Mitsubishi Montero (2004+). Manual — part 463

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-57

>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tool MB990802 to press-fit the side bearing inner
races into the differential case.

.

>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than

those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE: Select side bearing spacers with the same thickness
for both the drive pinion side and the drive gear side.

2. Push the differential case assembly to one side, and

measure the clearance between the gear carrier and the
side bearing adjusting spacer with a feeler gauge.

3. Measure the thickness of the side bearing adjusting spacers

on one side, select two pairs of spacers which correspond to
that thickness plus one half of the clearance plus 0.05 mm
(0.002 inch), and then install one pair each to the drive
pinion side and the drive gear side.

ACX01069 AD

MB990802

PIECE
OF
METAL

MB990802

PIECE OF
METAL

ACX01070 AB

ACX01071AB

ACX01072 AB

CLEARANCE / 2 + 0.05 mm
= THICKNESS OF THE
SPACER ON ONE SIDE

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-58

4. Install the side bearing adjusting spacers and differential

case assembly, as shown in the illustration, to the gear
carrier.

5. Tap the side bearing adjusting spacers with the special tool

to fit them to the side bearing outer race.

6. Align the mating marks on the gear carrier and the bearing

cap, and then tighten the bearing cap.

7. With the drive pinion locked in place, measure the drive gear

backlash with a dial indicator on the drive gear.
NOTE: Measure at four points or more on the circumference
of the drive gear.

Standard value: 0.11

− 0.16 mm (0.004 − 0.006 inch)

8. Change the side bearing adjusting spacers as illustrated,

and then adjust the drive gear backlash between the drive
gear and the drive pinion.
NOTE: When increasing the number of side bearing adjust-
ing spacers, use the same number for each, and as few as
possible.

9. Check the drive gear and drive pinion for tooth contact. If

poor contact is evident, make adjustment. (Refer to

P.26-43

).

ACX01070 AB

ACX01073 AB

MB990939

ACX01074AB

ACX01034AB

ACX01075

IF BACKLASH IS TOO SMALL

IF BACKLASH IS TOO LARGE

THINNER
SPACER

THICKER
SPACER

AB

THINNER
SPACER

THICKER
SPACER

SOLENOID VALVE AND VACUUM HOSE

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FRONT AXLE

26-59

10.Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.

Limit: 0.05 mm (0.002 inch)

11.If the drive gear runout exceeds the limit, reinstall by

changing the phase of the drive gear and differential case,
and remeasure.

12.If adjustment is not possible, replace the differential case or

replace the drive gear and drive pinion as a set.

SOLENOID VALVE AND VACUUM HOSE

REMOVAL AND INSTALLATION

M1262004500050

ACX01036 AB

AC000432

12

± 2 N

·

m

107

± 17 in-lb

1

11

2

12

10

9

10

16

15

7

6

5

4

1

3

13

10

8

10

18

17

17

± 3 N

·

m

13

± 2 ft-lb

12

± 2 N

·

m

107

± 17 in-lb

AB

14

9.0

± 1.0 N

·

m

80

± 9 in-lb

SOLENOID VALVE AND VACUUM HOSE

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FRONT AXLE

26-60

REMOVAL SERVICE POINT

.

<<A>> PIN REMOVAL
1. Remove one side of dust cover mounting part on vacuum

actuator assembly.

2. Match color of pin hole with that of another pin hole to

remove a pin with a punch.

INSTALLATION SERVICE POINTS

.

>>A<< VACUUM HOSE INSTALLATION
Match the color of each vacuum hose and solenoid valve and
vacuum pipe during assembly.

.

>>B<< CHECK VALVE INSTALLATION
Install so that the air direction arrow points to the vacuum side.

SOLENOID VALVE ASSEMBLY,
VACUUM TANK ASSEMBLY
REMOVAL STEPS

>>A<<

1. VACUUM HOSE (WHITE STRIPE).

>>A<<

2. VACUUM HOSE (BLUE STRIPE).

>>A<<

3. VACUUM HOSE (YELLOW STRIPE).

4. VACUUM PIPE ASSEMBLY

5. VACUUM HOSE ASSEMBLY

6. VACUUM PIPE ASSEMBLY

7. BREATHER

CAP

8. SOLENOID VALVE ASSEMBLY

>>B<<

9. CHECK

VALVE

10. VACUUM HOSE

11. VACUUM HOSE

12. VACUUM PIPE ASSEMBLY

13. BREATHER PIPE

14. VACUUM TANK ASSEMBLY

VACUUM ACTUATOR ASSEMBLY
REMOVAL STEPS

>>A<<

15. VACUUM HOSE (BLUE STRIPE)

CONNECTION

>>A<<

16. VACUUM HOSE (YELLOW STRIPE)

CONNECTION

<<A>>

17. PIN

18. VACUUM ACTUATOR ASSEMBLY

SOLENOID VALVE ASSEMBLY,
VACUUM TANK ASSEMBLY
REMOVAL STEPS (Continued)

ACX01019 AB

COLLAR

DUST COVER

PIN

ACX01077AB

VACUUM SIDE

AIR DIRECTION ARROW

SOLENOID
VALVE SIDE