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Home >> Mitsubishi >> 1999 >> Montero >> Repair and Diagnosis (Single Page) >> Transmission >> Transfer Case >> Overhaul >> Transfer Case Reassembly >> Reassembly >> Service Notes

Service Notes

  1. Ensure bearing retainer plate screws are coated with thread locking sealant.
  2. Ensure flat side of H-L clutch faces rear of transfer case and relieved side faces front.
  3. Ensure magnet and magnet holder are positioned in case.
  4. Install spring seats, spring and 2-4WD shift rail and shift lug into case. When installing spring pin, ensure split faces axial direction of shaft. See Fig 2 .
  5. When installing front output shaft, chain and 2-4WD Synchronizer, use the following alignment procedure: paint White marks on the 3 deep-grooved tooth portions of the synchronizer sleeve inner teeth. Paint a White mark on the 3 raised projections of the synchronizer hub. Align marks when installing in case.
  6. Install interlock plunger into position so it does not interfere with 2-4WD shift rail. Apply sealant and install chain cover.
  7. Install H-L shift rail and spring pin. See Fig 2 .
  8. Use the following procedure to select a rear cover output shaft bearing spacer: Measure amount of projection "A" of rear output shaft bearing from case surface. Measure depth of indentation in cover, measurement "B". Select a rear cover bearing spacer that allows a clearance of .001-.006" (.025-.150 mm). Apply sealant and install rear cover.
  9. When installing transfer case plate, align sub-gear teeth with notched portion of input gear. Apply sealant to transfer case plate and carefully install plate while sliding aligned input gear teeth along tooth space of countershaft cluster gear. Ensure teeth align and plate is seated. See Fig 4 .
  10. When installing speedometer gear, match mating mark on case with mark on gear housing which corresponds to the number of teeth on speedometer gear. See Fig 5 .
  11. When installing poppet springs with steel balls, ensure ball is on small end of spring. Mount position detection switches in their original positions. See Figure .
Fig 1: Positioning & Measuring Solder
G00013443Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 2: Installing 2-4WD & H-L Shift Rails
G00013444Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 3: Measuring Rear Cover Spacer
G00013445Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 4: Aligning Input Gear & Sub-Gear Teeth
G00013446Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 5: Installing Speedometer Drive
G00013448Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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