Mitsubishi Montero Sport (2004+). Manual — part 415
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-41
REMOVAL SERVICE POINT
.
<<A>> FRONT PROPELLER SHAFT REMOVAL
Make mating marks on the flange yoke and the differential car-
rier companion flange. Remove the front propeller shaft.
INSTALLATION SERVICE POINTS
.
>>A<< FRONT PROPELLER SHAFT INSTALLATION
Install the front propeller shaft so that the mating marks of the
flange yoke and the differential carrier companion flange are
aligned.
DISASSEMBLY
M1262002300102
AC003833 AB
MATING MARKS
AC004731AB
17
18 19 20
27 21
22
3
4
5
6
13
12
11
10
11
12
8
9
13
7
14
6
5
4
30
1
29
2
26
24 23 16
15
28
25
N
N
N
DISASSEMBLY
STEPS
<<A>>
•
INSPECTION BEFORE DISASSEMBLY
1. COVER
2. BEARING CAP
<<B>>
3. DIFFERENTIAL CASE ASSEMBLY
4. SIDE BEARING SPACER
5. SIDE BEARING OUTER RACE
<<C>>
6. SIDE BEARING INNER RACE
<<D>>
7. DRIVE
GEAR
<<E>>
8. LOCK
PIN
9. PINION SHAFT
10. PINION GEAR
11. PINION WASHER
12. SIDE GEAR
13. SIDE GEAR SPACER
14. DIFFERENTIAL CASE
<<F>>
15. SELF-LOCKING NUT
16. WASHER
<<G>>
17. DRIVE PINION ASSEMBLY
18. DRIVE PINION
19. DRIVE PINION FRONT SHIM (FOR
PINION HEIGHT ADJUSTMENT)
<<H>>
20. DRIVE PINION FRONT BEARING
INNER RACE
21. DRIVE PINION SPACER
DISASSEMBLY STEPS (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-42
Required Special Tools:
• MB990909: Working Base
• MB990939: Brass Bar
• MB991116: Adapter
• MB990339: Bearing Puller
• MB990590: Rear Axle Shaft Oil Seal Remover
• MB990648: Bearing Remover
• MB990767: End Yoke Holder
• MB990810: Side Bearing Puller
• MB990811: Differential Side Bearing Cap
DISASSEMBLY SERVICE POINTS
.
<<A>> INSPECTION BEFORE DISASSEMBLY
1. Remove the cover and gasket.
2. Hold special tools MB990909 and MB99116 in a vise, and
install the differential carrier assembly to it.
.
DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge to
measure the drive gear backlash in four or more places on
the drive gear.
Standard value: 0.11
− 0.16 mm (0.004 − 0.006 inch)
2. If the backlash is not within the standard value, insert side
bearing adjustment spacers, and then inspect the drive gear
tooth contact.
.
22. DRIVE PINION REAR SHIM (FOR
TURNING TORQUE ADJUSTMENT)
23. COMPANION FLANGE
24. OIL SEAL
25. DRIVE PINION REAR BEARING INNER
RACE
<<I>>
26. DRIVE PINION REAR BEARING
OUTER RACE
<<J>>
27. DRIVE PINION FRONT BEARING
OUTER RACE
<<K>>
28. OIL SEAL
29. GEAR CARRIER
30. VENT PLUG
DISASSEMBLY STEPS (Continued)
ACX01033
MB990909 AND
MB991116
AB
ACX01034AB
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-43
DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm (0.002 inch)
2. When the runout exceeds the limit value, check for foreign
material between drive gear rear side and differential case,
and for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive gear
and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.
.
DIFFERENTIAL GEAR BACKLASH
1. While locking the side gear with the wedge, 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)
2. Repeat the same procedure for both pinion gears.
3. If the backlash exceeds the limit, adjust by using the side
gear thrust spacers.
4. If adjustment is impossible, replace the side gear and pinion
gear as a set.
.
DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.
ACX01036 AB
ACX01035 AB
WEDGE
SIDE GEAR
THRUST
SPACER
SIDE GEAR
THRUST
SPACER
ACX01037 AB
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-44
CAUTION
If the drive gear is rotated too much, the tooth contact pat-
tern will become unclear and difficult to check.
2. Insert special tool MB990939 between the differential carrier
and the differential case, and then rotate the companion
flange by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque [approximate 2.5
− 3.0
N
⋅m (22.1 − 26.6 in-lb)] is applied to the drive pinion.
3. Check the tooth contact condition of the drive gear and drive
pinion.
AC004730 AB
MB990939
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