Mitsubishi Montero (2004+). Manual — part 465

SPECIFICATIONS

TSB Revision

FRONT AXLE

26-65

GENERAL SPECIFICATIONS

M1261000200258

SERVICE SPECIFICATIONS

M1261000300299

Breather pipe bolt

12

± 2 N⋅m (107 ± 17 in-lb)

Differential mount bracket <RH> and housing tube connection nut

89

± 9 N⋅m (65 ± 7 ft-lb)

Differential mount bracket bolt

69

± 9 N⋅m (51 ± 7 ft-lb)

Free wheeling engage switch assembly

25

± 5 N⋅m (22 ± 4 ft-lb)

Housing tube and differential carrier connection bolt

90

± 10 N⋅m (67 ± 7 ft-lb)

Vacuum tank bolt

12

± 2 N⋅m (107 ± 17 in-lb)

Solenoid valve, Vacuum pipe
Actuator bolt

17

± 3 N⋅m (13 ± 2 ft-lb)

Solenoid valve assembly bolt

9.0

± 1.0 N⋅m (80 ± 9 in-lb)

Vacuum pipe bolt

12

± 2 N⋅m (107 ± 17 in-lb)

Vacuum tank bolt

12

± 2 N⋅m (107 ± 17 in-lb)

ITEM

SPECIFICATION

ITEM

SPECIFICATION

Front axle hub bearing

Type

Taper roller type nut bearing

Driveshaft

Joint type

Outer

Under cut joint

Inner

Double-offset joint

Differential

Final drive gear type

Hypoid gear

Reduction ratio

4.300

Pinion gear type

2 pinion

ITEM

STANDARD VALUE

LIMIT

Wheel bearing axis backlash mm (in)

-

0 (0)

Front axle total backlash mm (in)

-

11 (0.4)

Solenoid valve resistance [at 20

°C (68°F)] Ω

36

− 46

-

Hub rotation starting torque N

⋅m (in-ft)

-

1.75 (15.48)

Hub rotary rotation starting torque N

⋅m (ft-lb)

80

± 5 (3.2 ± 0.1)

-

Opening dimension of the
special tool (MB991561) mm (in)

When the BJ boot
band (small) is
crimped

2.9 (0.11)

-

When the BJ boot
band (large) is
crimped

3.2 (0.13)

-

Crimped width of the BJ boot band mm (in)

2.4

− 2.8 (0.09 − 0.11)

-

Crimped height of BJ boot band (larger) mm (in)

-

9.5 (0.37)

Final drive gear backlash mm (in)

0.11

− 0.16 (0.004 − 0.006)

-

Drive gear runout mm (in)

-

0.05 (0.002)

Differential gear backlash mm (in)

0

− 0.076 (0 − 0.0030)

0.2 (0.007)

SPECIFICATIONS

TSB Revision

FRONT AXLE

26-66

LUBRICANTS

M1261000400423

SEALANTS AND ADHESIVES

M1261000500107

Drive pinion
turning torque
N

⋅m (in-lb)

Without oil seal

0.83

− 1.19 (7.35 − 10.53)

-

With oil seal

With anti-rust agent 0.93

− 1.28 (8.24 − 11.32)

-

With gear oil
applied

0.97

− 1.32 (8.59 − 11.68)

-

Main shaft assembly and clutch gear clearance mm
(in)

0.05

− 0.3 (0.002 − 0.012)

-

Drive gear runout mm (in)

-

0.05 (0.002)

ITEM

STANDARD VALUE

LIMIT

ITEM

SPECIFIED LUBRICANT

QUANTITY

Front axle gear oil

Hypoid gear oil API classification
GL-5 or higher

• Above −23°C(−10°F): SAE 90,

85W-90, 80W-90

• From −34 to −23°C(−30 to

−10°F): SAE 80W, 80W-90

• Below −34°C(−30°F): SAE 75W

1.15 dm

3

(1.21 qt)

DOJ boot grease

Repair kit grease

Approximately 120 g (4.2 oz)

UJ boot grease

Repair kit grease

Approximately 140 g (4.9 oz)

ITEM

SPECIFIED SEALANTS AND ADHESIVES

Contact surface of differential mounting bracket and
differential carrier

3M

TM

AAD Part No.8672, 8679, 8678, 8661, 8663 or

equivalent

Vent plug
Free-wheeling clutch assembly
Drive gear threaded hole

3M

TM

AAD Part No.8730, 8731 or equivalent

27-1

GROUP 27

REAR AXLE

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 END 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. . . . . . . . . . . . . . . . . . . . .

27-25

REMOVAL AND INSTALLATION . . . . . . . .

27-25

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

27-28

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

27-32

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

27-41

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

27-41

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

27-41

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

27-42

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

27-42

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

27-42

COMPONENT IDENTIFICATION . . . . . . . .

27-43

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