Disassembly and Reassembly: Disas Steps

DISASSEMBLY AND REASSEMBLY Page 1 of 21
DISASSEMBLY AND REASSEMBLY
Disas
steps
1. Breat
2. Air br
pipe
3. Vacuu
4. Vacuu
5. Breat
6. Vacuu
7. Vacuu
8. Vacuu
9. Vacuu
termin
10. 4LLC
>>d<< opera
detec
switch
11. Gaske
12. Steel
13. 2WD
>>d<< detec
switch
14. Gaske
15. Steel
16. Cente
>>d<< differe
lock d
switch
17. Gaske
18. Steel
19. 4H de
>>d<< switch
20. Gaske
21. Steel
22. 2WD/
>>d<< detec
switch
file:///L:/SERVICE/003/424B202020202020/SEARCH/2008/22/html/M12220010011520... 04/12/2021
23. Gaske
24. Steel
25. Wiring
harne
brack
26. Wiring
harne
brack
27. Contr
>>c<< housi
28. Spring
29. Chan
shifte
30. Trans
>>b<<
31. Conn
brack
>>a<<
>>a<<
>>a<<
>>Z<<
>>Y<<
>>X<<
>>X<<
>>X<<
>>X<<
>>W<<
>>W<<
<<A>>
>>V<<
<<B>> >>U<<
<<B>> >>U<<
<<C>> >>T<<
>>S<<
>>R<<
<<D>> >>Q<<
>>P<<
>>O<<
>>N<<
>>M<<
>>L<<
<<E>> >>K<<
<<E>> >>J<<
>>I<<
<<F>> >>H<<
<<F>>
>>G<<
>>F<<
>>E<<
<<G>>
>>D<<
>>C<<
>>C<<
>>B<<
<<H>> >>A<<
DISASSEMBLY SERVICE
POINTS
<<A>> SPRING PIN REMOVAL
With the control finger at the neutral position,

remove the spring pin.
<<B>> LOCK NUT REMOVAL
1.Slide the shift forks as illustrated to put the

two gears into engagement.
2.Using the special tool, Lock nut wrench (46)

(MD998835), remove the main shaft lock nut.

(MD998809), remove the counter shaft cluster
gear lock nut.
<<C>> BALL BEARING

REMOVAL
Using the special tool, Bearing and gear puller

(MD998348), remove the ball bearing from
counter shaft cluster gear.
<<D>> BALL BEARING

REMOVAL
Using the special tool, Bearing and gear puller

(MD998348), remove the ball bearing from
main shaft.
<<E>> REVERSE GEAR

BEARING SLEEVE / REVERSE
BRAKE GEAR REMOVAL
1.Attach the special tool, Bearing puller

(MD998020), the reverse brake gear.
2.Screw the center bolt of special tool, and
pull out the reverse gear bearing sleeve,
reverse brake gear, synchronizer spring and
ring together.
<<F>> COUNTER 5TH SPEED

GEAR / REVERSE IDLER GEAR
SHAFT REMOVAL
Lift the counter 5th speed gear to the slit in the

reverse idler gear shaft and remove them
altogether.
<<G>> SNAP RING REMOVAL
While pushing the main shaft and counter

shaft cluster gear against the intermediate
plate, remove the snap rings from the rear
bearing retainer mounting surface.
<<H>> INTERMEDIATE PLATE

REMOVAL
Removing the intermediate plate will set

free the main shaft, counter shaft cluster
caution
gear and main drive pinion at the same
time.
Lightly tapping the intermediate plate with a
plastic hammer or similar tool, remove the
intermediate plate from the main drive pinion,
main shaft, and counter shaft cluster gear.
REASSEMBLY SERVICE POINTS
>>A<< INTERMEDIATE PLATE

INSTALLATION
1.Install the main shaft and counter shaft

cluster gear to the transmission case.
2.Using a plastic hammer, install the

intermediate plate.
Push the intermediate plate
until the snap ring grooves
for the main shaft and
note counter shaft cluster gear
bearings come out the rear
bearing retainer mounting
surface.
3.Install the snap ring.
>>B<< SEAL BOLT

INSTALLATION
Apply the specified sealant to the threads.

