Mitsubishi Montero Sport (2004+). Manual — part 419
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-57
>>H<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the
drive gear by turning the special tool MB990813 (tap M10 x
1.25), and then clean the threaded holes by applying
compressed air.
3. Apply the 3M
AAD Part number 8730 or AAD Part number
8731 or equivalent to the threaded holes of the drive gear.
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
Tightening torque: 78
− 88 N⋅m (58 − 65 ft-lb)
.
>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tool MB990802 to press-fit the side bearing inner
races into the differential case.
.
>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE: Select side bearing spacers with the same thickness
for both the drive pinion side and the drive gear side.
ACX01068AB
TAP
AC000438 AB
ACX01069AC
MB990802
MB990802
PIECE OF
METAL
PIECE OF
METAL
ACX01070 AB
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-58
2. Push the differential case assembly to one side, and
measure the clearance between the gear carrier and the
side bearing adjusting spacer with a feeler gauge.
3. Measure the thickness of the side bearing adjusting spacers
on one side, select two pairs of spacers which correspond to
that thickness plus one half of the clearance plus 0.05 mm
(0.002 inch), and then install one pair each to the drive
pinion side and the drive gear side.
4. Install the side bearing adjusting spacers and differential
case assembly, as shown in the illustration, to the gear
carrier.
5. Tap the side bearing adjusting spacers with special tool
MB990939 to fit them to the side bearing outer race.
6. Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
ACX01071AB
ACX01072 AC
CLEARANCE/2 + 0.05 mm
(0.002 in) = THICKNESS OF
THE SPACER ON ONE SIDE
ACX01070 AB
ACX01073 AB
MB990939
ACX01074AB
DIFFERENTIAL CARRIER ASSEMBLY
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FRONT AXLE
26-59
7. With the drive pinion locked in place, measure the drive gear
backlash with a dial indicator on the drive gear.
NOTE: Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11
− 0.16 mm (0.004 − 0.006 inch)
8. Change the side bearing adjusting spacers as illustrated,
and then adjust the drive gear backlash between the drive
gear and the drive pinion.
NOTE: When increasing the number of side bearing adjust-
ing spacers, use the same number for each, and as few as
possible.
9. Check the drive gear and drive pinion for tooth contact. If
poor contact is evident, make adjustment. (Refer to
.)
10.Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm (0.002 inch)
11.If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12.If adjustment is not possible, replace the differential case or
replace the drive gear and drive pinion as a set.
ACX01034AB
ACX01075
IF BACKLASH IS TOO SMALL
IF BACKLASH IS TOO LARGE
THINNER
SPACER
THICKER
SPACER
AB
THINNER
SPACER
THICKER
SPACER
ACX01036 AB
SPECIFICATIONS
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FRONT AXLE
26-60
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1261005400224
ITEM
SPECIFICATION
Differential carrier
Cover bolt
19 N
⋅m (14 ft-lb)
Differential case bolt
78
− 88 N⋅m (58 − 65 ft-lb)
Drain plug
59
− 64 N⋅m (44 − 51 ft-lb)
Drive pinion self-locking nut
216 N
⋅m (159 ft-lb)
Filler plug
49 N
⋅m (36 ft-lb)
Front suspension crossmember nut
98
− 118 N⋅m (72 − 87 ft-lb)
Front propeller shaft connection nut
49
− 59 N⋅m (36 − 43 ft-lb)
Differential mounting bracket <LH> bolt
88 N
⋅m (65 ft-lb)
Differential mounting bracket <RH> nut
93 N
⋅m (69 ft-lb)
Differential mount insulator assembly
35 N
⋅m (26 ft-lb)
Differential support bracket bolt
69 N
⋅m (51 ft-lb)
Differential support bracket nut
44 N
⋅m (32 ft-lb)
Dynamic damper nut
22 N
⋅m (16 ft-lb)
Bearing cap bolt
54
− 64 N⋅m (40 − 47 ft-lb)
Drive shaft
Driveshaft and inner shaft connection nut
49
− 59 N⋅m (36 − 43 ft-lb)
Front axle hub
ABS Rotor bolt
22 N
⋅m (16 ft-lb)
Brake disc and front hub assembly connection nut
49
− 59 N⋅m (36 − 43 ft-lb)
Caliper assembly bolt
88 N
⋅m (65 ft-lb)
Hub cap bolt
49
− 59 N⋅m (36 − 43 ft-lb)
Jam nut
127
− 196 N⋅m → 0 N⋅m → 25
N
⋅m (94 − 145 ft-lb → 0 in-lb →
18 ft-lb)
Inner shaft
Breather pipe bolt
12 N
⋅m (106 ft-lb)
Housing tube bolt
88 N
⋅m ( 65 ft-lb)
Differential mounting bracket nut
93 N
⋅m (69 ft-lb)
Heat protector bolt
12 N
⋅m (106 in-lb)
Knuckle
Lower arm ball joint and knuckle connection nut
118
− 177 N⋅m (87 − 131 ft-lb)
Shock absorber nut (lower)
88
− 103 N⋅m (65 − 76 ft-lb)
Stabilizer bracket bolt
12 N
⋅m (106 in-lb)
Tie rod end connection nut
44 N
⋅m (32 ft-lb)
Upper arm ball joint and knuckle connection nut
59
− 88 N⋅m (44 − 65 ft-lb)
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