B. Re-Sealing Transfer Case

CAUTION
During disassembly of the transfer case, DO NOT separate the transfer case at the area indicated In the above illustration. On 5-speed transfer cases, DO NOT remove the single bolt in the center of the transfer case cover.





1. Remove the gear housing-to-adapter housing 0-ring.

A CAUTION
DO NOT damage the 0-ring seat

NOTE:
The 0-ring is located on the adapter housing for 5-speed equipped vehicles and in the gear housing for 6-speed equipped vehicles.

2. Clean the adapter housing flange and 0-ring seat (5-speed).

3. Clean the gear housing flange and 0-ring seat (6-speed).





4. Remove the six bolts that secure the gear housing cover to the gear housing.

CAUTION
On 5-speed vehicles, do NOT remove the bolt in the center of the cover.

5. Place the gear housing on the work surface with the cover facing upward.

6. While holding the gear housing, tap one of the cover bolt bosses until the cover has turned sufficiently.

7. Set the gear housing on the work surface with the cover on the side. While holding the gear housing with your thumb in the input gear shaft cavity, tap the gear housing cover with a plastic hammer until it is separated from the housing. DO NOT damage the seal.





8. Remove the input gear from the gear housing.





9. Remove the 0-ring from the gear housing cover.

NOTE:
Some early-production 5-speed transfer cases do NOT have a cover O-ring.

10. Clean the gear housing cover flange and the cover 0-ring groove and surface.

11. Remove any sealant from the gear housing and cover bolt holes.

12. Using a brass drift or a socket extension and a plastic hammer, remove the input shaft seal from the gear housing.

13. Set the adapter housing/extension housing assembly on the work surface with the output shaft facing upward.





14. Carefully remove the output shaft seal. To remove the seal, place a flat blade screwdriver under the seal with the screwdriver shaft resting on the extension housing cuff. Remove the seal by quickly hitting the screwdriver handle and popping the seal from its seat.

NOTE:
Protect the end of the output shaft by placing a shop rag over it prior to the seal removal.





15. Place the new input shaft seal from the kit (Pos. D, oil seal) into the seal seat on the input gear housing.

a. For 5-speed transfer cases: Use a flat seal installation tool to press the seal into the housing with a lever press until the seal is flush with the housing surface.





Remove the seal installation tool and place the supplied 2 mm spacer from the kit (Pos. D, Distance washer) on top of the input shaft seal. Place the tool on top of the spacer and press the seal further into the housing with the lever press until the spacer is flush with the housing surface. Remove the tool and spacer.

b. For 6-speed transfer gases: Use a 36 mm socket to press the seal into the housing with a lever press until the seal contacts the seat.

16. Lubricate the input shaft seal lip with a small amount of Mitsubishi White Lithium Grease (A999ZC1X05).





17. Lubricate the gear housing cover 0-ring from the sealing kit (Pos. A, 0-Ring) with Mitsubishi 75W-90/GL-5 Diamond Gear Lube (A991ZC2X01), then install the 0-ring into the groove on the gear housing cover. DO NOT twist the 0-ring.

NOTE:
Some early production 5-speed transfer cases did NOT have a cover 0-ring. However, some of these covers do have an O-ring groove. A new cover O-ring MUST be installed if the cover has an 0-ring groove. If the cover does NOT have an 0-ring groove, DO NOT install a cover 0-ring.





18. Install the input gear into the gear housing by placing the input gear assembly on the work surface with the shaft facing upward. Place the gear housing over the shaft. Make sure that the shaft slides easily into the input shaft seal and that the seal lip is not twisted.





19. Place your thumb into the input shaft opening to hold the gear in position and then turn the gear housing over.





20. Run a bead of sealant (Mitsubishi Transmission Gasket Sealant A990ZC1X02) on the gear housing cover flange.





21. Carefully install the gear housing cover onto the gear housing. Position the cover by loosely installing two of the cover bolts. Seat the cover by tapping it with a plastic hammer or by using a press.

22. Remove the two bolts used to position the cover.

23. Apply Mitsubishi Threadlock (A990ZC1X05) to the threads of all cover bolts. Install the bolts and tighten each to 220 in-lbs (25Nm).





24. Lubricate gear housing-to-adapter housing 0-ring (Pos. B, 0-Ring) in the kit, with Mitsubishi 75W-90/GL-5 Diamond Gear Lube (A991ZC2X01). Install the 0-ring onto the adapter housing (5-speed) or into the gear housing (6-speed). Make sure that the 0-ring is not twisted.

NOTE:
There are two different gear housing-to-adapter housing 0-rings contained in the repair kit. Make sure that the correct O-ring is used for the vehicle being serviced. The Pos. B 0-ring for the 5-speed vehicle is the smaller diameter, with the 0-ring for the 6-speed being the larger diameter.





25. FOR 6-SPEED TRANSFER CASES ONLY: Put a bead of sealant (Mitsubishi Transmission Gasket Sealant A990ZC1X02) on the gear housing flange.

NOTE:
Do NOT use sealant on the 5-speed gearhousing-to-adapter housing joint.

26. Stand the adapter housing assembly vertically on the work surface and then install the gear housing assembly onto the adapter housing. Make sure the dowel pins are properly aligned. Seat the gear housing by lightly tapping it with a plastic hammer.

27. Apply Mitsubishi Threadlock (A99OZC1 X05) to the threads of the adapter housing-to-gear housing bolts, and then install the bolts and tighten to 220 in-lbs (25 Nm).

NOTE:
For 6-speed transfer cases, the bolts are not all the same length. Make sure that the one longer bolt is used in the position with the raised boss.

28. With the output shaft facing upward, place the transfer case on the work surface.





29. Place the supplied output shaft seal (Pos. E, Oil seal) from the kit into the extension housing seat.

30. Using a 36 mm socket as a seal installation tool, press the output shaft seal into the housing with a lever press until the new seal contacts the seal seat.

31. Install a new aluminum gasket onto the drain plug. Install the drain plug into the transfer case and tighten the plug to 300 in-lbs (35 Nm). Two of these aluminum gaskets are supplied in the kit, and are marked Pos. G & H. The other gasket is for the transfer filler plug, which will be used in the next step.

32. Install a new aluminum gasket onto the filler plug. Install the filler plug into the transfer case and tighten the plug to 300 in-lbs (35 Nm).





33. Clean the transfer case breather and seat, apply Mitsubishi Weatherstrip Adhesive (A99OZC1XO3) around the breather hole and then install the breather.

34. The transfer case is now ready for installation into the vehicle. Proceed with Section C - Installing Transfer Case.