Mitsubishi Montero (2004+). Manual — part 475
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-39
>>H<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the
drive gear by turning the tap (M10 x 1.25). Clean the
threaded holes by applying compressed air.
3. Apply 3M
stud locking 4170 or equivalent to the threaded
holes of the drive gear.
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
Tightening torque: 152
± 15 N⋅m (112 ± 10 ft-lb)
.
>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tools MD998812 and MD998829 to press-fit the
side bearing inner races into the differential case.
.
>>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR
BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Assemble the differential case with the side bearing outer
race to the gear carrier.
2. Press the differential case to one side to measure the
clearance of the side bearing outer race and the gear carrier.
3. Select two pairs of side bearing spacer. Determine the
thickness by adding 1/2 of the clearance to the pre-load
0.05mm (0.002 inch).
ACX01068AB
TAP
ACX02430
ACX02431AB
MD998812
MD998829
ACX01071
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-40
4. Remove the side bearing, using special tools MB990810
and MB991407.
NOTE: Hook the claws of the special tool MB990810 with
the side bearing inner race by using the notches (two areas)
of the differential case side.
5. Assemble the selected side bearing spacers to each side.
6. Use special tool MB990802 to press-fit the side bearing
inner case into the differential case. After installing the outer
race, assemble the differential case to the gear carrier.
7. Align the mating marks of differential carrier and the bearing
cap with each other and tighten to the specified torque.
Tightening torque: 74
± 5 N⋅m (55 ± 3 ft-lb)
8. Measure the drive gear backlash.
NOTE: Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.13
− 0.18 mm (0.005 − 0.007 inch)
9. If the backlash is not within the standard value, move the
side bearing spacer as shown in the illustration to adjust the
backlash.
NOTE: The increment of side bearing spacer must be the
same as the decreased amount.
10.Inspect the tooth condition at the final drive gear and adjust
if required. (Refer to GROUP 26, Inspection Before
Disassembly
11.Measure the drive gear runout.
Limit: 0.05 mm (0.002 inch)
12.If drive gear runout exceeds the limit, remove the differential
case and then the drive gears, moving them to different
positions and reinstall them.
13.If adjustment is not possible, replace the differential case or
drive gear and drive pinion as a set.
ACX01041AB
MB990810
MB991407
ACX02432
DRIVE
PINION
REAR
SHIM
MB990802
MB990802
AB
ACX01034
ACX02433AB
WHEN THE BACKLASH IS SMALL
WHEN THE BACKLASH IS LARGE
DECREASED
DECREASED
INCREASED
INCREASED
ACX01036
SPECIFICATIONS
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REAR AXLE
27-41
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1271004000257
GENERAL SPECIFICATIONS
M1271000200130
ITEM
SPECIFICATION
Rear axle hub assembly, drive shaft assembly
Backing plate bolt
133
± 14 N⋅m (98 ± 10 ft-lb)
Lower arm and knuckle connection nut
152
± 25 N⋅m (113 ± 18 ft-lb)
Rear brake caliper bolt
100
± 10 N⋅m (74 ± 7 ft-lb)
Rear drive shaft and companion shaft connection nut
113
± 14 N⋅m (84 ± 10 ft-lb)
Rear drive shaft nut
255
± 29 N⋅m (188 ± 21 ft-lb)
Knuckle
Toe-control arm and knuckle connection nut
67
± 7 N⋅m (50 ± 5 ft-lb)
Trailing arm and knuckle connection bolt
231
± 34 N⋅m (170 ± 25 ft-lb)
Upper arm and knuckle connection nut
150
± 30 N⋅m (111 ± 22 ft-lb)
Differential carrier assembly
Bearing cap bolt
74
± 5 N⋅m (55 ± 3 ft-lb)
Differential cover bolt
35
± 5 N⋅m (25 ± 4 ft-lb)
Dynamic damper bolt
83
± 12 N⋅m (61 ± 9 ft-lb)
Drain plug
63
± 4 N⋅m (47 ± 2 ft-lb)
Drive gear bolt
152
± 15 N⋅m (112 ± 10 ft-lb)
Drive pinion self-locking nut
216
± 29 N⋅m (159 ± 22 ft-lb)
Filler plug
49
± 9 N⋅m (37 ± 6 ft-lb)
Lower arm and knuckle connection nut
152
± 25 N⋅m (113 ± 18 ft-lb)
Rear drive shaft and companion shaft connection nut
113
± 14 N⋅m (84 ± 10 ft-lb)
Rear differential mount member nut
152
± 25 N⋅m (113 ± 18 ft-lb)
Toe-control tower bar bolt and nut
46
± 8 N⋅m (34 ± 6 ft-lb)
ITEM
SPECIFICATION
Reduction gear type
Hypoid gear
Reduction ratio
4.300
Differential gear type (Type
× number
of gears)
Side gear
Straight bevel gear
× 2
Pinion gear
Straight bevel gear
× 2
Number of teeth
Drive gear
43
Drive pinion
10
Side gear
18
Pinion gear
10
SPECIFICATIONS
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REAR AXLE
27-42
SERVICE SPECIFICATIONS
M1271000300308
LUBRICANTS
M1271000400242
SEALANT AND ADHESIVE
M1271000500142
Bearings (Outside diameter
× Inside
diameter) mm (in)
Side
90.0
× 55.0 (3.54 × 2.17)
Front
68.3
× 30.2 (2.69 × 1.19)
Rear
79.4
× 36.5 (3.13 × 1.44)
ITEM
SPECIFICATION
ITEM
STANDARD VALUE
LIMIT
Rear axle total backlash mm (in)
−
5 (0.2)
Wheel bearing end play mm (in)
−
0 (0)
Wheel bearing rotation starting torque N
⋅m (in-lb)
−
1.76 (15.6)
DOJ boot assembly dimension mm (in)
110
± 3 (4.3 ± 0.1)
−
Drive gear backlash mm (in)
0.13
− 0.18 (0.005 − 0.007)
−
Drive gear runout mm (in)
0.05 (0.002)
−
Differential gear backlash mm (in)
0
− 0.076 (0 − 0.0030)
0.2 (0.01)
Drive pinion
turning torque
N
⋅m (in-lb)
Without oil seal
1.94
− 2.25 (17.2 − 19.9)
−
With
oil seal
Companion flange (oil seal
contacting area) with anti-rust
agent
2.03
− 2.34 (18.0 − 20.7)
−
Companion flange (oil seal
contacting area) with gear oil
applied
2.10
− 2.40 (18.6 − 21.2)
−
ITEM
SPECIFIED LUBRICANT
QUANTITY
Rear differential 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
Approximately 1.6 dm
3
(1.7 qt)
BJ joint
Repair kit grease
245
± 10 g (8.7 ± 0.3 oz)
DOJ joint
Repair kit grease
295
± 10 g (10.5 ± 0.3 oz)
ITEM
SPECIFIED SEALANT AND ADHESIVE
Differential cover
3M
AAD Part No. 8672, 8679, 8678, 8661, 8663 or
equivalent
Drive gear and differential case mounting part
3M
AAD Part No. 8730, 8731 or equivalent
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