23D

23D-1-1

R4A51, V4A51 - Specifications

1. SPECIFICATIONS TRANSMISSION MODEL TABLE - MODEL 2000 Transmission models EUR

EXP

Vehicle model

Engine model

V4A51-5-DHA3

K96W

6G72

V4A51-5-DHA4

K96W

6G72

R4A51-5-DCA

K86W

6G72

R4A51-5-DEA

K86W

6G72

V4A51-5-DHA3

K96W

6G72

V4A51-5-DHA4

K96W

6G72

V4A51-5-QIA

K97W

4M40

V4A51-5-QIA1

K97W

4M40

TRANSMISSION MODEL TABLE - MODEL 2001 Transmission models EUR

EXP

MMAL

E Mitsubishi Motors Corporation

Vehicle model

Engine model

V4A51-5-DHA3

K96W

6G72

V4A51-5-DHA4

K96W

6G72

V4A51-7-QBA

V66W, V76W

4M40

V4A51-7-DCA

V63W, V73W

6G72

V4A51-7-DCA1

V63W, V73W

6G72

R4A51-5-DCA

K86W

6G72

R4A51-5-DEA1

K86W

6G72

V4A51-5-DHA3

K96W

6G72

V4A51-5-DHA4

K96W

6G72

V4A51-5-QIA

K97W

4M40

V4A51-5-QIA1

K97W

4M40

R4A51-4-DHA

K66T

6G72

R4A51-4-GDA

K66T

6G72

V4A51-4-DIA

K76T

6G72

V4A51-5-DHA4

K96W

6G72

July 2000

PWEE8920-J

Revised

23D-14-1

R4A51, V4A51 - Transfer

14. TRANSFER DISASSEMBLY AND ASSEMBLY - V4A51-4 PART TIME 4WD 35 Nm

9

34 Nm

34 Nm

3 10

11

4 5

35 Nm

1 6 7 8

2

12

35 Nm

13

Apply gear oil to all moving parts before installation.

14

15

Disassembly steps 1. 2-4WD detection switch 2. Gasket 3. H-L detection switch 4. Gasket 5. Steel ball "LA 6. Plug "PA 7. Spring 8. Steel ball

E Mitsubishi Motors Corporation

July 2000

"LA 9. "PA 10. 11. "LA 12. "LA 13. 14. "OA 15.

PWEE8920-J

18 Nm

Plug Spring Steel ball Plug Plug Speedometer sleeve clamp Speedometer gear

Revised

23D-14-3a

R4A51, V4A51 - Transfer

DISASSEMBLY AND ASSEMBLY - V4A51-5 PART TIME 4WD 35 Nm

9

34 Nm

34 Nm

3 10

11

4 5

35 Nm

1 6 7 8

2

12

35 Nm

13

Apply gear oil to all moving parts before installation.

14

15

Disassembly steps 1. 2-4WD detection switch 2. Gasket 3. H-L detection switch 4. Gasket 5. Steel ball "LA 6. Plug "PA 7. Spring 8. Steel ball

E Mitsubishi Motors Corporation

July 2000

"LA 9. "PA 10. 11. "LA 12. "LA 13. 14. "OA 15.

PWEE8920-J

18 Nm

Plug Spring Steel ball Plug Plug Speedometer sleeve clamp Speedometer gear

Revised

23D-14-3b

R4A51, V4A51 - Transfer

21 Nm 18 Nm

32 33 35 Nm

26

29

25 35 Nm

28 27 23

34

35 Nm

22 30

31

16

24 20

17

35 Nm

21

32 Nm

35 Nm

Apply gear oil to all moving parts before installation.

19 18 35 Nm

Disassembly steps "NA 16. Transfer case plate 17. Needle bearing 18. Countershaft gear "MA 19. Spacer "LA 20. Plug "KA 21. H-L shift rail plug 22. Low switch 23. Gasket 24. Dynamic damper 25. Harness bracket

E Mitsubishi Motors Corporation

July 2000

"JA "IA "IA "HA "QA "GA

26. 27. 28. 29. 30. 31. 32. "FA 33. "EA 34.

PWEE8920-J

Control housing Support pin Return spring Rear cover Oil cover Spacer Dust seal guard Oil seal Spring pin (H-L shift fork)

Revised

23D-14-3c

R4A51, V4A51 - Transfer

47

44

45 44 43

35 Nm

46 40

39 42

35

41

49 48

8.8 Nm

51 36 52 50 37 38

54

Apply gear oil to all moving parts before installation.

55

53

AA" "EA AA" "DA "DA "CA

Disassembly steps 35. H-L shift rail 36. Chain cover 37. H-L shift fork 38. H-L clutch sleeve 39. Interlock plunger 40. Spring pin 41. 2-4WD shift lug 42. Distance piece 43. E-clip 44. Spring seat 45. Spring

E Mitsubishi Motors Corporation

July 2000

AB" "BA AB" "BA AB" "BA

"AA

PWEE8920-J

46. 47. 48. 49. 50. 51. 52. 53. 54. 55.

2-4WD shift rail 2-4WD shift fork Rear output shaft Chain Front output shaft Side cover Side cover gasket Dust seal guard Oil seal Transfer case

Revised

23D-14-3d

R4A51, V4A51 - Transfer DISASSEMBLY AND ASSEMBLY - V4A51-7 PART TIME 4WD

35 Nm

9 10 1

11

34 Nm

3 35 Nm

6 7 8

2

34 Nm

4

15

5 12

14 35 Nm

13

18 Nm

16

17

35 Nm

Disassembly steps 1. 4WD switch 2. Gasket 3. Transfer switch 4. Gasket 5. Steel ball "LA 6. Plug "PA 7. Spring 8. Steel ball "LA 9. Plug

E Mitsubishi Motors Corporation

July 2000

35 Nm

"PA 10. 11. "LA 12. "LA 13. 14. 15. 16. 17.

