Mitsubishi Montero (2004+). Manual — part 458

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-37

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

REMOVAL AND INSTALLATION

M1262001800074

Pre-removal and Post-installation Operation
• Under Cover Removal and Installation

• Skid Plate Removal and Installation (Refer to GROUP 51-

Front Bumper

P.51-3

).

• Gear Oil Draining and Refill (Refer to

P.26-15

).

• Driveshaft Removal and Installation (Refer to

P.26-24

).

• Inner Shaft Removal and Installation (Refer to

P.26-32

).

AC309396AB

8

2

7

6

5

9

2

10

11

1

4

4

3

12

9

11

69

± 9 N

·

m *

51

± 7 ft-lb *

25

± 5 N

·

m

22

± 4 ft-lb

69

± 9 N

·

m *

51

± 7 ft-lb *

128

± 9 N

·

m

94

± 7 ft-lb

89

± 9 N

·

m

65

± 7 ft-lb

59

± 9 N

·

m

43

± 7 ft-lb

60

± 10 N

·

m

45

± 7 ft-lb

69

± 9 N

·

m *

51

± 7 ft-lb *

90

± 10 N

·

m

67

± 7 ft-lb

SEALANT:

3M

TM

AAD PART NO.8672, 8679,

8678, 8661, 8663 OR EQUIVALENT

REMOVAL

STEPS

<<A>>

>>B<<

1. FRONT PROPELLER SHAFT

CONNECTION

2. FRONT FRAME AND DIFFERENTIAL

MOUNTING BRACKET
CONNECTION

3. FRONT FRAME AND NO.2

CROSSMEMBER ASSEMBLY
CONNECTION

4. VACUUM

HOSE

5. COLLAR

<<B>>

6. PIN

7. FREEWHEEL

ENGAGE

SWITCH

CONNECTION

>>A<<

8. DIFFERENTIAL

MOUNTING

BRACKET <RH> AND HOUSING
TUBE ASSEMBLY

9. FREEWHEEL CLUTCH ASSEMBLY

>>A<<

10. DIFFERENTIAL MOUNTING

BRACKET <LH>

REMOVAL STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-38

REMOVAL SERVICE POINTS

.

<<A>> FRONT PROPELLER SHAFT REMOVAL

CAUTION

• Be careful not to damage joint boot by crimping with

the bent propeller shaft joint.

• Hang propeller shaft with wires to prevent it from fall-

ing.

Make mating marks on the flange yoke and the differential car-
rier companion flange. Remove the front propeller shaft.

.

<<B>> PIN REMOVAL
1. Remove one side of dust cover mounting part on the

vacuum actuator assembly.

2. Match a pin with a pin hole and remove the pin with a punch.

11. DIFFERENTIAL CARRIER

12. NO.2 CROSSMEMBER ASSEMBLY

REMOVAL STEPS (Continued)

AC000430AB

JOINT ASSEMBLY (BJ)

CLOTH

PROPELLER
SHAFT

JOINT BOOT

ACX01018 AB

MATING
MARKS

ACX01019 AB

COLLAR

DUST COVER

PIN

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-39

INSTALLATION SERVICE POINTS

.

>>A<< DIFFERENTIAL MOUNTING BRACKET ASSEMBLY
Tighten differential mounting insulator in the order of A, B, C, D
or A, C, B, D as shown, in the left diagram.

.

>>B<< FRONT PROPELLER SHAFT INSTALLATION

CAUTION

Remove grease from fastener threads before tightening.
Fastener threads covered with oily products could become
loose.
Install the front propeller shaft so that the mating marks of the
flange yoke and the differential carrier companion flange are
aligned.

DIFFERENTIAL CARRIER AND FREE
WHEELING CLUTCH INSPECTION

INSPECTION

M1262001900048

FREEWHEEL ENGAGE SWITCH CHECK

ACX01020 AB

C

B

D

A

SHAFT(SWITCH)
POSITION

TESTER
CONNECTION

SPECIFIED
CONDITION

PRESSED(ON)

1-2

Less than 2 ohms

RELEASED(OFF) -

Open circuit

ACX01021AB

OFF

ON

1 2

BALL

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-40

FREE WHEELING CLUTCH DISASSEMBLY AND ASSEMBLY

M1262002900074

Required Special Tools:

• MB990560: Bearing Remover

• MB990799: Ball Joint Remover and Installer

• MB990890 or MB990891: Rear Suspension

Bushing Base

• MB990926: Bearing and Oil Seal Installer Set

• MB990938: Bearing and Oil Seal Installer Set

• MB991168: Differential Oil Seal Installer

DISASSEMBLY SERVICE POINTS

.

<<A>> MAIN SHAFT/BEARING REMOVAL
1. After special tool MB990560 has been installed as shown,

tighten the nut of special tool MB990560 until portion "A" of
special tool MB990560 touches the bearing outer race.

CAUTION

Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing.

.

AC101907AB

12

10

9

12

11

10

4

13

7

3

2

1

6

5

8

9

FREE WHEELING CLUTCH
DISASSEMBLY STEPS

<<A>>

1.

MAIN SHAFT ASSEMBLY

<<A>>

>>F<<

2.

BEARING

>>E<<

3.

SPACER

4.

CLUTCH SLEEVE

>>D<<

5.

SPRING PIN

6.

SNAP RING

7.

SHIFT FORK

8.

SHIFT ROD

>>C<<

9.

OIL SEAL

<<B>>

>>B<<

10. CLUTCH GEAR

<<B>>

>>B<<

11. BEARING

>>A<<

12. OIL SEAL
13. CLUTCH HOUSING

FREE WHEELING CLUTCH
DISASSEMBLY STEPS
(Continued)

ACX01023 AB

A

MB990560