Mitsubishi Montero (2002-2004). Manual — part 225

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-33

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL PRESS-FITTING
Use special tool MB991168 to press-fit the oil seal.

.

>>B<< DRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
Use special tools MB990938 and MB991445 to press-fit the
drive pinion rear bearing outer race.

.

>>C<< DRIVE PINION FRONT BEARING OUTER RACE
PRESS-FITTING
Use special tools MB990938 and MB990934 to press-fit the
drive pinion front bearing outer race.

.

ACX01105 AB

MB991168

OIL SEAL

ACX01106 AB

MB990938

MB991445

ACX01107AB

MB990938

MB990934

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-34

>>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool

MB990819.

2. Install special tool MB990819, MB991770 and drive pinion

front and rear bearing inner races to the gear carrier as
shown in the illustration.

3. Tighten the nut of special tool MB990819 a little at a time,

while measuring the turning torque of the drive pinion. Then
confirm that the turning torque (without the oil seal) is at the
standard value.

Standard value:

4. Clean the side bearing hub.

5. Place special tool MB991534 between the side bearing hub

of the gear carrier, and position the notch as shown in the
illustration. Then tighten side bearing mounting bolt.

6. Use a thickness gauge to measure the clearance (A)

between special tools MB991169 and MB991534.

7. Remove special tools MB991169 and Mb991534.

BEARING DIVISION

TURNING TORQUE

New

1.94

− 2.25 N⋅m

17.2

− 19.9 in-lb

AC000178

MB990819

AB

REPLACE THE
HEAD WITH
MB991770

ACX01055 AB

MB990819

AC102911

MB990326

AC

MB990685

ACX01109AB

MB991534

NOTCH

MB991169

THICKNESS
GAUGE

A

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-35

8. Use a micrometer to measure the shown dimensions (B, C)

of special tools MB991169 and MB991534.

9. Install the bearing cap, and then use a cylinder gauge to

measure the inside diameter (D) of the bearing cap.

10.Calculate thickness (F) of the required drive pinion rear

shim twice by the following formula. Select a shim which
most closely matches this thickness.
F = A + B + C

− 1/2D − 86.00 mm (3.385 inches)

11.Fit the selected drive pinion rear shim(s) to the drive pinion,

and press-fit the drive pinion rear bearing inner race by
using special tool MB990802.

.

>>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT/
OIL SEAL INSTALLATION
1. Insert the drive pinion into the gear carrier, and then install

the following parts in sequence from the carrier rear side:
Drive pinion spacer, drive pinion front shim and drive pinion
front bearing inner race, companion flange.
NOTE: Do not install the oil seal.

2. Tighten the companion flange to the specified torque by

using special tool MB990850.

Tightening torque: 216

± 29 N⋅m (159 ± 22 ft-lb)

ACX01058AB

MB991534

B

C

ACX01110 AB

CYLINDER GAUGE

ACX02428

MB990802

DRIVE PINION
REAR SHIM

AB

ACX01065AB

MB990850

216

±

29 N

•

m

159

±

22 ft-lb

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-36

3. Measure the drive pinion turning torque (without the oil

seal).

Standard value:

4. If the drive pinion turning torque is not within the standard

value, adjust the turning torque by replacing the drive pinion
front shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims to a
minimum by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following two
types.

5. Remove the companion flange and drive pinion again. Then

insert the drive pinion front bearing inner race into the gear
carrier. Use special tool MB990727 to press-fit the oil seal.

6. Install the drive pinion assembly and companion flange with

the mating marks properly aligned. Tighten the companion
flange self-locking nut to the specified torque using special
tool MB990850.

Tightening torque: 216

± 29 N⋅m (159 ± 22 ft-lb)

BEARING DIVISION

TURNING TORQUE

New

1.94

− 2.25 N⋅m

17.2

− 19.9 in-lb

HEIGHT OF DRIVE PINION
SPACER mm (in)

IDENTIFICATION COLOR

52.50 (2.067)

Yellow

52.84 (2.080)

Red

ACX01062AB

MB990326

MB990685

ACX01063 AB

IDENTIFICATION

COLOR

ACX01064 AC

MB990727

ACX01065AB

MB990850

216

±

29 N

•

m

159

±

22 ft-lb