Mitsubishi Montero (2002-2004). Manual — part 209
INNER SHAFT ASSEMBLY
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FRONT AXLE
26-33
2. After special tool MB990560 has been installed as shown,
tighten the nut of special tool MB990560 until the portion of
special tool MB990560 touches the bearing outer race.
3. Press out the inner shaft from the bearing.
ASSEMBLY SERVICE POINTS
.
>>A<< DUST SEAL INSTALLATION
Press-fit the new dust seal into the housing tube by using spe-
cial tools MB990938 and MB990955, until it is flush with the
housing tube end face.
.
>>B<< DUST COVER INSTALLATION
Using a steel pipe, install a new dust cover onto the inner shaft.
.
ACX01003AB
A
MB990560
ACX01013 AB
MB990560
ACX01014 AB
MB990955
MB990938
STEEL PIPE
mm (in)
Overall length
50 (2.0)
Outside diameter
75 (3.0)
Wall thickness
4 (0.16)
ACX01015 AB
STEEL PIPE
INNER SHAFT ASSEMBLY
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FRONT AXLE
26-34
>>C<< BEARING INSTALLATION
Use special tool MB990560 to press-fit the bearing onto the
inner shaft.
ACX01016AB
MB990560
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
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FRONT AXLE
26-35
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
REMOVAL AND INSTALLATION
M1262001800063
Pre-removal and Post-installation Operation
• Under Cover Removal and Installation
• Skid Plate Removal and Installation (Refer to GROUP 51-
• Gear Oil Draining and Refill (Refer to
• Driveshaft Removal and Installation (Refer to
• Inner Shaft Removal and Installation (Refer to
AC102456AB
8
2
7
6
5
9
2
10
11
1
4
4
3
12
9
11
69
±
9 N
·
m *
51
±
7 ft-lb *
25
±
5 N
·
m
22
±
4 ft-lb
69
±
9 N
·
m *
51
±
7 ft-lb *
128
±
9 N
·
m
94
±
7 ft-lb
89
±
9 N
·
m
65
±
7 ft-lb
59
±
9 N
·
m
43
±
7 ft-lb
60
±
10 N
·
m
45
±
7 ft-lb
69
±
9 N
·
m *
51
±
7 ft-lb *
90
±
10 N
·
m
67
±
7 ft-lb
SEALANT:
3M
TM
AAD PART NO.8672, 8679,
8678, 8661, 8663 OR EQUIVALENT
REMOVAL
STEPS
>>B<<
1. FRONT PROPELLER SHAFT
CONNECTION
2. FRONT FRAME AND DIFFERENTIAL
BRACKET CONNECTION
3. FRONT FRAME AND NO.2
CROSSMEMBER ASSEMBLY
CONNECTION
4. VACUUM
HOSE
5. COLLAR
6. PIN
7. FREEWHEEL
ENGAGE
SWITCH
CONNECTION
>>A<<
8. DIFFERENTIAL
MOUNTING
BRACKET <RH> AND HOUSING
TUBE ASSEMBLY
9. FREEWHEEL CLUTCH ASSEMBLY
10. DIFFERENTIAL MOUNTING
BRACKET <LH>
11. DIFFERENTIAL CARRIER
12. NO.2 CROSSMEMBER ASSEMBLY
REMOVAL STEPS (Continued)
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
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FRONT AXLE
26-36
REMOVAL SERVICE POINTS
.
<<A>> FRONT PROPELLER SHAFT REMOVAL
CAUTION
• Be careful not to damage joint boot by crimping with
the bent propeller shaft joint.
• Hang propeller shaft with wires to prevent it from fall-
ing.
Make mating marks on the flange yoke and the differential car-
rier companion flange. Remove the front propeller shaft.
.
<<B>> PIN REMOVAL
1. Remove one side of dust cover mounting part on the
vacuum actuator assembly.
2. Match a pin with a pin hole and remove the pin with a punch.
INSTALLATION SERVICE POINTS
.
>>A<< DIFFERENTIAL MOUNTING BRACKET ASSEMBLY
Tighten differential mounting insulator in the order of A, B, C, D
or A, C, B, D as shown, in the left diagram.
.
AC000430AB
JOINT ASSEMBLY (BJ)
CLOTH
PROPELLER
SHAFT
JOINT BOOT
ACX01018 AB
MATING
MARKS
ACX01019 AB
COLLAR
DUST COVER
PIN
ACX01020 AB
C
B
D
A
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