Specified sealant:
3M™ STUD Locking No. 4170 or equivalent
The new bolt does not require
note sealant application as it is
precoated with sealant.
>>C<< SPRING PIN

INSTALLATION
Press in the spring pin so that its slit is parallel

with the shift rail.
>>D<< TRANSMISSION CASE

INSTALLATION
Apply the specified sealant to the transmission

case before installation.
Specified sealant:
Mitsubishi Part No. MD997740 or
equivalent
>>E<< SPACER INSTALLATION
Install the selected spacer into ball bearing. (Refer to

ADJUSTMENT OF TRANSMISSION-SPACER
SELECTION FOR ADJUSTMENT OF BALL
BEARING END PLAY .)
>>F<< OIL SEAL INSTALLATION
1.Using special tool, Oil seal installer

(MD998304), install the oil seal into the clutch
housing.
2.Apply specified grease to the lip of the oil
seal.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
>>G<< CLUTCH HOUSING

INSTALLATION
Be careful not to damage the oil seal by

caution
the spline of the main drive pinion.
Apply the specified sealant to the transmission
case before installation.
Specified sealant:
equivalent
>>H<< COUNTER 5TH SPEED

GEAR INSTALLATION
Before reassembly, make sure that the

counter 5th speed gear faces the correct
direction.
>>I<< 5TH SPEED

SYNCHRONIZER HUB
INSTALLATION
Before reassembly, make sure that the 5th

speed synchronizer hub faces the correct
direction.
>>J<< REVERSE BRAKE GEAR

INSTALLATION
Using special tools to install the reverse brake

gear.
• Installer cap (MD998812)

• Installer-100 (MD998813)
• Installer adapter (42) (MD998820)
>>K<< REVERSE GEAR

BEARING SLEEVE
INSTALLATION
Using special tools to install the reverse gear

bearing sleeve.

>>L<< 5TH SPEED

SYNCHRONIZER SLEEVE
INSTALLATION
Before reassembly, make sure that the 5th

speed synchronizer sleeve faces the correct
direction.
>>M<< REVERSE
SYNCHRONIZER SLEEVE
INSTALLATION

reverse synchronizer sleeve faces the correct
direction.
>>N<< POPPET SPRING

INSTALLATION
Install the poppet spring with the small end

directed to the steel ball.
>>O<< SPRING PIN

INSTALLATION
Press in the spring pin so that its slit is parallel

with the shift rail.
>>P<< REVERSE GEAR

INSTALLATION
Install the reverse gear while aligning the deep

grooves in the synchronizer hub section with
the projection on the sleeve inner periphery.
>>Q<< BALL BEARING

INSTALLATION
Using special tools to install the ball bearing to

the main shaft.

>>R<< REVERSE IDLER GEAR

INSTALLATION

reverse idler gear faces the correct direction.
>>S<< COUNTER REVERSE

GEAR INSTALLATION

counter reverse gear faces the correct
direction.
>>T<< BALL BEARING

INSTALLATION
Using special tools to install the ball bearing to

the counter shaft cluster gear.

>>U<< LOCK NUT

INSTALLATION
1.Slide the synchronizer sleeves as illustrated

to put the two gears into engagement.

(MD998835), tighten the main shaft lock nut to
the specified torque of 255 ± 10 N·m.

(MD998809), tighten the counter shaft cluster
gear lock nut to the specified torque of 255 ±
10 N·m.
4.Stake the two lock nuts firmly using a punch

or like.
>>V<< TRANSFER CASE

ADAPTER INSTALLATION
Apply specified sealant to the transmission

case mating surface of the transfer case
adapter as illustrated.
Specified sealant:
equivalent
>>W<< SPECIAL BOLT / NUT

INSTALLATION
1.Apply the specified sealant to the bolt as

shown.
Specified sealant:
equivalent
2.Apply the specified sealant to the nut

threads.
Specified sealant
3M ™ AAD Part No. 2353 or equivalent
>>X<< NEUTRAL RETURN

PLUNGER / NEUTRAL RETURN
SPRING INSTALLATION
Coat the entire surface of the neutral return

plunger with grease. Then, install the neutral
return plunger to the upper cover and attach
the spring.
>>Y<< UPPER COVER

