Mitsubishi Montero (2002-2004). Manual — part 211

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-41

DIFFERENTIAL CARRIER DISASSEMBLY

M1262002300113

Required Special Tools:

• MB990810: Side Bearing Puller

• MB990811: Differential Side Bearing Cap

• MB990850: End Yoke Holder

• MB990339: Bearing Puller

• MB990648: Bearing Remover

• MB990939: Bearing and Oil Seal Installer Set

ACX01032 AB

1

28

2

3

4

5

22

27

26

23

24

25

6

30

15 14

9

11

12

19

29

20

21

18

17

16

10 8

7

13

DISASSEMBLY

STEPS

<<A>>

•

INSPECTION BEFORE DISASSEMBLY

1. COVER

<<B>>

2. DIFFERENTIAL CASE ASSEMBLY

3. SIDE BEARING SPACER

4. SIDE BEARING OUTER RACE

<<C>>

5. SIDE BEARING INNER RACE

<<D>>

6. DRIVE

GEAR

<<E>>

7. SELF-LOCKING

NUT

8. WASHER

<<F>>

9. DRIVE PINION ASSEMBLY

10. COMPANION FLANGE

11. DRIVE PINION SPACER

12. DRIVE PINION REAR SHIM (FOR

TURNING TORQUE ADJUSTMENT)

<<G>>

13. DRIVE PINION FRONT BEARING

INNER RACE

14. DRIVE PINION REAR SHIM (FOR

PINION HEIGHT ADJUSTMENT)

15. DRIVE PINION

<<H>>

16. OIL SEAL

<<H>>

17. DRIVE PINION REAR BEARING INNER

RACE

<<H>>

18. DRIVE PINION REAR BEARING

OUTER RACE

<<I>>

19. DRIVE PINION FRONT BEARING

OUTER RACE

20. OIL SEAL

21. DIFFERENTIAL CARRIER

<<J>>

22. LOCK PIN

23. PINION SHAFT

24. PINION GEAR

25. PINION WASHER

26. SIDE GEAR

27. SIDE GEAR SPACER

28. FILLER PLUG

29. DRAIN PLUG

30. DIFFERENTIAL CASE

29. GEAR CARRIER

30. VENT PLUG

DISASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-42

DISASSEMBLY SERVICE POINTS

.

<<A>> INSPECTION BEFORE DISASSEMBLY
1. Remove the cover and gasket.
2. Hold the special tool in a vise, and install the differential

carrier assembly to the special tool.

.

DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge to

measure the drive gear backlash in four or more places on
the drive gear.

Standard value: 0.11

− 0.16 mm (0.004 − 0.006 inch)

2. If the backlash is not within the standard value, adjust the

drive gear backlash (Refer to

P.26-47

).

3. After the adjustment, inspect the drive gear tooth contact.

.

DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.

Limit: 0.05 mm (0.002 inch)

2. When runout exceeds the limit value, check for foreign

material between drive gear rear side and differential case,
or for loose drive gear installation bolts.

3. When step (2) gives normal results, reposition the drive gear

and differential case and remeasure.

4. If adjustment is impossible, replace the differential case, or

replace the drive gear and pinion as a set.

.

DIFFERENTIAL GEAR BACKLASH
1. 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 − 0.003 inch)

Limit: 0.2 mm (0.007 inch)

Use the measurement procedure for both pinion gears.
2. If the backlash exceeds the limit, adjust by using the side

gear thrust spacers.

3. If adjustment is impossible, replace the side gear and pinion

gear as a set.

.

ACX01033 AB

MB990909

ACX01034AB

AC102886

AC102885

WEDGE

SIDE GEAR
SPACER

SIDE GEAR
SPACER

AC

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-43

DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces

of the drive gear teeth.

2. Insert special tool MB990939 between the differential carrier

and the differential case, and then rotate the companion
flange by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque [approximately 2.5

− 3.0

N

⋅m (22.1 − 26.6 in-lb)] is applied to the drive pinion.

CAUTION

If the drive gear is rotated too much, the tooth contact pat-
tern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and drive

pinion.

ACX01037AB

ACX01038AB

MB990939

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-44

NOTE: Check the tooth contact pattern to confirm that the
adjustments of the pinion height and backlash have been done
properly. Continue to adjust the pinion height and backlash until
the tooth contact pattern resembles the standard pattern. If,
even after adjustments have been made, the correct tooth con-
tact pattern cannot be obtained, it means that the drive gear
and the drive pinion have become worn beyond the allowable
limit. Replace the gear set.

.

<<B>> DIFFERENTIAL CASE ASSEMBLY REMOVAL

CAUTION

When taking out the differential case assembly, be careful
not to drop and damage the bearing outer races.
NOTE: Keep the right and left side bearings and side bearing
adjusting spacers separate, so that they do not become mixed
during reassembly.

.

STANDARD TOOTH CONTACT PATTERN PROBLEM

SOLUTION

1. Narrow tooth side
2. Drive-side tooth surface (the side
applying power during forward movement)
3. Wide tooth side
4. Coast-side tooth surface (the side
applying power during reverse movement)

Tooth contact pattern resulting
from excessive pinion
height

The drive pinion is positioned too
far from the center of the drive
gear.

Increase the thickness of
the drive pinion rear shim,
and position the drive pinion
closer to the center of the
drive gear. Also, for
backlash adjustment,
position the drive gear
farther from the drive
pinion.

Tooth contact pattern resulting
from insufficient pinion
height.

The drive pinion is positioned too
close to the center of the drive
gear.

Decrease the thickness of
the drive pinion rear shim,
and position the drive pinion
farther from the center of
the drive gear. Also, for
backlash adjustment,
position the drive gear
closer to the drive pinion.

ACX01039 AF

1

3

4

2

AC107260

1

2

3

4

AB

AC107261AB

1

2

3

4

AC107262

1

2

3

4

AB

AC107263

1

2

3

4

AB

ACX01040AB