Mitsubishi Montero (2002-2004). Manual — part 224
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-29
<<D>> DRIVE GEAR REMOVAL
1. Make 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>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.
.
<<F>> SELF-LOCKING NUT REMOVAL
Use special tool MB990850 to hold the companion flange, and
then remove the companion flange self-locking nut.
.
<<G>> DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
CAUTION
Do not make mating marks on the contact surfaces of the
companion flange and propeller shaft.
1. Make mating marks to the drive pinion and companion
flange.
ACX01042AB
MATING
MARKS
ACX01048AB
PUNCH
ACX01043AB
MB990850
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-30
2. Use special tool MB990810 to pull out the companion
flange.
.
<<H>> DRIVE PINION REAR BEARING INNER RACE
REMOVAL
Use special tool MD998801 to pull out the front bearing inner
race.
.
<<I>> OIL SEAL/DRIVE PINION FRONT BEARING INNER
RACE/DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion front
bearing outer race.
.
<<J>> DRIVE PINION REAR BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion rear
bearing outer race.
ACX01044 AB
MB990810
COMPANION
FLANGE
ACX02423
MD998801
AB
ACX01101AB
DRIVE PINION
FRONT BEARING
OUTER RACE
DRIVE PINION
FRONT
BEARING
OUTER RACE
OIL SEAL
DRIVE PONION
REAR BEARING
OUTER RACE
MB990939
ACX01102 AB
MB990939
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-31
ASSEMBLY
M1272002300125
AC203534AB
35 ± 5 N·m
25 ± 4 ft-lb
15
5
23
17
18
20
20
18 17
FINAL DRIVE GEAR SET
DIFFERENTIAL GEAR SET
12
32
2
31
15
14 13
19
20
26 25
24
17
18
21
20
27
29
30
18
11
4
1
28
9
8
7
10
3
6 5
26
25
24
23
17
N
N
N
N
N
N
N
N
152 ± 15 N·m
112 ± 10 ft-lb
74 ± 5 N·m
55 ± 3 ft-lb
49 ± 9 N·m
37 ± 6 ft-lb
63 ± 4 N·m
47 ± 2 ft-lb
216 ± 29 N·m
159 ± 22 ft-lb
22
19
16
N
ASSEMBLY STEPS
1. DIFFERENTIAL CARRIER
>>A<<
2. OIL SEAL
>>B<<
3. DRIVE PINION REAR BEARING
OUTER RACE
>>C<<
4. DRIVE PINION FRONT BEARING
OUTER RACE
>>D<<
• DRIVE PINION HEIGHT
ADJUSTMENT
5. DRIVE PINION
6. DRIVE PINION REAR SHIM (FOR
ADJUSTING DRIVE PINION
HEIGHT)
7. DRIVE PINION REAR BEARING
INNER RACE
8. DRIVE PINION SPACER
>>E<<
• DRIVE PINION TURNING TORQUE
ADJUSTMENT
9. DRIVE PINION FRONT SHIM (FOR
ADJUSTING DRIVE PINION
PRELOAD)
10. DRIVE PINION ASSEMBLY
11. DRIVE PINION FRONT BEARING
INNER RACE
>>E<<
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
26. SIDE BEARING SHIM
27. DIFFERENTIAL CASE ASSEMBLY
>>J<<
28. BEARING CAP
29. VENT PLUG
30. DIFFERENTIAL COVER
31. DRAIN PLUG
32. FILLER PLUG
>>J<<
• FINAL DRIVE GEAR BACKLASH
ADJUSTMENT
ASSEMBLY STEPS (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-32
Required Special Tools:
• MB991168: Drive Pinion Oil Seal Installer
• MB990938: Bar
• MB991445: Bushing Remover and Installer Base
• MB990934: Installer Adapter
• MB991770: Head
• MB990819: Drive Pinion Gauge
• MB990326: Preload Socket
• MB990685: Torque Wrench
• MB991169: Drive Pinion Gauge
• MB991534: Cylinder Gauge
• MB990802: Bearing Installer
• MB990850: End Yoke Holder
• MB990727: Drive Pinion Oil Seal Installer
• MD998812: Installer Cap
• MD998829: Installer Adapter
• MB990810: Side Bearing Puller
• MB991407: Differential Rear Support Arbor
LUBRICATION AND ADHESIVE POINTS
ACX01104 AC
2 3 mm (0.08 0.12 in)
(BEAD DIAMETER)
–
–
TM
TM
ADHESIVE:
3M PART NO. 8730,
8731 OR EQUIVALENT
SEMI-DRYING SEALANT:
3M AAD PART NO. 8672, 8679,
8678, 8661, 8663 OR EQUIVALENT
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