PWEE8920-J

Apply gear oil to all moving parts before installation.

Spring Steel ball Plug Plug Dynamic damper Dust seal guard Vehicle speed sensor Under guard

Revised

23D-14-3e

R4A51, V4A51 - Transfer

35 Nm 18 Nm

24

27

25

29

26 30 35 Nm

23

28 18

35 Nm

22 19

35 Nm

32 Nm

Apply gear oil to all moving parts before installation.

21 20 35 Nm

Disassembly steps "NA 18. Transfer case plate 19. Needle bearing 20. Countershaft gear "MA 21. Spacer "LA 22. Plug "KA 23. H-L shift rail plug 24. Low switch

E Mitsubishi Motors Corporation

July 2000

"JA "HA "GA "FA "EA

PWEE8920-J

25. 26. 27. 28. 29. 30.

Gasket Control housing Rear cover Spacer Oil seal Spring pin (H-L shift fork)

Added

23D-14-3f

R4A51, V4A51 - Transfer

43

42

38

40

41 39 40

35 Nm

44

35

36

31

45

37

33 32 46 Apply gear oil to all moving parts before installation.

34

49 47

AA" "EA AA" "DA "DA "CA

Disassembly steps 31. H-L shift rail 32. Chain cover 33. H-L shift fork 34. H-L clutch sleeve 35. Interlock plunger 36. Spring pin 37. 2-4WD shift lug 38. Distance piece 39. E-clip 40. Spring seat

E Mitsubishi Motors Corporation

July 2000

48

AB" "BA AB" "BA AB" "BA "AA

PWEE8920-J

41. 42. 43. 44. 45. 46. 47. 48. 49.

Spring 2-4WD shift rail 2-4WD shift fork Rear output shaft Chain Front output shaft Dust seal guard Oil seal Transfer case

Added

23D-14-9

R4A51, V4A51 - Transfer

"QA OIL COVER INSTALLATION Install the oil cover so that the oil hole is located as shown in the illustration.

Oil hole

Oil cover

INSPECTION 2-4WD, H-L DETECTION SWITCH Check for the continuity between the connector terminal and switch body. Switch state

Continuity

Switch end pressed

No

Switch end released

Yes

LOW RANGE OPERATION DETECTION SWITCH Check for the continuity between the connector terminal and switch body.

E Mitsubishi Motors Corporation

July 2000

Switch state

Continuity

Switch end pressed

Yes

Switch end released

No

PWEE8920-J

Revised

23D-15-1

R4A51, V4A51 - Transfer Case Plate

15. TRANSFER CASE PLATE DISASSEMBLY AND ASSEMBLY 18 Nm

Apply gear oil to all moving parts before installation.

1 2 3

6 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

E Mitsubishi Motors Corporation

July 2000

PWEE8920-J

Revised

R4A51, V4A51 -

Rear Output Shaft

23D-18-1

18. REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY

18

3

4 255 Nm

2 1 9

5 6

13

8

7

10 11 12

Apply gear oil to all moving parts before installation.

14 16

15

17

Disassembly steps 1. Snap ring 2. Clutch hub 3. Low speed gear 4. Needle bearing AB" "DA 5. Jam nut AC" "CA 6. Ball bearing 7. Oil guide 8. Sprocket spacer 9. Steel ball

"FA AA" "EA

E Mitsubishi Motors Corporation

July 2000

10. 11. 12. 13. 14. AD" "BA 15. AD" "AA 16. AD" "AA 17. 18.

PWEE8920-J

Drive sprocket Needle bearing Sprocket sleeve Steel ball Clutch sleeve Clutch hub Stopper plate Ball bearing Rear output shaft

Revised

23D-18-2

R4A51, V4A51 -

Rear Output Shaft

DISASSEMBLY AND ASSEMBLY 21

22 23 24

25 3 2

255 Nm

9

4

7



1

5

10

12

6 8

19 20

16 10

18

11 13 15

Apply gear oil to all moving parts before installation.

14

17

"FA AA" "EA

AB" "DA AC" "CA

Disassembly steps 1. Snap ring 2. Clutch hub 3. Low speed gear 4. Needle bearing 5. Snap ring (V4A51-7) 6. Rotor (V4A51-7) 7. Steel ball 8. Jam nut 9. Ball bearing 10. Spacer (V4A51-7) Oil guide (V4A51-5) 11. Sprocket spacer 12. Steel ball

E Mitsubishi Motors Corporation

July 2000

13. 14. 15. 16. 17. 18. 19. 20. 21. AD" "BA 22. AD" "AA 23. AD" "AA 24. 25.

PWEE8920-J

Drive sprocket Needle bearing Sprocket sleeve Steel ball Synchronizer inner ring Synchronizer cone Synchronizer outer ring Synchronizer spring Clutch sleeve Clutch hub Stopper plate Ball bearing Rear output shaft

Revised

R4A51, V4A51 - Speedometer Gear

23D-20-1

20. SPEEDOMETER GEAR DISASSEMBLY AND ASSEMBLY Apply gear oil to all moving parts before installation.

1

3 2 5

4

Disassembly steps 1. O-ring "AA 2. Spring pin 3. Driven gear 4. O-ring 5. Sleeve

Slit

Spring pin

E Mitsubishi Motors Corporation

July 2000

ASSEMBLY SERVICE POINT "AA SPRING PIN INSTALLATION Drive the spring pin in, while making sure that slit does not face gear shaft.

PWEE8920-J

Revised