Mitsubishi Montero Sport (2004+). Manual — part 433

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-33

<<H>> DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL

CAUTION

Do not make mating marks on the contact surfaces of the
companion flange and propeller shaft.
1. Make mating marks to the drive pinion and companion

flange.

2. Use special tool MB990810 to pull out the companion

flange.

.

<<I>> DRIVE PINION REAR BEARING INNER RACE
REMOVAL
Use special tool MD998801 to pull out the front bearing inner
race.

.

<<J>> OIL SEAL/DRIVE PINION FRONT BEARING INNER
RACE/DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion front
bearing outer race.

.

AC004922 AB

MATING MARKS

AC104970AC

MD998801

ACX01101AB

DRIVE PINION
FRONT BEARING
OUTER RACE

DRIVE PINION
FRONT
BEARING
OUTER RACE

OIL SEAL

DRIVE PONION
REAR BEARING
OUTER RACE

MB990939

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-34

<<K>> DRIVE PINION REAR BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion rear
bearing outer race.

ASSEMBLY

M1272002300255

ACX01102 AB

MB990939

AC309415AB

<LIMITED SLIP DIFFERENTIAL>

DIFFERENTIAL GEAR SET

FINAL DRIVE GEAR SET

<CONVENTIONAL DIFFERENTIAL>

137 - 167 N·m
101 - 123 ft-lb

19 N·m
14 ft-lb

19 N·m
14 ft-lb

69 - 78 N·m
51 - 58 ft-lb

216 N·m
159 ft-lb

19 N·m
14 ft-lb

19 N·m
14 ft-lb

137 - 167 N·m
101 - 123 ft-lb

29

28

26

25

16

24

23

24

29

28

23

4

14

20

18

18

20

29

25

24

15

23

22

19

20

21

18

17

24

25

26

18

17

20

19

4

5

6

2

10

9

11

27

1

27

3

12

13

14

8

7

N

N

29

28

25

28

ASSEMBLY STEPS

1. DIFFERENTIAL CARRIER

>>A<<

2. DRIVE PINION REAR BEARING

OUTER RACE

>>B<<

3. DRIVE PINION FRONT BEARING

OUTER RACE

>>C<<

• DRIVE PINION HEIGHT

ADJUSTMENT

4. DRIVE PINION

5. DRIVE PINION REAR SHIM (FOR

ADJUSTING DRIVE PINION
HEIGHT)

6. DRIVE PINION REAR BEARING

INNER RACE

>>D<<

• DRIVE PINION PRELOAD

ADJUSTMENT

7. DRIVE PINION FRONT BEARING

INNER RACE

ASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-35

Required Special Tools:

• MB990326: Preload Socket

• MB990685: Torque Wrench

• MB990802: Bearing Installer

• MB990819: Drive Pinion Gauge

• MB990850: End Yoke Holder

• MB990934: Installer Adapter

• MB990938: Bar

• MB991168: Drive Pinion Oil Seal Installer

• MB991169: Drive Pinion Gauge Attachment

• MB991367: Special Spanner

• MB991385: Pin

• MB991445: Bushing Remover and Installer Base

• MB991534: Cylinder Gauge

• MD998812: Installer Cap

• MD998829: Installer Adapter

>>E<<

8. OIL SEAL
9. DRIVE PINION FRONT SHIM (FOR

ADJUSTING DRIVE PINION
PRELOAD)

10. DRIVE PINION SPACER
11. DRIVE PINION ASSEMBLY
12. COMPANION FLANGE
13. WASHER
14. SELF-LOCKING NUT
15. DIFFERENTIAL CASE
16. LIMITED SLIP DIFFERENTIAL CASE

ASSEMBLY

17. SIDE GEAR THRUST SPACER
18. SIDE GEAR
19. PINION WASHER
20. PINION GEAR

>>E<<

• DIFFERENTIAL GEAR BACKLASH

ADJUSTMENT

21. PINION SHAFT

>>F<<

22. LOCK PIN

>>G<<

23. DRIVE GEAR

>>H<<

24. SIDE BEARING INNER RACE
25. SIDE BEARING OUTER RACE
26. DIFFERENTIAL CASE ASSEMBLY

>>I<<

27. BEARING CAP

>>J<<

• DRIVE GEAR BACKLASH

ADJUSTMENT

28. SIDE BEARING NUT
29. LOCK PLATE

ASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-36

LUBRICATION AND ADHESIVE POINTS

ASSEMBLY SERVICE POINTS

.

>>A<< DRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
Use special tools MB990938, MB991445 to press-fit the drive
pinion rear bearing outer races into the gear carrier.

.

AC004925

<CONVENTIONAL DIFFERENTIAL>

<LIMITED SLIP DIFFERENTIAL>

AD

ADHESIVE: 3M™ AAD PART NO. 8730, 8731
OR EQUIVALENT

AC102907AF

MB990938

MB991445