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Pajero 4 (2006-2021) Pajero 1 and 2 (1982-1999)

Disassembling the transfer case (Mitsubishi Pajero 4)

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  • 4 (2006-2021)
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  • Disassembling the transfer case
0


1. Remove the shift shaft drive gear (1).

2. Remove the dynamic shock absorber (2).

3. Remove the dust seal protection (3).

4. Remove the vehicle speed sensor (4).

5. Remove the sealing ring (5).

6. Remove the rear output shaft speed sensor (6).

7. Remove the sealing ring (7).

8. Remove the front output shaft speed sensor (8).

9. Remove the sealing ring (9).

10. Remove the shift drive (10).

11. Remove the sealing ring (11).

12. Remove the main shaft rack (12).



13. Remove the back cover (13).

14. Remove the oil seal (14).

15. Remove the spring ring (15).

16. Remove the rotor sensor (16).

17. Remove the steel ball (17).

18. Remove the oil guide (18).

19. Remove the washer (19).

20. Remove the spring ring (20).

21. Remove the spring ring (21).



22. Remove the gearbox wiring protection (22).

23. Remove the connector bracket (23).

24. Remove the connector bracket (24).

25. Remove the chain cover (25).

26. Remove the rear output shaft (26).

27. Remove the sealing ring (27).

28. Remove the needle bearing (28).

29. Remove the spring ring (29).

30. Remove the planetary bearing of the central differential (30).

31. Remove the viscosity coupling (31).

32. Remove the chain (32).

33. Remove the front output shaft (33).

34. Remove the drive sprocket (34).

35. Remove the needle bearing (35).

36. Remove the inner synchronizer ring (36).

37. Remove the inner synchronizer cone (37).

38. Remove the outer synchronizer ring (38).

39. Remove the inner synchronizer spring (39).

40. Remove the spring ring (40).

41. Remove the 2-4WD clutch sleeve (41).

42. Remove the central gear wheel (42).

1) Remove the chain, front output shaft and central gear assembly from the transfer case housing.



43. Remove the needle bearing (43).

44. Remove the wave spring (44).

45. Remove the 2-4WD clutch ring (45).

46. Remove the 2-4WD shift fork (46).

47. Remove the washer (47).

48. Remove the steel ball (48).



49. Remove the spring ring (49).

50. Remove the differential lock bushing (50).



51. Remove the transfer case housing plate (51).

52. Remove the needle bearing (52).

53. Remove the counter shaft gear (53).

54. Remove the washer (54).

55. Remove the HL clutch ring (55).

56. Remove the HL shift fork (56).

57. Remove the spring ring (57).

58. Remove the HL coupling sleeve (58).

59. Remove the low speed gear (59).

60. Remove the needle bearing (60).

61. Unscrew the seal bolt (61).

62. Remove the rear bearing mount (62).

63. Remove the transfer case drive shaft (63).

64. Remove the dust seal protection (64).

65. Remove the oil seal (65).

66. Remove the oil reservoir cover (66).

Caution: If the oil reservoir cap has been removed, a new transfer case housing must be used.


1) Loosen the cover at the points indicated in the figure and remove the oil reservoir cover.



67. Remove the oil guide (67).

68. Remove the transfer case housing (68).
This article is available at: russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian
This article was reviewed by: Miroslav Rakov
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Pajero 4: Manual gearbox
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Checking the main shaft
Assembling the main shaft
Disassembling the main shaft
Counter shaft
Main drive gear
Adjustment before assembly
Transfer case assembly
Transfer case housing plate
Transfer case input gear
Counter shaft
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Pajero 4 (2006-2021) 
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