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Tech: Replacing the Transfer-Case Roll-Stopper
www.4x4wire.com/mitsubishi/tech/rollstopper Short Cuts
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Author: Phil Hansford July 13, 2001

Applicable Vehicle: Any Mitsubishi 4 or 6 cylinder (3.0l) standard or auto

Mitsubishi trucks and SUVs are known for their well-insulated drivetrains. When this insulation begins to wear down, however, the resulting vibrations can be earth shattering! The drivetrain is isolated from the chassis at several points, such as the number two crossmember, and the transfer-case roll-stopper. The latter is a large, round bushing which inhibits side-to-side movement of the transmission assembly. If your transfer-case roll-stopper is worn, you will be painfully aware of some or all of the following symptoms:



Locating the Source of Vibration

These "bad vibrations" can usually be felt under the driver's feet, which is where this mount resides. To confirm your suspicions, visually inspect the mount. It appears just to the driver's side of the transmission skidplate, between the frame rail and the torsion bar, and is hidden by an oval metal plate. This round bushing is approximately the diameter of your truck's inclinometer. A sleeve goes through it, inside of which is a bolt that connects the transmission/transfer assembly to the chassis. To test functionality of the mount, grab the transfer assembly from the opposite side, and check for movement. In the case of our subject vehicle, movement was quite pronounced; I was able to physically move the entire assembly a range of over 5 cm (2.5 inches). Note that some movement is required, otherwise the drivetrain would not be sufficiently isolated. The bushing in this particular case was totally deformed, allowing the transmission/transfer assembly to move considerably.

Removing the Roll-Stopper

removal2.jpg
The arrows indicate the bolts which have to be removed

As with any repair involving the removal of exposed fasteners, begin by soaking the bolts liberally with penetrating oil. After the oil has had time to work, remove the two bolts indicated on the mounting the plate, one on the side of the transmission, and finally the bolt which passes through the pin inside the bushing. On this bolt, you will have to put a ratchet on the nut as well, to keep it from turning. Once these bolts are removed, the transfer-case roll-stopper can be removed for inspection.

Editor's Note: The service manual recommends placing a floor jack under the transmission/transfer assembly while removing the mount. While I didn't find this to be necessary, it would be a wise safety precaution, in case the assembly begins to shift out of place. Also, as always when working under a vehicle, ensure that the wheels are blocked, the emergency brake is set, and the vehicle is in gear or P.

Inspection - Reinstallation

removal.jpg old_new.jpg
Carefully remove the old fasteners, using lots of penetrating oil The old bushing on the right is obviously worn out of round

Once you have removed the roll-stopper, inspect it for cracks, and deformation. The old roll-stopper on our vehicle was completely out-of-round, and missing several rubber "spokes".

After putting the new bushing in place, (listed as "Cushion, Trans Mounting". Mitsubishi part number MB260676) and lining up the sleeve, bolt the mount back onto the transfer assembly with a torque of 30-42 NM (22-29 ft.lbs) and then bolt the other side back to the chassis, using a force of 18-25 NM (13-18 ft.lbs).

When the new roll-stopper is bolted in place, check for play in your drivetrain, and in your shifter/transfer-case lever. And then go enjoy vibe-free driving again!


Contacts: Related Links:


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OutdoorWire, 4x4Wire, JeepWire, TrailTalk, MUIRNet-News, and 4x4Voice are all trademarks and publications of OutdoorWire, Inc. and MUIRNet Consulting.
Copyright (c) 1999-2019 OutdoorWire, Inc and MUIRNet Consulting - All Rights Reserved, no part of this publication may be reproduced in any form without express written permission
You may link freely to this site, but no further use is allowed without the express written permission of the owner of this material.
All corporate trademarks are the property of their respective owners.