lug 47. Dust seal guard
38. Distance piece "AA 48. Oil seal
39. E-clip 49. Transfer case
40. Spring seat
Counter
shaft
TRM1615
Oil cover
INSPECTION
2-4WD, H-L DETECTION SWITCH
Check for the continuity between the connector terminal and
switch body.
50.5 mm
"TA MAIN SHIFT RAIL / SHIFT ACTUATOR
INSTALLATION
1. Connect a 12V power supply across the terminals of the
B A actuator connector in a polarity appropriate for causing
View Z the actuator motor to move in the rod extending direction
or retracting direction until the amount of extension of
Rod extends Z the rod is as indicated in the drawing.
Terminal A Terminal B Rod movement
Power supply (+) Power supply (–) Extension
Power supply (–) Power supply (+) Retraction
Mark
Third gear
INSPECTION
SWITCHES
Check for the continuity between the connector terminal and
switch body. Replace the switch if found faulty.
5
4
Disassembly steps
"BA 1. Bolt
2. Bearing retainer
3. Transfer input gear
"AA 4. Oil seal
5. Baffle plate
6. Transfer case plate
18
4
3
255 Nm
2
1
9
5
13 7
8
10
11
12
Apply gear oil to all
moving parts before
installation.
14
15
16
17
Disassembly steps
"FA 1. Snap ring 10. Drive sprocket
AA" "EA 2. Clutch hub 11. Needle bearing
3. Low speed gear 12. Sprocket sleeve
4. Needle bearing 13. Steel ball
AB" "DA 5. Jam nut 14. Clutch sleeve
AC" "CA 6. Ball bearing AD" "BA 15. Clutch hub
7. Oil guide AD" "AA 16. Stopper plate
8. Sprocket spacer AD" "AA 17. Ball bearing
9. Steel ball 18. Rear output shaft
23
24
25
3 255 Nm
2 9 7
4
1 <V4A51-7>
10 5
12
6
8
<V4A51-5>
16
19
18 10
20 11
13
15 14 Apply gear oil to all
moving parts before
installation.
17
Disassembly steps
"FA 1. Snap ring 13. Drive sprocket
AA" "EA 2. Clutch hub 14. Needle bearing
3. Low speed gear 15. Sprocket sleeve
4. Needle bearing 16. Steel ball
5. Snap ring (V4A51-7) 17. Synchronizer inner ring
6. Rotor (V4A51-7) 18. Synchronizer cone
7. Steel ball 19. Synchronizer outer ring
AB" "DA 8. Jam nut 20. Synchronizer spring
AC" "CA 9. Ball bearing 21. Clutch sleeve
10. Spacer (V4A51-7) AD" "BA 22. Clutch hub
Oil guide (V4A51-5) AD" "AA 23. Stopper plate
11. Sprocket spacer AD" "AA 24. Ball bearing
12. Steel ball 25. Rear output shaft
3
2
Disassembly steps
1. O-ring
"AA 2. Spring pin
3. Driven gear
4. O-ring
5. Sleeve