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#1068858 - 02/06/14 07:37 AM 89 Mighty max transmission/transfer case issue?  
Hamer  Offline

Getting the Wheeling Fever
Joined: Feb 2014
Posts: 80
MI
Hey folks I have a 89 Mighty max 4x4 with the 2.6L engine and a 5 speed manual tranny. I need some help please. The tranny has an issue. The truck will not down shift at all and unless you are super careful it will grind the gears trying to up shift.

I recently changed the tranny fluid and the transfer case fluid hoping a fluid change would help it a little do to how thick the fluid was. I could feel resistance when free wheeling when it was cold like the brake was applied. If I let it warm up good 1st the resistance would not be there. When I drained the tranny fluid it looked great but the transfer case oil was full of metal. The transfer case has 215,000 miles on it and 100,000 miles of it was from being towed behind a motor home. It is nearly shot IMO.

I drained the tranny oil 1st at the pan plug and then filled the tranny oil from the fill hole on the side of the tranny with the proper amount called for. I then drained the transfer case and discovered getting to the fill plug was difficult so I took the easy fill option for the transfer case and removed the stick shifter and boot and 4 bolts and removed the shifters and top plates exposing the gears below the main shifter and the 4x4 shift lever. From inside the truck I poured the transfer case gear lube in the stick shifter square holes over the tops of the gears. I put in the proper amount which is something like 2.5 quarts.

I noticed that the shifting gears below the main shift lever and the gears to put it into 4x4 share the same oil. I also noticed that the syncro gears or what looks like syncro gears because they are very thin were chewed up when I looked into the gearbox opening from above. I could actually only see one thin gear. The rest were substantial sized gears. The gears for the tranny and the gears for the 4x4 are clearly visible though. I drove the truck down my drive way with the cover off and could see the gears turning below the shifting lever even when in 4x2. It was then I thought that at least some of the gears to shift it must be in the transfer case or perhaps all of them. I made sure the oil I just put in from above over those gears was in the transfer case by removing the drain plug again and oil began to come out again confirming what I suspected.

What I want to know is can I replace those gears without removing the entire transmission? It appears they are part of the transfer case and not the main transmission itself?

Could I just buy a new gearbox (transfer case) and bolt it in and if I did would all those gears below the 2 shift levers be included in that new transfer case?

It is frustrating because I cannot find the needed data or an exploded view of the manual trans and transfer case and how they go together and how the gears work. I have never owned a 4x4 so I am inept at the knowledge part of a 4X4 manual trans. The transfer case appears to contain all the 4x4 gears and all the gears for the manual trans right below the shifter levers. Is this the case on a Mighty max?

This may all sound odd or stupid but it sure looks like those gears to shift it are in the transfer case. It appears some kind of rod that the gears turn on runs thru the front of the transfer case into the tranny where the clutch etc is located. Am I dreaming about what I am seeing or are the shifting gears and scyncros all inside that transfer case and can I just unbolt the transfer case and all those gears would come out with it?

Thanks for the help. Sorry if this all sounds dumb and sorry for such a wordy posting but I need help and wanted to explain it the best I could.

Matt.


Matt Hamer 89 Mighty Max SPX Macro Cab 2.6L 5 speed 4X4 Auto hubs.

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#1068859 - 02/06/14 08:01 AM Re: 89 Mighty max transmission/transfer case issue? [Re: Hamer]  
Jay Ayala  Offline
Body Damage is Cool
Joined: Jul 2002
Posts: 1,758
Hillsboro, OR.
Hey hammer. Can you post some pictures? Do you still have those gears exposed?


89 Raider - V6, Automatic, rear LSD, A/C Retrofit, Cruise Control Retrofit.

#1068860 - 02/06/14 08:21 AM Re: 89 Mighty max transmission/transfer case issue? [Re: Jay Ayala]  
Hamer  Offline

Getting the Wheeling Fever
Joined: Feb 2014
Posts: 80
MI
I am sorry but I do not have them exposed but I could get Pics of them if need be sometime tmrw. It is 2:20 a.m. here so I have no way to take a pic right now

The transfer case bolts to the back of the tranny but I need to figure out if those gears come out with the transfer case or not. I am stumped. A new/used manual tranny is not cheap but a transfer case is. I have an old Haynes manual and go figure that the part on the manual tranny and transfer case is all of 2 pages.

Have you ever seen a transfer case that has all the gears to shift the truck inside it on a manual transmission? The shifter lever and the 4x4 shifter lever are right next to each other. Inches apart.

Its worth noting or perhaps not that the speedometer cable is connected into the side of the transfer case. You have to unhook it to get to the Transfer case oil fill hole if you want to fill it from the proper spot. It would seem to me that if the speedo cable is connected to the transfer case that the gears inside must also perform the shifting functions?


Matt Hamer 89 Mighty Max SPX Macro Cab 2.6L 5 speed 4X4 Auto hubs.

#1068861 - 02/06/14 10:24 AM Re: 89 Mighty max transmission/transfer case issue? [Re: Hamer]  
geocrasher  Offline

Rock Warrior
Joined: Sep 2011
Posts: 628
Castle Rock WA, US
Your new best friend:

http://www.mitsubishilinks.com

Get the Factory Service Manual. The shifter is part of the tailhousing in the 2wd version of the transmission and in the 4wd version, the tailhousing is part of the transfer case adapter. So no, the shifty-bits are not in the transfer case, but the shifter linkage (which is internal) is.


