Mitsubishi Montero Sport (2004+). Manual — part 418

DIFFERENTIAL CARRIER ASSEMBLY

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FRONT AXLE

26-53

1. Apply multipurpose grease to the washer of special tool

MB990819.

2. Install special tool MB990819, drive pinion front and rear

bearing inner races to the gear carrier.

3. Tighten the nut of special tool MB990819 while measuring

the turning torque of the drive pinion. Gradually keep
tightening the nut of special tool MB990819 until the turning
torque of the drive pinion (without oil seal) is at the standard
value.

Standard value:

NOTE: The special tools MB990326, MB990819 cannot be
turned a full revolution, so turn it several times within the
range of movement to run in the bearing, and then measure
the turning torque.

4. Clean the side bearing hub.
5. Install special tool MB991170 to the side bearing hub of the

gear carrier, and then install the bearing cap.
NOTE: Always check that the notch is in the shown position
and that special tools MB991170 are touching firmly against
the side bearing hub.

6. Use a feeler gauge to measure the clearance (A) between

special tools MB991170, MB990819.

7. Remove special tools MB991170, MB990819.

BEARING
DIVISION

BEARING
LUBRICATION

TURNING
TORQUE

New

None (with
anti-rust agent)

0.83

− 1.19 N⋅m

7.35

− 10.53 in-lb

ACX01054 AB

MB990819

WASHER

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

ACX01057 AC

FEELER GAUGE

MB990819

A

MB991170

NOTCH

DIFFERENTIAL CARRIER ASSEMBLY

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FRONT AXLE

26-54

8. Use a micrometer to measure special tools MB991170,

MB990819 in the places (B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge and

micrometer to measure the inside diameter (D) of the
bearing cap as shown in the illustration.

10.Calculate the thickness (E) of the required drive pinion front

shim by the following formula, and then select a shim which
most closely matches this thickness.
E = A + B + C-1/2D-100.0 mm (3.94 inches)

11.Fit the selected drive pinion front shim(s) to the drive pinion,

and press-fit the drive pinion front bearing inner race by
using special tool MB990802.

.

>>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT
Adjust the drive pinion turning torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install

the drive pinion spacer, the drive pinion rear shim, the drive
pinion rear bearing inner race, and the companion flange in
that order.
NOTE: Do not install the oil seal.

2. Tighten the companion flange to the specified torque by

using special tool MB990767.

ACX01058

MB991170

B

C

AE

MB990819

ACX01059AB

BEARING CAP

D

ACX01060

DRIVE
PINION
FRONT
SHIM

MB990802

MB990802

AC

AC004803 AB

MB990767

DIFFERENTIAL CARRIER ASSEMBLY

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FRONT AXLE

26-55

3. Use special tools MB990685, MB990326 to measure the

drive pinion turning torque (without the oil seal).

Standard value:

4. If the drive pinion turning torque is not within the range of the

standard value, adjust the preload by replacing the drive
pinion rear shim(s) or the drive pinion spacer.

5. Remove the companion flange and drive pinion again. Then,

after inserting the drive pinion rear bearing inner race into
the gear carrier, use special tools MB990031 or MB990699
press-fit the oil seal.

6. Install the drive pinion assembly and companion flange with

mating marks properly aligned, and tighten the companion
flange self-locking nut to the specified torque by using
special tool MB990767.

7. Use special tools MB990685, MB990326 to measure the

drive pinion turning torque (with the oil seal).

Standard value:

BEARING
DIVISION

BEARING
LUBRICATION

TURNING
TORQUE

New

None (with
anti-rust agent)

0.83

− 1.19 N⋅m

7.35

− 10.53 in-lb

DRIVE PINION SPACER
HEIGHT mm (in)

IDENTIFICATION COLOR

56.67 (2.231)

White

57.01 (2.244)

−

BEARING
DIVISION

BEARING
LUBRICATION

TURNING
TORQUE

New

None (with
anti-rust agent)

0.93

− 1.28 N⋅m

8.23

− 11.33 in-lb

Gear oil applied

0.97

− 1.32 N⋅m

8.59

− 11.68 in-lb

ACX01062AB

MB990326

MB990685

ACX01063 AB

IDENTIFICATION

COLOR

ACX01064 AB

MB990031
OR
MB990699

AC004803 AB

MB990767

ACX01062AB

MB990326

MB990685

DIFFERENTIAL CARRIER ASSEMBLY

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FRONT AXLE

26-56

8. If the drive pinion turning torque is not within the standard

value, check the tightening torque of the companion flange
self-locking nut and the oil seal.

.

>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
1. Assemble the side gears, side gear spacers, pinion gears

and pinion washers into the differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not drive in the lock pin yet.

3. Insert a wedge between the side gear and the pinion shaft to

lock the side gear.

4. Measure the differential gear backlash with a dial indicator

on the pinion gear.

Standard value: 0

− 0.076 mm (0 − 0.0030 inch)

Limit: 0.2 mm (0.08 inch)

5. If the differential gear backlash exceeds the limit, adjust the

backlash by installing thicker side gear spacers.

6. If adjustment is not possible, replace the side gears and

pinion gears as a set.

7. Measure the differential gear backlash once again, and

confirm that it is within the limit.

.

>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the differential case

lock pin hole, and drive in the lock pin.

2. Stake the lock pin with a punch at two points.

.

ACX01066AB

ACX01035 AB

WEDGE

SIDE GEAR
THRUST
SPACER

SIDE GEAR
THRUST
SPACER

ACX01067AB