Mitsubishi Montero (2002-2004). Manual - part 211

 

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Mitsubishi Montero (2002-2004). Manual - part 211

 

 

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-41

DIFFERENTIAL CARRIER DISASSEMBLY

M1262002300113

Required Special Tools:

• MB990810: Side Bearing Puller

• MB990811: Differential Side Bearing Cap

• MB990850: End Yoke Holder 

• MB990339: Bearing Puller

• MB990648: Bearing Remover

• MB990939: Bearing and Oil Seal Installer Set

ACX01032 AB

1

28

2

3

4

5

22

27

26

23

24

25

6

30

15 14

9

11

12

19

29

20

21

18

17

16

10 8

7

13

 

  

DISASSEMBLY 

STEPS

<<A>>  

INSPECTION BEFORE DISASSEMBLY

 

 

1. COVER

<<B>>  

2.  DIFFERENTIAL CASE ASSEMBLY

 

 

3.  SIDE BEARING SPACER

 

 

4.  SIDE BEARING OUTER RACE

<<C>>  

5.  SIDE BEARING INNER RACE

<<D>>  

6. DRIVE 

GEAR

<<E>>  

7. SELF-LOCKING 

NUT

 

 

8. WASHER

<<F> 

9.  DRIVE PINION ASSEMBLY

 

 

10. COMPANION FLANGE

 

 

11.  DRIVE PINION SPACER

 

 

12.  DRIVE PINION REAR SHIM (FOR 

TURNING TORQUE ADJUSTMENT)

<<G>>  

13.  DRIVE PINION FRONT BEARING 

INNER RACE

 

 

14.  DRIVE PINION REAR SHIM (FOR 

PINION HEIGHT ADJUSTMENT)

 

 

15. DRIVE PINION

<<H>>  

16. OIL SEAL

<<H>>  

17.  DRIVE PINION REAR BEARING INNER 

RACE

<<H>>  

18.  DRIVE PINION REAR BEARING 

OUTER RACE

<<I>>  

19.  DRIVE PINION FRONT BEARING 

OUTER RACE

 

 

20. OIL SEAL

 

 

21. DIFFERENTIAL CARRIER

<<J>>  

22. LOCK PIN

 

 

23. PINION SHAFT

 

 

24. PINION GEAR

 

 

25. PINION WASHER

 

 

26. SIDE GEAR

 

 

27.  SIDE GEAR SPACER

 

 

28. FILLER PLUG

 

 

29. DRAIN PLUG

 

 

30. DIFFERENTIAL CASE

 

 

29. GEAR CARRIER

 

 

30. VENT PLUG

 

 

 

DISASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-42

DISASSEMBLY SERVICE POINTS

.

<<A>> INSPECTION BEFORE DISASSEMBLY
1. Remove the cover and gasket. 
2. Hold the special tool in a vise, and install the differential 

carrier assembly to the special tool.

.

DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge to 

measure the drive gear backlash in four or more places on 
the drive gear. 

Standard value: 0.11 

 0.16 mm (0.004  0.006 inch)

2. If the backlash is not within the standard value, adjust the 

drive gear backlash (Refer to 

P.26-47

).

3. After the adjustment, inspect the drive gear tooth contact.

.

DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the 

reverse side of the drive gear. 

Limit: 0.05 mm (0.002 inch)

2. When runout exceeds the limit value, check for foreign 

material between drive gear rear side and differential case, 
or for loose drive gear installation bolts.

3. When step (2) gives normal results, reposition the drive gear 

and differential case and remeasure.

4. If adjustment is impossible, replace the differential case, or 

replace the drive gear and pinion as a set.

.

DIFFERENTIAL GEAR BACKLASH
1. While locking the side gear with the wedge, measure the 

differential gear backlash with a dial indicator on the pinion 
gear. 

Standard value: 0 

 0.076 mm (0  0.003 inch)

Limit: 0.2 mm (0.007 inch)

    Use the measurement procedure for both pinion gears.
2. If the backlash exceeds the limit, adjust by using the side 

gear thrust spacers.

3. If adjustment is impossible, replace the side gear and pinion 

gear as a set. 

.

ACX01033 AB

MB990909

ACX01034AB

AC102886

AC102885

WEDGE

SIDE GEAR
SPACER

SIDE GEAR
SPACER

AC

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-43

DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps 
below.
1. Apply a thin, uniform coat of machine blue to both surfaces 

of the drive gear teeth.

2. Insert special tool MB990939 between the differential carrier 

and the differential case, and then rotate the companion 
flange by hand (once in the normal direction, and then once 
in the reverse direction) while applying a load to the drive 
gear so that the revolution torque [approximately 2.5 

− 3.0 

N

⋅m (22.1 − 26.6 in-lb)] is applied to the drive pinion.

CAUTION

If the drive gear is rotated too much, the tooth contact pat-
tern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and drive 

pinion.

ACX01037AB

ACX01038AB

MB990939

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-44

NOTE: Check the tooth contact pattern to confirm that the 
adjustments of the pinion height and backlash have been done 
properly. Continue to adjust the pinion height and backlash until 
the tooth contact pattern resembles the standard pattern. If, 
even after adjustments have been made, the correct tooth con-
tact pattern cannot be obtained, it means that the drive gear 
and the drive pinion have become worn beyond the allowable 
limit. Replace the gear set.

.

<<B>> DIFFERENTIAL CASE ASSEMBLY REMOVAL

CAUTION

When taking out the differential case assembly, be careful 
not to drop and damage the bearing outer races.
NOTE: Keep the right and left side bearings and side bearing 
adjusting spacers separate, so that they do not become mixed 
during reassembly.

.

STANDARD TOOTH CONTACT PATTERN PROBLEM

SOLUTION

1. Narrow tooth side
2. Drive-side tooth surface (the side 
applying power during forward movement)
3. Wide tooth side
4. Coast-side tooth surface (the side 
applying power during reverse movement)
   

Tooth contact pattern resulting 
from excessive pinion 
height

The drive pinion is positioned too 
far from the center of the drive 
gear.

Increase the thickness of 
the drive pinion rear shim, 
and position the drive pinion 
closer to the center of the 
drive gear. Also, for 
backlash adjustment, 
position the drive gear 
farther from the drive 
pinion.

Tooth contact pattern resulting 
from insufficient pinion 
height.

The drive pinion is positioned too 
close to the center of the drive 
gear.

Decrease the thickness of 
the drive pinion rear shim, 
and position the drive pinion 
farther from the center of 
the drive gear. Also, for 
backlash adjustment, 
position the drive gear 
closer to the drive pinion.

ACX01039 AF

1

3

4

2

AC107260

1

2

3

4

AB

AC107261AB

1

2

3

4

AC107262

1

2

3

4

AB

AC107263

1

2

3

4

AB

ACX01040AB

 

 

 

 

 

 

 

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