1987 Raider, 346K miles and going strong -31" tires, otherwise stock.
http://tidbitsfortechs.com/
http://actionpcs.com <-- $39 remote PC repair, guaranteed.
How to include pictures in threads on 4x4wire (Youtube video)

#1068862 - 02/06/14 05:26 PM Re: 89 Mighty max transmission/transfer case issue? [Re: geocrasher]  
spencevans  Offline
Mudrunner
Joined: Mar 2008
Posts: 413
Utah
What you are dealing with is a 25 year old tranny that has been used and abused. It did not receive proper maintenance and it is on it's last legs. This is very common for the KM145 tranny. They get used and abused and fail. When they are properly maintained they will run for 300-400K miles. The KM145 is a cheap trans to replace. You can typically find a rebuilt tranny for under $1000. It is super easy to replace and with a buddy you can replace it in just a few hours. I have replaced this tranny well over a dozen times and I can do it in under 2 hours all by myself.


Spence
1985 Mitsubishi PU 2.3 Turbo Diesel, 13" lift, Watercooled turbo, 4D56 Head, Atlas II,Fox Coilovers, Elockers,

1983 Mitsubishi PU 2.5 Turbo Diesel 4x4, fully restored

2003 G500, sliders, beadlocks, roofrack, ladder etc.

#1068863 - 02/06/14 06:41 PM Re: 89 Mighty max transmission/transfer case issue? [Re: spencevans]  
Hamer  Offline

Getting the Wheeling Fever
Joined: Feb 2014
Posts: 80
MI
I looked at the manual on that link and maybe I am reading it wrong. If I buy a new transfer case for the exact same truck and unbolt the old one are you saying that when I remove the old transfer case that those gears I see under the shift levers will not come out with the old transfer case? They use transfer case oil for that adapter and its gears so shouldn't the new/used transfer case come with that adapter and all the gears?

I cannot afford to buy a new tranny. I can barley afford a used one if I need to buy one and on top of that the truck is not worth putting to much money into. I would have to buy used.

The transmission is fine and the tranny oil tested clean but the transfer case oil had obviously metal in it and tons of it. That metal came from that transfer case extension.

The tail extension you speak of is kind of vague and looks like it is part to the transfer case. If I order a transfer case wouldn't that extension with those gears come with it? It looks like one whole piece and also looks like it would be difficult to split apart from the transfer case. I would think If buying one used you would get the extension with it to save the salvage yard the effort of trying to separate it all.

When my father had the old tranny replaced with a used one do to popping out of gear the old transfer case was the only part not replaced and it never shifted right from that point forward. That tail extension must be integrated into the transfer case. The old extension was reused. I bet the old tranny that was popping out of gear had nothing wrong with it an it was that extension with those chewed up gears all along?

Have any of you replaced the transfer case with a used one on the 4x4 5 speed Might max. When you did was the extension and the gears under the shifters included on the used transfer case?


Matt Hamer 89 Mighty Max SPX Macro Cab 2.6L 5 speed 4X4 Auto hubs.

#1068864 - 02/06/14 06:56 PM Re: 89 Mighty max transmission/transfer case issue? [Re: Hamer]  
off-roader  Offline

Web Wheeler
Joined: Jan 2000
Posts: 16,224
Bay Area, CA *****
Quote
It is 2:20 a.m. here so I have no way to take a pic right now...


Heck nothing a modern cell phone/camera, flashlight, & Arctic Parka wouldn't fix. <img src="/forums/images/graemlins/wink.gif" alt="" />

Glad you found us. The guys here are top notch when it comes to technical knowledge on the Mitsu. The FSM is a must have IMHO since both the Chilton's and Haynes equivalents, are crap for accuracy. <img src="/forums/images/graemlins/cheers.gif" alt="" />


Off Roader
96SR (3.15:1 xcase, 35's)
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#1068865 - 02/06/14 07:05 PM Re: 89 Mighty max transmission/transfer case issue? [Re: off-roader]  
Hamer  Offline

Getting the Wheeling Fever
Joined: Feb 2014
Posts: 80
MI
Thanks for the welcome. You are correct about the manuals. The Haynes manual is darn near useless for everything I have had to study up on.

I have a carb issue I will eventually need to address but for now I need to figure out if a used transfer case comes with the transfer case extension. If it does I will be stoked because I can unbolt it and pop a new one in and have the issue solved. If not I am kinda screwed


Matt Hamer 89 Mighty Max SPX Macro Cab 2.6L 5 speed 4X4 Auto hubs.

#1068866 - 02/06/14 07:22 PM Re: 89 Mighty max transmission/transfer case issue? [Re: Hamer]  
off-roader  Offline

Web Wheeler
Joined: Jan 2000
Posts: 16,224
Bay Area, CA *****
Quote
...but for now I need to figure out if a used transfer case comes with the transfer case extension. If it does I will be stoked because I can unbolt it and pop a new one in and have the issue solved. If not I am kinda screwed

I just checked on car-part.com for Mitsu 89 D50 pickup transfer cases. There are plenty available ranging from $50-400. Try calling one of the parts pullers from there and ask them if it's included if you buy an xcase or if you can purchase it separately for cheaper.


#1068867 - 02/06/14 07:33 PM Re: 89 Mighty max transmission/transfer case issue? [Re: off-roader]  
Hamer  Offline

Getting the Wheeling Fever
Joined: Feb 2014
Posts: 80
MI
I called a few and none of them know weather the extension is on the transfer case. Its like they do not know what I am talking about.


I was hoping to find out before I try to even mess with it if anyone here has ever replaced the transfer case and if that extension with all those gears was included on the transfer case or not? If so then I need to know how easy it is to replace just that part and can it be done with the tranny in the truck?

Last edited by Hamer; 02/06/14 08:29 PM.

Matt Hamer 89 Mighty Max SPX Macro Cab 2.6L 5 speed 4X4 Auto hubs.

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