Mitsubishi Montero (2002-2004). Manual — part 226
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-37
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.
.
>>F<< 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)
Limit: 0.2 mm (0.01 inch)
5. Measure by the same procedure for the other pinion gear.
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.
8. Check that the backlash is within the limit value and that the
differential gear turns smoothly.
.
BEARING
DIVISION
COMPANION
FLANGE
LUBRICATION
TURNING
TORQUE
New
None (with anti-rust
agent)
2.03
− 2.34 N⋅m
18.0
− 20.7 in-lb
Gear oil applied
2.10
− 2.40 N⋅m
18.6
− 21.2 in-lb
ACX01062AB
MB990326
MB990685
ACX01066
AC102885
WEDGE
SIDE GEAR
SPACER
SIDE GEAR
SPACER
AC
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-38
>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the differential case
lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch on both sides.
.
>>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 tap (M10 x 1.25). Clean the
threaded holes by applying compressed air.
3. Apply 3M
ä stud locking 4170 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: 152
± 15 N⋅m (112 ± 10 ft-lb)
.
>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tools MD998812 and MD998829 to press-fit the
side bearing inner races into the differential case.
ACX02429
ACX01068AB
TAP
ACX02430
ACX02431AB
MD998812
MD998829
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-39
.
>>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR
BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Assemble the differential case with the side bearing outer
race to the gear carrier.
2. Press the differential case to one side to measure the
clearance of the side bearing outer race and the gear carrier.
3. Select two pairs of side bearing spacer. Determine the
thickness by adding 1/2 of the clearance to the pre-load
0.05mm (0.002 inch).
4. Remove the side bearing, using special tools MB990810
and MB991407.
NOTE: Hook the claws of the special tool MB990810 with
the side bearing inner race by using the notches (two areas)
of the differential case side.
5. Assemble the selected side bearing spacers to each side.
6. Use special tool MB990802 to press-fit the side bearing
inner case into the differential case. After installing the outer
race, assemble the differential case to the gear carrier.
7. Align the mating marks of differential carrier and the bearing
cap with each other and tighten to the specified torque.
Tightening torque: 74
± 5 N⋅m (55 ± 3 ft-lb)
8. Measure the drive gear backlash.
NOTE: Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.13
− 0.18 mm (0.005 − 0.007 inch)
ACX01071
ACX01041AB
MB990810
MB991407
ACX02432
DRIVE
PINION
REAR
SHIM
MB990802
MB990802
AB
ACX01034
SPECIFICATIONS
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REAR AXLE
27-40
9. If the backlash is not within the standard value, move the
side bearing spacer as shown in the illustration to adjust the
backlash.
NOTE: The increment of side bearing spacer must be the
same as the decreased amount.
10.Inspect the tooth condition at the final drive gear and adjust
if required. (Refer to GROUP 26, Inspection Before
Disassembly
11.Measure the drive gear runout.
Limit: 0.05 mm (0.002 inch)
12.If drive gear runout exceeds the limit, remove the differential
case and then the drive gears, moving them to different
positions and reinstall them.
13.If adjustment is not possible, replace the differential case or
drive gear and drive pinion as a set.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1271004000257
ACX02433AB
WHEN THE BACKLASH IS SMALL
WHEN THE BACKLASH IS LARGE
DECREASED
DECREASED
INCREASED
INCREASED
ACX01036
ITEM
SPECIFICATION
Rear axle hub assembly, drive shaft assembly
Backing plate bolt
133
± 14 N⋅m (98 ± 10 ft-lb)
Lower arm and knuckle connection nut
152
± 25 N⋅m (113 ± 18 ft-lb)
Rear brake caliper bolt
100
± 10 N⋅m (74 ± 7 ft-lb)
Rear drive shaft and companion shaft connection nut
113
± 14 N⋅m (84 ± 10 ft-lb)
Rear drive shaft nut
255
± 29 N⋅m (188 ± 21 ft-lb)
Knuckle
Toe-control arm and knuckle connection nut
67
± 7 N⋅m (50 ± 5 ft-lb)
Trailing arm and knuckle connection bolt
231
± 34 N⋅m (170 ± 25 ft-lb)
Upper arm and knuckle connection nut
150
± 30 N⋅m (111 ± 22 ft-lb)
Differential carrier assembly
Bearing cap bolt
74
± 5 N⋅m (55 ± 3 ft-lb)
Differential cover bolt
35
± 5 N⋅m (25 ± 4 ft-lb)
Dynamic damper bolt
83
± 12 N⋅m (61 ± 9 ft-lb)
Drain plug
63
± 4 N⋅m (47 ± 2 ft-lb)
Drive gear bolt
152
± 15 N⋅m (112 ± 10 ft-lb)
Drive pinion self-locking nut
216
± 29 N⋅m (159 ± 22 ft-lb)
Filler plug
49
± 9 N⋅m (37 ± 6 ft-lb)
Lower arm and knuckle connection nut
152
± 25 N⋅m (113 ± 18 ft-lb)
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