With lots of pics, this definitely has the makings of a tech article <img src="/forums/images/graemlins/kewl.gif" alt="" /> Good work DD!!!

I've already started working on putting together a very detailed procedure, step-by-step, from removing the t-case, disassembly, rebuild, and reinstallation with part numbers, materials used, special tools & techniques, torque values, and diagrams and pictures when necessary.

It started as a personal need to be very organized, since I've never done anything like this. The FSM leaves out a lot of steps that a competent mechanic would just naturally understand--I'll fill in those gaps as I go along.

When it's done I'll make it available somehow. It'll be too big to store here, but maybe someone like MontyMcV would store it on their website. If nothing else, I'll email it upon request.

Send it to me and I'll host it. PM me whenever you're ready.

I'll do what I can. Times are busy and I don't always log in. Best to email me when the time comes.

Keep up the good work... <img src="/forums/images/graemlins/cheers.gif" alt="" />

I'm kinda bummed out. I got most of the parts needed to rebuild the V4AW2 transfer case, but some fairly critical ones are not available from Mitsubishi anymore.

The two biggest disappointments are the needle bearing that the new Aussie low speed gear rotates on, and the selectable snap ring that determines end play where the Aussie low speed gear mounts. So unless the Aussie low speed gear has EXACTLY the same dimensions as the original gear, there is going to be some slop--slop that causes accelerated wear of the needle bearing that is no longer available.

Any ideas on alternate sources for that needle bearing? You think it could be a common part that a bearing manufacturer might have in stock?

The other obsolete parts are the selectable snap rings to control end play of the input gear, the needle bearings under the drive sprocket (two required and it looks like I got the last one for sale in North America!), and the "as required" spacer I mentioned in item 7 in the post above.

Hey brother, send me your MITSUBISHI part numbers and I'll see what I can come up with when I get back home (Whenever that may be).

I appreciate it Jon, but I'm not too worried about it right now--it will go together fine. My disappointment stems from the fact that, just like the M/T before it, now A/T stuff isn't supported anymore. I guess I shouldn't complain. It's a 19 year old truck after all. But I want to be driving it when it is a 49 year old truck. And I might still--but with another drivetrain.

I have a second tranny that I think only needs a little attention. And a second t-case that should be fine. I sometimes get tired of tripping over them, but think I'll make room somewhere in case I need them later... <img src="/forums/images/graemlins/confused.gif" alt="" />

Damn, and to think I ripped apart a Quest MT just to see more about it. There would have been lots o' parts in it that could be used in a Montero MT. And I gave away another Quest one. <img src="/forums/images/graemlins/baby.gif" alt="" />

I'm glad that when I had my 2.85 gears installed 3 1/2 years ago I had the t-case completely rebuilt as well.

Well, the end of my stay in the Andaman Sea may be in sight. Can you please send me the entire list of factory parts needed for the install? I'm having some ideas... <img src="/forums/images/graemlins/notooth.gif" alt="" />