Mitsubishi Montero Sport (2004+). Manual — part 434
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-37
>>B<< DRIVE PINION FRONT BEARING OUTER RACE
PRESS-FITTING
Use special tools MB990938 and MB990934 to press-fit the
drive pinion front bearing outer race.
.
>>C<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool
MB990819.
2. Install special tool MB990819, MB991169 and drive pinion
front and rear bearing inner races to the gear carrier as
shown in the illustration.
3. Tighten the nut of special tool MB990819 a little at a time
while measuring the turning torque of the drive pinion. Then
confirm that the turning torque (without the oil seal) is at the
standard value.
Standard value:
4. Clean the side bearing hub.
ACX01107AB
MB990938
MB990934
BEARING TYPE BEARING
LUBRICATION
TURNING
TORQUE
New
None (with
anti-rust agent)
0.6
− 0.9 N⋅m
5.3
− 8.0 in-lb
New or reuse
Gear oil applied
0.4
− 0.5 N⋅m
3.5
− 4.4 in-lb
(
)
AC004937AB
WASHER
MB991169
DRIVE PINION
ATTACHMENT
MB990819
ACX01055 AB
MB990819
ACX01056AB
MB990326
MB990819
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-38
5. Place special tool MB991534 between the side bearing hub
of the gear carrier, and position the notch as shown in the
illustration. Then tighten side bearing mounting bolt.
6. Use a feeler gauge to measure the clearance (A) between
special tools MB991169 and MB991534.
7. Remove special tool MB991169.
8. Use a micrometer to measure the shown dimensions (B, C)
of special tools MB991169 and MB991534.
9. Install the bearing cap, and then use a cylinder gauge to
measure the inside diameter (D) of the bearing cap.
10.Calculate thickness (F) of the required drive pinion rear
shim twice by the following formula. Select a shim which
most closely matches this thickness.
F = A + B + C
− 1/2D − 120.00 mm (4.724 inches)
11.Fit the selected drive pinion rear shim(s) to the drive pinion,
and press-fit the drive pinion rear bearing inner race by
using special tool MB990802.
.
>>D<< DRIVE PINION PRELOAD ADJUSTMENT
1. Insert the drive pinion into the gear carrier, and then install
the following parts in sequence from the carrier rear side.
Drive pinion spacer, drive pinion front shim and drive pinion
front bearing inner race, companion flange.
NOTE: Do not install the oil seal.
ACX01109AE
FEELER
GAUGE
MB991169
NOTCH
MB991534
A
ACX01058AD
MB991534
B
C
MB991169
AC102914
CYLINDER GAUGE
AC
D
ACX02428 AE
DRIVE PINION
REAR SHIM
MB990802
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-39
2. Tighten the companion flange to the specified torque by
using special tool MB990850.
Tightening torque: 216 N
⋅m (159 ft-lb)
3. Measure the drive pinion turning torque (without the oil
seal).
Standard value:
4. If the drive pinion turning torque is not within the standard
value, adjust the turning torque by replacing the drive pinion
front shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims to a
minimum by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following two
types.
5. Remove the companion flange and drive pinion again. Then
insert the drive pinion front bearing inner race into the gear
carrier. Use special tool MB991168 to press-fit the oil seal.
BEARING TYPE BEARING
LUBRICATION
TURNING
TORQUE
New
None (with
anti-rust agent)
0.6
− 0.9 N⋅m
5.3
− 8.0 in-lb
New or reuse
Gear oil applied
0.4
− 0.5 N⋅m
3.5
− 4.4 in-lb
ACX01065 AC
216 N·m
159 ft-lb
MB990850
ACX01062AB
MB990326
MB990685
HEIGHT OF DRIVE PINION
SPACER mm (in)
IDENTIFICATION
COLOR
52.50 (2.067)
Yellow
52.84 (2.080)
Red
ACX01063 AB
IDENTIFICATION
COLOR
ACX01064 AD
MB991168
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-40
6. Install the drive pinion assembly and companion flange with
mating marks properly aligned. Tighten the companion
flange self-locking nut to the specified torque using special
tool MB990850.
Tightening torque: 216 N
⋅m (159 ft-lb)
7. Measure the drive pinion turning torque (with oil seal) to
verify that the drive pinion turning torque complies with the
standard value.
Standard value:
8. If the turning torque is not within the standard value, check
the tightening torque of the companion flange self-locking
nut, and the installation of the oil seal.
.
>>E<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear thrust spacers, pinion
gears, and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE: Do not assemble the thrust block and lock pin yet.
3. Insert a wedge between the side gear and the pinion shaft to
lock the side gear.
4. 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)
5. Measure by the same procedure for the other pinion gear.
Limit: 0.2 mm (0.01 inch)
6. If the backlash exceeds the limit value, replace side bearing
adjustment spacers.
7. If adjustment is not possible, replace the side gears and
pinion gears as a set.
BEARING
DIVISION
COMPANION FLANGE
LUBRICATION
TURNING
TORQUE
New
None (with anti-rust
agent)
0.85
− 1.15 N⋅m
7.52
− 10.18 in-lb
Gear oil applied
0.65
− 0.75 N⋅m
5.75
− 6.64 in-lb
ACX01065 AC
216 N·m
159 ft-lb
MB990850
ACX01062AB
MB990326
MB990685
ACX01066
ACX01035 AB
WEDGE
SIDE GEAR
THRUST
SPACER
SIDE GEAR
THRUST
SPACER
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