Mitsubishi Montero Sport (2004+). Manual — part 416

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-45

NOTE: Check the tooth contact pattern to confirm that the
adjustments of the pinion height and backlash have been
done properly. Continue to adjust the pinion height and
backlash until the tooth contact pattern resembles the stan-
dard pattern. If, even after adjustments have been made, the
correct tooth contact pattern cannot be obtained, it means
that the drive gear and the drive pinion have become worn
beyond the allowable limit. Replace the gear set.

.

<<B>> DIFFERENTIAL CASE ASSEMBLY REMOVAL

CAUTION

When taking out the differential case assembly, be careful
not to drop and damage the side bearing outer races.
NOTE: Keep the right and left side bearings and side bearing
adjusting spacers separate, so that they do not become mixed
during assembly.

.

STANDARD TOOTH CONTACT PATTERN PROBLEM

SOLUTION

1. Narrow tooth side
2. Drive-side tooth surface
(the side applying power during forward
movement)
3. Wide tooth side
4. Coast-side tooth surface
(the side applying power during reverse
movement)

Tooth contact pattern resulting
from excessive pinion
height

The drive pinion is positioned too
far from the center of the drive
gear.

Increase the thickness of
the drive pinion rear shim,
and position the drive pinion
closer to the center of the
drive gear. Also, for
backlash adjustment,
position the drive gear
farther from the drive
pinion.

Tooth contact pattern resulting
from insufficient pinion
height.

The drive pinion is positioned too
close to the center of the drive
gear.

Decrease the thickness of
the drive pinion rear shim,
and position the drive pinion
farther from the center of
the drive gear. Also, for
backlash adjustment,
position the drive gear
closer to the drive pinion.

ACX01039 AF

1

3

4

2

AC107260

1

2

3

4

AB

AC107261AB

1

2

3

4

AC107262

1

2

3

4

AB

AC107263

1

2

3

4

AB

ACX01040AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-46

<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810, MB990811 to pull out the side
bearing inner races.
NOTE: There are two notches provided (at the differential case
side) for the claw part of the special tools; use special tools
MB990810, MB990811 at that position.

.

<<D>> DRIVE GEAR REMOVAL
1. Make the mating marks to the differential case and the drive

gear.

2. Loosen the drive gear attaching bolts in diagonal sequence

to remove the drive gear.

.

<<E>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.

.

<<F>> SELF-LOCKING NUT REMOVAL
Use the special tool MB990767 to hold the companion flange,
and then remove the companion flange self-locking nut.

.

ACX01041AC

MB990811

MB990810

ACX01042AB

MATING
MARKS

ACX01048AB

PUNCH

AC004732 AB

MB990767

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-47

<<G>> DRIVE PINION ASSEMBLY REMOVAL

CAUTION

The mating mark made on the companion flange must not
be on the coupling surface of the flange yoke and the front
propeller shaft.
1. Make mating marks on the drive pinion and companion

flange.

2. Drive out the drive pinion together with the drive pinion

spacer and drive pinion shims.

.

<<H>> DRIVE PINION FRONT BEARING INNER RACE
REMOVAL
Use special tools MB990339, MB990648 to pull out the front
bearing inner race.

.

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

.

AC004790 AB

MATING MARKS

ACX01045 AB

MB990339

MB990648

ACX01046AB

MB990939

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-48

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

.

<<K>> OIL SEAL REMOVAL
Use special tool MB990590 to remove the oil seal.

ACX01047 AB

MB990939

AC004791 AB

MB990590