INSTALLATION
Apply a bead of specified sealant to the upper

cover as illustrated.
Specified sealant:
equivalent
>>Z<< RESISTANCE SPRING

PLUG INSTALLATION
Apply the specified sealant to the resistance

spring plug as illustrated.
Specified sealant:
3M ™ AAD Part No. 8660 or equivalent
>>a<< RAIL SWITCH

INSTALLATION
Install the switches, ensuring that each is

installed correctly as identified by the
identification tape.
Mounting Rail Identification
position switch tape color
A 1st and Red
2nd
B 3rd Blue
and
4th
C 5th White
and
reverse
>>b<< TRANSFER
INSTALLATION
1.Apply specified sealant to the transfer case

adapter mating surface of the transfer.
Specified sealant:
equivalent
2.Apply grease to the leading end of the

transfer input gear as illustrated.
3.Assemble the transfer and transmission with
care not to damage the control shaft oil seal.
At this time, mount the change shifter to the
control shaft.
>>c<< CONTROL HOUSING

INSTALLATION
Apply specified sealant to the illustrated

position of the control housing.
Specified sealant:

equivalent
>>d<< SWITCH INSTALLATION
Install the switches as illustrated.

Mounting Switch Tube Connector
Position Name color color
A 2WD/4WD Blue Black
detection
switch
B 4LLC Black Brown
operation
detection
switch
C 2WD Black Black
detection
switch
D 4H Green White
detection
switch
E Center Blue Brown
differential
lock
detection
switch

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DISASSEMBLY AND REASSEMBLY Page 1 of 21

DISASSEMBLY AND REASSEMBLY

<<A>> SPRING PIN REMOVAL

With the control finger at the neutral position,

<<B>> LOCK NUT REMOVAL

1.Slide the shift forks as illustrated to put the

2.Using the special tool, Lock nut wrench (46)

3.Using the special tool, Lock nut wrench (41)

<<C>> BALL BEARING

Using the special tool, Bearing and gear puller

<<D>> BALL BEARING

Using the special tool, Bearing and gear puller

<<E>> REVERSE GEAR

1.Attach the special tool, Bearing puller

<<F>> COUNTER 5TH SPEED

Lift the counter 5th speed gear to the slit in the

<<G>> SNAP RING REMOVAL

While pushing the main shaft and counter

<<H>> INTERMEDIATE PLATE

Removing the intermediate plate will set

REASSEMBLY SERVICE POINTS

>>A<< INTERMEDIATE PLATE

1.Install the main shaft and counter shaft

2.Using a plastic hammer, install the

>>B<< SEAL BOLT

Apply the specified sealant to the threads.

>>C<< SPRING PIN

Press in the spring pin so that its slit is parallel

>>D<< TRANSMISSION CASE

Apply the specified sealant to the transmission

>>E<< SPACER INSTALLATION

Install the selected spacer into ball bearing. (Refer to

>>F<< OIL SEAL INSTALLATION

1.Using special tool, Oil seal installer

>>G<< CLUTCH HOUSING

Be careful not to damage the oil seal by

>>H<< COUNTER 5TH SPEED

Before reassembly, make sure that the

>>I<< 5TH SPEED

Before reassembly, make sure that the 5th

>>J<< REVERSE BRAKE GEAR

Using special tools to install the reverse brake

• Installer cap (MD998812)

>>K<< REVERSE GEAR

Using special tools to install the reverse gear

• Installer cap (MD998812)

>>L<< 5TH SPEED

Before reassembly, make sure that the 5th

Before reassembly, make sure that the

>>N<< POPPET SPRING

Install the poppet spring with the small end

>>O<< SPRING PIN

Press in the spring pin so that its slit is parallel

>>P<< REVERSE GEAR

Install the reverse gear while aligning the deep

>>Q<< BALL BEARING

Using special tools to install the ball bearing to

• Installer cap (MD998812)

>>R<< REVERSE IDLER GEAR

Before reassembly, make sure that the

>>S<< COUNTER REVERSE

Before reassembly, make sure that the

>>T<< BALL BEARING