Mitsubishi Montero (2004+). Manual — part 472
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-27
2. Use special tools MB991050, MB991218, MB991162 and
MB991816 to remove the bushing.
NOTE: When removing the bushing, insert special tool
MB991162 from the forward of vehicle and fix the nut with a
wrench.
3. Use special tools MB991816, MB991218, MB991162 and
MB990955 to press-fit the bushing.
NOTE: When installing the bushing, insert special tool
MB991162 from the forward of vehicle and fix the nut with a
wrench. Press-fit the bushing until the bushing end face is
flush with the rear suspension crossmember.
4. Install the rear differential.
AC206040
REAR
SUSPENSION
CROSSMEMBER
MB991050
WRENCH
BUSHING
MB991050
NUT
REAR
SUSPENSION
CROSSMEMBER
MB991162
MB991816
MB991218
AB
AC206041
WRENCH
BUSHING
MB990955
NUT
REAR
SUSPENSION
CROSSMEMBER
MB991162
MB991816
MB991218
AC
REAR
SUSPENSION
CROSSMEMBER
MB991816
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-28
DISASSEMBLY
M1272002200236
CAUTION
Do not disassemble the limited slip differential case assembly.
AC203533 AC
1
2
20
22
23
24
30
25 26
7
9
8
17
10
16
15
18
19
21
27
28
29
32
5
13
14
7 8
9
1615
16
4
13
12
11
14
3
31
N
N
N
N
N
DISASSEMBLY STEPS
<<A>>
• INSPECTION BEFORE
DISASSEMBLY
1. FILLER PLUG
2. DRAIN PLUG
3. DIFFERENTIAL COVER
4. VENT PLUG
5. BEARING CAP
<<B>>
6. DIFFERENTIAL CASE ASSEMBLY
<<B>>
7. DIFFERENTIAL SIDE SHIM
<<B>>
8. SIDE BEARING OUTER RACE
<<C>>
9. SIDE BEARING INNER RACE
<<D>>
10. DRIVE GEAR
<<E>>
11. LOCK PIN
12. PINION SHAFT
13. PINION GEAR
14. PINION WASHER
15. SIDE GEAR
16. SIDE GEAR SPACER
17. DIFFERENTIAL CASE
<<F>>
18. SELF-LOCKING NUT
19. WASHER
<<G>>
20. DRIVE PINION ASSEMBLY
<<G>>
21. COMPANION FLANGE
22. DRIVE PINION FRONT SHIM (FOR
ADJUSTING PRELOAD OF DRIVE
PINION)
23. DRIVE PINION SPACER
<<H>>
24. DRIVE PINION REAR BEARING
INNER RACE
25. DRIVE PINION REAR SHIM (FOR
ADJUSTING DRIVE PINION
HEIGHT)
26. DRIVE PINION
<<I>>
27. OIL SEAL
<<I>>
28. DRIVE PINION FRONT BEARING
INNER RACE
<<I>>
29. DRIVE PINION FRONT BEARING
OUTER RACE
<<J>>
30. DRIVE PINION REAR BEARING
OUTER RACE
31. OIL SEAL
32. DIFFERENTIAL CARRIER
DISASSEMBLY STEPS (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-29
Required Special Tools:
• MB990810: Side Bearing Puller
• MB991407: Differential Rear Support Arbor
• MB990850: End Yoke Holder
• MD998801: Bearing Remover
• MB990939: Brass Bar
DISASSEMBLY SERVICE POINTS
.
<<A>> INSPECTION BEFORE DISASSEMBLY
Except for the following standard values, inspection procedure
is the same as GROUP 26, inspection before disassembly
.
DRIVE GEAR BACKLASH
Standard value: 0.13
− 0.18 mm (0.005 − 0.007 inch)
DIFFERENTIAL GEAR BACKLASH
Standard value: 0
− 0.076 mm (0 − 0.0030 inch)
Limit: 0.2 mm (0.01 inch)
.
<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL
SIDE SHIM/SIDE BEARING OUTER RACE REMOVAL
CAUTION
When taking out the differential case assembly, be careful
not to drop and damage the differential side shims or the
side bearing outer races.
Use the wooden handle of a hammer to remove the differential
case assembly, differential side shims and side bearings.
NOTE: Keep the right and left side bearings and side bearing
outer race separated, so that they do not become mixed during
assembly.
.
<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and MB991407 to pull out the side
bearing inner race.
NOTE: Attach the prongs of special tools to the inner race of
the side bearing through the openings in the differential case.
.
ACX02422
ACX01041AB
MB990810
MB991407
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-30
<<D>> DRIVE GEAR REMOVAL
1. Make 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>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.
.
<<F>> SELF-LOCKING NUT REMOVAL
Use special tool MB990850 to hold the companion flange, and
then remove the companion flange self-locking nut.
.
<<G>> DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
CAUTION
Do not make mating marks on the contact surfaces of the
companion flange and propeller shaft.
1. Make mating marks to the drive pinion and companion
flange.
ACX01042AB
MATING
MARKS
ACX01048AB
PUNCH
ACX01043AB
MB990850
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