Mitsubishi Montero (2004+). Manual — part 460
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-45
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 − 0.0030 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.
.
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.
AC102886
AC102885
WEDGE
SIDE GEAR
SPACER
SIDE GEAR
SPACER
AC
ACX01037 AB
ACX01038 AB
MB990939
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
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FRONT AXLE
26-46
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 stan-
dard pattern. If, even after adjustments have been made, the
correct tooth contact 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
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
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FRONT AXLE
26-47
<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and MB990811 to pull out the side
bearing inner races.
NOTE: There are two notches provided (at the differential case
side) for the claw part of the special tools; use special tools
MB990810 and MB990811 at that position.
.
<<D>> DRIVE GEAR REMOVAL
1. Make the 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>> SELF-LOCKING NUT REMOVAL
Use special tool MB990850 to hold the companion flange, and
then remove the companion flange self-locking nut.
.
<<F>> DRIVE PINION ASSEMBLY REMOVAL
CAUTION
The mating mark made on the companion flange must not
be on the coupling surface of the flange yoke and the front
propeller shaft.
1. Make mating marks on the drive pinion and companion
flange.
AC102890AE
MB990810
MB990811
ACX01042AB
MATING
MARKS
ACX01043AB
MB990850
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
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FRONT AXLE
26-48
2. Pull out the drive pinion together with special tool
MB990810.
.
<<G>> DRIVE PINION FRONT BEARING INNER RACE
REMOVAL
Use special tools MB990339 and MB990648 to pull out the
front bearing inner race.
.
<<H>> OIL SEAL/DRIVE PINION REAR BEARING INNER
RACE/DRIVE PINION REAR OUTER RACE REMOVAL
Use special tool MB990939 to remove the drive pinion rear
bearing outer race.
.
<<I>> DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion front
bearing outer race.
.
ACX01044 AB
MB990810
COMPANION
FLANGE
ACX01045 AB
MB990339
MB990648
ACX01046AB
MB990939
ACX01047 AB
MB990939
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