Mitsubishi Montero (2002-2004). Manual — part 212

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-45

<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and 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 and 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 a diagonal

sequence to remove the drive gear.

.

<<E>> SELF-LOCKING NUT REMOVAL
Use special tool MB990850 to hold the companion flange, and
then remove the companion flange self-locking nut.

.

<<F>> 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.

ACX01041AB

MB990810

MB991407

ACX01042AB

MATING
MARKS

ACX01043AB

MB990850

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-46

2. Pull out the drive pinion together with special tool

MB990810.

.

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

.

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

.

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

.

ACX01044 AB

MB990810

COMPANION
FLANGE

ACX01045 AB

MB990339

MB990648

ACX01046AB

MB990939

ACX01047 AB

MB990939

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-47

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

ASSEMBLY

M1262002500139

ACX01048AB

PUNCH

AC204225AB

83

±

5 N

·

m

62

±

3 ft-lb

18

±

3 N

·

m

13

±

2 ft-lb

50

±

10 N

·

m

37

±

7 ft-lb

216

±

29 N

·

m

159

±

22 ft-lb

65

±

5 N

·

m

48

±

4 ft-lb

59

±

5 N

·

m *

44

±

3 ft-lb *

28

30

27

16

23

19

20 21

17

18 22

24

25 26

5 6

7

8

9

10

29

2

1

4

11

12

14

13

15

23

5

15

17

17

18

18

20

20

3

DIFFERENTIAL GEAR SET

FINAL DRIVE GEAR SET

ASSEMBLY

STEPS

1. DIFFERENTIAL

CARRIER

>>A<<

2. OIL

SEAL

>>B<<

3. DRIVE PINION FRONT BEARING

OUTER RACE

>>C<<

4. DRIVE PINION REAR BEARING

OUTER RACE

>>D<<

•

PINION HEIGHT ADJUSTMENT

5. DRIVE

PINION

6. DRIVE PINION FRONT SHIM (FOR

PINION HEIGHT ADJUSTMENT)

7. DRIVE PINION FRONT BEARING

INNER RACE

8. DRIVE PINION SPACER

>>E<<

•

DRIVE PINION TURNING TORQUE
ADJUSTMENT

9. DRIVE PINION REAR SHIM (FOR

TURNING TORQUE ADJUSTMENT)

10. DRIVE PINION ASSEMBLY

ASSEMBLY

STEPS

(Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

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NOTE: Specified torque with asterisks means that it
is covered with oil.

Required Special Tools:

• MB990031 or MB990699: Drive Pinion Oil Seal

Installer

• MB990326: Preload Socket

• MB990685: Torque Wrench

• MB990802: Bearing Installer

• MB990819: Drive Pinion Gauge Assembly

• MB990934: Installation Adapter

• MB990936: Installation Adapter

• MB990938: Bar

• MB990939: Brass Bar

• MB991170: Cylinder Gauge

11. DRIVE PINION REAR BEARING INNER

RACE

12. OIL SEAL

13. COMPANION FLANGE

14. WASHER

15. SELF-LOCKING NUT

16. DIFFERENTIAL CASE

>>F<<

•

DIFFERENTIAL GEAR BACKLASH
ADJUSTMENT

17. SIDE GEAR SPACER

18. SIDE GEAR

19. PINION WASHER

20. PINION GEAR

21. PINION SHAFT

>>G<<

22. LOCK PIN

>>H<<

23. DRIVE GEAR

>>I<<

24. SIDE BEARING INNER RACE

25. SIDE BEARING OUTER RACE

>>J<<

•

DRIVE GEAR BACKLASH
ADJUSTMENT

26. SIDE BEARING SPACER

ASSEMBLY

STEPS

(Continued)

27. DIFFERENTIAL CASE ASSEMBLY

29. COVER

30. DRAIN PLUG

31. FILLER PLUG

ASSEMBLY

STEPS

(Continued)