Mitsubishi Montero (2002-2004). Manual — part 210

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-37

>>B<< FRONT PROPELLER SHAFT INSTALLATION

CAUTION

Remove grease from fastener threads before tightening.
Fastener threads covered with oily products could become
loose.
Install the front propeller shaft so that the mating marks of the
flange yoke and the differential carrier companion flange are
aligned.

INSPECTION

FREEWHEEL ENGAGE SWITCH CHECK

M1262005000058

FREE WHEELING CLUTCH DISASSEMBLY AND ASSEMBLY

M1262002900074

SHAFT
(SWITCH)
POSITION

TESTER
CONNECTION

SPECIFIED
CONDITION

PRESSED (ON)

1-2

Less than 2 ohms

RELEASED
(OFF)

−

Open circuit

ACX01021AB

OFF

ON

1 2

BALL

AC101907AB

12

10

9

12

11

10

4

13

7

3

2

1

6

5

8

9

FREEWHEEL CLUTCH
DISASSEMBLY STEPS

<<A>>

1.

MAIN SHAFT ASSEMBLY

<<A>>

>>F<<

2.

BEARING

>>E<<

3.

SPACER

4.

CLUTCH SLEEVE

>>D<<

5.

SPRING PIN

6.

SNAP RING

7.

SHIFT FORK

8.

SHIFT ROD

>>C<<

9.

OIL SEAL

<<B>>

>>B<<

10. CLUTCH GEAR

<<B>>

>>B<<

11. BEARING

FREEWHEEL CLUTCH
DISASSEMBLY STEPS

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-38

Required Special Tools:

• MB990560: Bearing Remover

• MB990799: Ball Joint Remover and Installer

• MB990890 or MB990891: Rear Suspension

Bushing Base

• MB990926: Bearing and Oil Seal Installer Set

• MB990938: Bearing and Oil Seal Installer Set

• MB991168: Differential Oil Seal Installer

DISASSEMBLY SERVICE POINTS

.

<<A>> MAIN SHAFT/BEARING REMOVAL
1. After special tool MB990560 has been installed as shown,

tighten the nut of special tool MB990560 until portion "A" of
special tool MB990560 touches the bearing outer race.

CAUTION

Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing.

.

<<B>> CLUTCH GEAR/BEARING REMOVAL
1. Use a press and steel plate to remove the clutch gear and

bearing together.

2. Using a press, hold the supports against the bearing inner

race, and separate the clutch gear and bearing.

>>A<<

12. OIL SEAL
13. CLUTCH HOUSING

FREEWHEEL CLUTCH
DISASSEMBLY STEPS

ACX01023 AB

A

MB990560

ACX01024 AB

METAL PLATE

ACX01025 AB

METAL PLATE

SUPPORT

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-39

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
Use special tool MB991168 to tap the oil seal until it is flush
with the clutch housing.

.

>>B<< BEARING/CLUTCH GEAR INSTALLATION
1. Use special tool MB990799 to press-fit the bearing to the

shoulder of the clutch gear.

CAUTION

Place special tool MB990890 or MB990891 against the
outer race of the bearing.
2. Use special tools MB990890 or MB990891 to press-fit the

bearing to the side of the clutch housing.

.

>>C<< OIL SEAL INSTALLATION

.

ACX01026 AB

OIL SEAL

CLUTCH
HOUSING

MB991168

ACX01027AB

MB990799

BEARING

CLUTCH
GEAR

ACX01028 AB

MB990890
OR
MB990891

CLUTCH
HOUSING

ACX01029AC

OIL SEAL

MB990938

MB990926

CLUTCH
HOUSING

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-40

>>D<< SPRING PIN INSTALLATION
Tap the spring pin from the chamfered side of the shaft rod until
the projection length becomes the length shown in the illustra-
tion.

.

>>E<< SPACER INSTALLATION
1. Place the current spacer in the area shown in the illustration

to check that the dimensions shown in the illustration are
within the standard values.

Standard Value (A): 0.05

− 0.3 mm (0.002 − 0.012 inch)

2. If the dimensions are outside of the standard values, select

the correct spacer type to fit in the standard values.
Spacer type

.

>>F<< BEARING INSTALLATION
Press-fit the bearing to the shoulder of the mainshaft.

ACX01030 AB

SPRING PIN

SHIFT ROD

0 – 1 mm
(0 – 0.03 in)

CHAMFER

Part Number Thickness

mm (in)

Part Number Thickness

mm (in)

MR111526

1.1 (0.04)

MR111530

2.1 (0.08)

MR111527

1.35 (0.05)

MR111531

2.35 (0.09)

MR111528

1.6 (0.06)

MR111532

2.6 (0.10)

MR111529

1.85 (0.07)

MR111533

2.85 (0.11)

AC101906AB

CLUTCH GEAR

MAIN SHAFT
ASSEMBLY

SPACER

A

ACX01031AB

MAIN SHAFT