Mitsubishi Montero (2004+). Manual — part 461
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-49
<<J>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.
ASSEMBLY
M1262002500151
ACX01048AB
PUNCH
AC204225AB
83
± 5 N
·
m
62
± 3 ft-lb
18
± 3 N
·
m
13
± 2 ft-lb
50
± 10 N
·
m
37
± 7 ft-lb
216
± 29 N
·
m
159
± 22 ft-lb
65
± 5 N
·
m
48
± 4 ft-lb
59
± 5 N
·
m *
44
± 3 ft-lb *
28
30
27
16
23
19
20 21
17
18 22
24
25 26
5 6
7
8
9
10
29
2
1
4
11
12
14
13
15
23
5
15
17
17
18
18
20
20
3
DIFFERENTIAL GEAR SET
FINAL DRIVE GEAR SET
ASSEMBLY
STEPS
1. DIFFERENTIAL
CARRIER
>>A<<
2. OIL
SEAL
>>B<<
3. DRIVE PINION FRONT BEARING
OUTER RACE
>>C<<
4. DRIVE PINION REAR BEARING
OUTER RACE
>>D<<
•
PINION HEIGHT ADJUSTMENT
5. DRIVE
PINION
6. DRIVE PINION FRONT SHIM (FOR
PINION HEIGHT ADJUSTMENT)
7. DRIVE PINION FRONT BEARING
INNER RACE
8. DRIVE PINION SPACER
>>E<<
•
DRIVE PINION TURNING TORQUE
ADJUSTMENT
9. DRIVE PINION REAR SHIM (FOR
TURNING TORQUE ADJUSTMENT)
10. DRIVE PINION ASSEMBLY
ASSEMBLY
STEPS
(Continued)
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-50
NOTE: Specified torque with asterisks means that it
is covered with oil.
Required Special Tools:
• MB990031 or MB990699: Drive Pinion Oil Seal
Installer
• MB990326: Preload Socket
• MB990685: Torque Wrench
• MB990802: Bearing Installer
• MB990819: Drive Pinion Gauge Assembly
• MB990934: Installation Adapter
• MB990936: Installation Adapter
• MB990938: Bar
• MB990939: Brass Bar
• MB991170: Cylinder Gauge
• MB990850: End Yoke Holder
• MB990813: Tap
11. DRIVE PINION REAR BEARING INNER
RACE
12. OIL SEAL
13. COMPANION FLANGE
14. WASHER
15. SELF-LOCKING NUT
16. DIFFERENTIAL CASE
>>F<<
•
DIFFERENTIAL GEAR BACKLASH
ADJUSTMENT
17. SIDE GEAR SPACER
18. SIDE GEAR
19. PINION WASHER
20. PINION GEAR
21. PINION SHAFT
>>G<<
22. LOCK PIN
>>H<<
23. DRIVE GEAR
>>I<<
24. SIDE BEARING INNER RACE
25. SIDE BEARING OUTER RACE
>>J<<
•
DRIVE GEAR BACKLASH
ADJUSTMENT
26. SIDE BEARING SPACER
27. DIFFERENTIAL CASE ASSEMBLY
ASSEMBLY
STEPS
(Continued)
28. COVER
29. DRAIN PLUG
30. FILLER PLUG
ASSEMBLY
STEPS
(Continued)
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-51
LUBRICATION, SEALING AND ADHESIVE POINTS
ASSEMBLY SERVICE POINTS
.
>>A<< OIL SEAL INSTALLATION
Use special tools MB990938 and MB990934 to insert the oil
seal, and then apply a thin coat of multipurpose grease to the
lip of the oil seal.
AC102455
(APPLY ALL
AROUND LIP)
φ 2 - 3 mm
φ 0.08 - 0.12 in
AB
(APPLY ALL
AROUND
LIP)
SEALANT:
3M
TM
AAD PART NO.8672, 8679,
8678, 8661, 8663 OR EQUIVALENT
ADHESIVE:
3M
TM
AAD PART NO.8730,
8731 OR EQUIVALENT
ACX01051AB
OIL SEAL
MB990938
MB990934
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-52
.
>>B<< DRIVE PINION FRONT BEARING OUTER RACE
INSTALLATION
Use special tools MB990938 and MB990936 to press-fit the
drive pinion front bearing outer races into the gear carrier.
.
>>C<< DRIVE PINION REAR BEARING OUTER RACE
INSTALLATION
Use special tools MB990938 and MB990934 to press-fit the
drive pinion rear bearing outer races into the gear carrier.
.
>>D<< PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special tool.
2. Install the special tool, drive pinion front and rear bearing
inner races to the gear carrier.
ACX01052AB
MB990938
MB990936
ACX01053 AB
MB990938
MB990934
ACX01054 AB
MB990819
WASHER
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