Mitsubishi Montero (2002-2004). Manual — part 217

27-1

GROUP 27

CONTENTS

GENERAL DESCRIPTION. . . . . . . . .

27-2

SPECIAL TOOLS. . . . . . . . . . . . . . . .

27-2

REAR AXLE DIAGNOSIS . . . . . . . . .

27-6

INTRODUCTION. . . . . . . . . . . . . . . . . . . . .

27-6

TROUBLESHOOTING STRATEGY . . . . . .

27-6

SYMPTOM CHART. . . . . . . . . . . . . . . . . . .

27-6

SYMPTOM PROCEDURES . . . . . . . . . . . .

27-6

ON-VEHICLE SERVICE. . . . . . . . . . .

27-12

REAR AXLE TOTAL BACKLASH CHECK .

27-12

GEAR OIL LEVEL CHECK . . . . . . . . . . . . .

27-12

WHEEL BEARING AXIAL PLAY CHECK . .

27-12

REAR AXLE HUB ASSEMBLY . . . . .

27-13

REMOVAL AND INSTALLATION . . . . . . . .

27-13

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

27-15

KNUCKLE . . . . . . . . . . . . . . . . . . . . . .

27-16

REMOVAL AND INSTALLATION . . . . . . . .

27-16

DRIVE SHAFT ASSEMBLY . . . . . . . .

27-18

REMOVAL AND INSTALLATION . . . . . . . .

27-18

DISASSEMBLY AND ASSEMBLY . . . . . . .

27-20

DIFFERENTIAL CARRIER
ASSEMBLY. . . . . . . . . . . . . . . . . . . . .

27-24

REMOVAL AND INSTALLATION . . . . . . . .

27-24

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

27-27

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

27-31

SPECIFICATIONS . . . . . . . . . . . . . . .

27-40

FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .

27-40

GENERAL SPECIFICATIONS . . . . . . . . . .

27-41

SERVICE SPECIFICATIONS . . . . . . . . . . .

27-41

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .

27-42

SEALANT AND ADHESIVE . . . . . . . . . . . .

27-42

COMPONENT IDENTIFICATION . . . . . . . .

27-42

GENERAL DESCRIPTION

TSB Revision

REAR AXLE

27-2

.

GENERAL DESCRIPTION

M1271000100207

The rear axle has the following features.

• DOJ-type on the differential side and BJ-type on

the hub side constant velocity joints are featured
in the drive shaft.

• Large capacity and high rigidity taper-roller type

unit bearing in the wheel bearing is featured.

• ABS rotor to detect wheel speed is press-fitted

into the drive shaft.

NOTE: The structure of differential is basically the
same as featured in existing models.

CONSTRUCTION DIAGRAM

SPECIAL TOOLS

M1271000600291

ACX02216

KNUCKLE

REAR HUB

UNIT BEARING

DIFFERENTIAL CARRIER

BJ

DOJ

DRIVE SHAFT

AB

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990767
End yoke holder

MB990767-01

Removal and installation of the
drive shaft nut

MB991897
Ball joint remover

MB991113-01,
MB990635-01 or
General service
tool

Disconnection of ball joint
NOTE: Steering linkage puller
(MB990635 or MB991113)is
also used to disconnect knuckle
and tie rod end ball joint.

MB990909
Working base

−

Supporting of the differential
carrier

B990767

AC106827

MB990909

SPECIAL TOOLS

TSB Revision

REAR AXLE

27-3

MB990810
Side bearing puller

MB990810-01

• Removal of the side bearing

inner race

• Removal of the companion

flange

MB991407
Differential rear support
arbor

−

Removal of the side bearing
inner race

MB990850
End yoke holder

−

• Removal of the self-locking

nut

• Adjustment of the drive

pinion turning torque

MD998801
Bearing remover

−

Removal of the drive pinion rear
bearing inner race

MB991168
Drive pinion oil seal installer

−

Press-fitting of the drive pinion
oil seal

MB991445
Bushing remover and
installer base

−

Press-fitting of the drive pinion
rear bearing outer race
(Use together with MB990938)

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990810

MB991407

MB990850

MB991168

SPECIAL TOOLS

TSB Revision

REAR AXLE

27-4

MB991171
Pinion height gauge set
A: MB991169

Drive pinion gauge

attachment

B: MB991170

Cylinder gauge

C: MB990819

Drive pinion gauge

−

Measurement of the pinion
height

MB991768
Drive pinion gauge set
A: MB991770

Head

−

MB991534
Cylinder gauge

−

MB990326
Preload socket

General service
tool

• Measurement of the starting

torque of ball bearing

• Measurement of the starting

torque of ball bearing

MB990685
Torque wrench

MB990998
Front hub remover and
installer

MB990998-01 or
General service
tool

• Measure at the wheel

bearing rotation starting
torque

• Wheel bearing backlash

check

MB990802
Bearing installer

MB990802-01

Press-fitting of the drive pinion
rear bearing inner race

MB990727
Drive pinion oil seal installer

−

Press-fitting of the drive pinion
oil seal

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB991171

A

B

C

MB991768

A

MB991534

MB990326

MB990685AC

MB990998

MB990802

MB990727