Mitsubishi Montero (2004+). Manual — part 459

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-41

<<B>> CLUTCH GEAR/BEARING REMOVAL
1. Use a press and steel plate to remove the clutch gear and

bearing together.

2. Using a press, hold the supports against the bearing inner

race, and separate the clutch gear and bearing.

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
Use special tool MB991168 to tap the oil seal until it is flush
with the clutch housing.

.

>>B<< BEARING/CLUTCH GEAR INSTALLATION
1. Use special tool MB990799 to press-fit the bearing to the

shoulder of the clutch gear.

ACX01024 AB

METAL PLATE

ACX01025 AB

METAL PLATE

SUPPORT

ACX01026 AB

OIL SEAL

CLUTCH
HOUSING

MB991168

ACX01027AB

MB990799

BEARING

CLUTCH
GEAR

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-42

CAUTION

Place special tool MB990890 or MB990891 against the
outer race of the bearing.
2. Use special tools MB990890 or MB990891 to press-fit the

bearing to the side of the clutch housing.

.

>>C<<OIL SEAL INSTALLATION
Use special tools MB990926 and MB990938 To press-fit the oil
seal to the clutch housing.

.

>>D<< SPRING PIN INSTALLATION
Tap the spring pin from the chamfered side of the shaft rod until
the projection length becomes the length shown in the illustra-
tion.

.

>>E<< SPACER INSTALLATION
1. Place the current spacer in the area shown in the illustration

to check that the dimensions shown in the illustration are
within the standard values.

Standard Value (A): 0.05

− 0.3 mm (0.002 − 0.012 inch)

2. If the dimensions are outside of the standard values, select

the correct spacer type to fit in the standard values.
Spacer type

ACX01028 AB

MB990890
OR
MB990891

CLUTCH
HOUSING

ACX01029AC

OIL SEAL

MB990938

MB990926

CLUTCH
HOUSING

ACX01030 AB

SPRING PIN

SHIFT ROD

0 – 1 mm
(0 – 0.03 in)

CHAMFER

Part Number Thickness

mm (in)

Part Number Thickness

mm (in)

MR111526

1.1 (0.04)

MR111530

2.1 (0.08)

AC101906AB

CLUTCH GEAR

MAIN SHAFT
ASSEMBLY

SPACER

A

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-43

.

>>F<< BEARING INSTALLATION
Press-fit the bearing to the shoulder of the mainshaft.

DIFFERENTIAL CARRIER DISASSEMBLY

M1262002300124

MR111527

1.35 (0.05)

MR111531

2.35 (0.09)

MR111528

1.6 (0.06)

MR111532

2.6 (0.10)

MR111529

1.85 (0.07)

MR111533

2.85 (0.11)

Part Number Thickness

mm (in)

Part Number Thickness

mm (in)

ACX01031AB

MAIN SHAFT

ACX01032 AB

1

28

2

3

4

5

22

27

26

23

24

25

6

30

15 14

9

11

12

19

29

20

21

18

17

16

10 8

7

13

DISASSEMBLY

STEPS

<<A>>

•

INSPECTION BEFORE DISASSEMBLY

1. COVER

<<B>>

2. DIFFERENTIAL CASE ASSEMBLY

3. SIDE BEARING SPACER

4. SIDE BEARING OUTER RACE

<<C>>

5. SIDE BEARING INNER RACE

<<D>>

6. DRIVE

GEAR

<<E>>

7. SELF-LOCKING

NUT

8. WASHER

<<F>>

9. DRIVE PINION ASSEMBLY

10. COMPANION FLANGE

11. DRIVE PINION SPACER

12. DRIVE PINION REAR SHIM (FOR

TURNING TORQUE ADJUSTMENT)

<<G>>

13. DRIVE PINION FRONT BEARING

INNER RACE

14. DRIVE PINION REAR SHIM (FOR

PINION HEIGHT ADJUSTMENT)

DISASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-44

Required Special Tools:

• MB990810: Side Bearing Puller

• MB990811: Differential Side Bearing Cap

• MB990850: End Yoke Holder

• MB990339: Bearing Puller

• MB990648: Bearing Remover

• MB990939: Bearing and Oil Seal Installer Set

• MB990909: Working Base

• MB991116: Adapter

DISASSEMBLY SERVICE POINTS

.

<<A>> INSPECTION BEFORE DISASSEMBLY
1. Remove the cover and gasket.
2. Hold the special tools MB990909 and MB991116 in a vise,

and install the differential carrier assembly to the special
tool.

.

DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge to

measure the drive gear backlash in four or more places on
the drive gear.

Standard value: 0.11

− 0.16 mm (0.004 − 0.006 inch)

2. If the backlash is not within the standard value, adjust the

drive gear backlash (Refer to

P.26-49

).

3. After the adjustment, inspect the drive gear tooth contact.

.

15. DRIVE PINION

<<H>>

16. OIL SEAL

<<H>>

17. DRIVE PINION REAR BEARING INNER

RACE

<<H>>

18. DRIVE PINION REAR BEARING

OUTER RACE

<<I>>

19. DRIVE PINION FRONT BEARING

OUTER RACE

20. OIL SEAL

21. DIFFERENTIAL CARRIER

<<J>>

22. LOCK PIN

23. PINION SHAFT

24. PINION GEAR

25. PINION WASHER

26. SIDE GEAR

27. SIDE GEAR SPACER

28. FILLER PLUG

29. DRAIN PLUG

30. DIFFERENTIAL CASE

DISASSEMBLY STEPS (Continued)

AC102883AE

MB990909
AND
MB991116

ACX01034AB