Mitsubishi Montero (2002-2004). Manual - part 212

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-45

<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and MB990811 to pull out the side 
bearing inner races.
NOTE:  There are two notches provided (at the differential case 
side) for the claw part of the special tools; use special tools 
MB990810 and MB990811 at that position.

.

<<D>> DRIVE GEAR REMOVAL
1. Make the 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>> SELF-LOCKING NUT REMOVAL
Use special tool MB990850 to hold the companion flange, and 
then remove the companion flange self-locking nut.

.

<<F>> DRIVE PINION ASSEMBLY REMOVAL

CAUTION

The mating mark made on the companion flange must not 
be on the coupling surface of the flange yoke and the front 
propeller shaft.
1. Make mating marks on the drive pinion and companion 

flange.

ACX01041AB

MB990810

MB991407

ACX01042AB

MATING 
MARKS

ACX01043AB

MB990850

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-46

2. Pull out the drive pinion together with special tool 

MB990810.

.

<<G>> DRIVE PINION FRONT BEARING INNER RACE 
REMOVAL
Use special tools MB990339 and MB990648 to pull out the 
front bearing inner race.

.

<<H>> OIL SEAL/DRIVE PINION REAR BEARING INNER 
RACE/DRIVE PINION REAR OUTER RACE REMOVAL
Use special tool MB990939 to remove the drive pinion rear 
bearing outer race.

.

<<I>> DRIVE PINION FRONT BEARING OUTER RACE 
REMOVAL
Use special tool MB990939 to remove the drive pinion front 
bearing outer race.

.

ACX01044 AB

MB990810

COMPANION
FLANGE

ACX01045 AB

MB990339

MB990648

ACX01046AB

MB990939

ACX01047 AB

MB990939

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-47

<<J>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.

ASSEMBLY

M1262002500139

ACX01048AB

PUNCH

AC204225AB

83 

± 

5 N

·

m

62 

± 

3 ft-lb

18 

± 

3 N

·

m

13 

± 

2 ft-lb

50 

± 

10 N

·

m

37 

± 

7 ft-lb

216 

± 

29 N

·

m

159 

± 

22 ft-lb

65 

± 

5 N

·

m

48 

± 

4 ft-lb

59 

± 

5 N

·

m *

44 

± 

3 ft-lb *

28

30

27

16

23

19

20 21

17

18 22

24

25 26

5 6

7

8

9

10

29

2

1

4

11

12

14

13

15

23

5

15

17

17

18

18

20

20

3

DIFFERENTIAL GEAR SET

FINAL DRIVE GEAR SET

 

  

ASSEMBLY 

STEPS

 

 

1. DIFFERENTIAL 

CARRIER

 >>A<<

2. OIL 

SEAL

 >>B<<

3. DRIVE PINION FRONT BEARING 

OUTER RACE

 >>C<<

4.  DRIVE PINION REAR BEARING 

OUTER RACE

 >>D<<

•

PINION HEIGHT ADJUSTMENT

 

 

5. DRIVE 

PINION

 

 

6.  DRIVE PINION FRONT SHIM (FOR 

PINION HEIGHT ADJUSTMENT)

 

 

7.  DRIVE PINION FRONT BEARING 

INNER RACE

 

 

8.  DRIVE PINION SPACER

 >>E<<

•

DRIVE PINION TURNING TORQUE 
ADJUSTMENT

 

 

9.  DRIVE PINION REAR SHIM (FOR 

TURNING TORQUE ADJUSTMENT)

 

 

10.  DRIVE PINION ASSEMBLY

 

  

ASSEMBLY 

STEPS 

(Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-48

NOTE: Specified torque with asterisks means that it 
is covered with oil.

Required Special Tools:

• MB990031 or MB990699: Drive Pinion Oil Seal 

Installer

• MB990326: Preload Socket

• MB990685: Torque Wrench

• MB990802: Bearing Installer

• MB990819: Drive Pinion Gauge Assembly

• MB990934: Installation Adapter

• MB990936: Installation Adapter

• MB990938: Bar

• MB990939: Brass Bar

• MB991170: Cylinder Gauge

 

 

11.  DRIVE PINION REAR BEARING INNER 

RACE

 

 

12. OIL SEAL

 

 

13. COMPANION FLANGE

 

 

14. WASHER

 

 

15. SELF-LOCKING NUT

 

 

16. DIFFERENTIAL CASE

 >>F<<

•

DIFFERENTIAL GEAR BACKLASH 
ADJUSTMENT

 

 

17.  SIDE GEAR SPACER

 

 

18. SIDE GEAR

 

 

19. PINION WASHER

 

 

20. PINION GEAR

 

 

21. PINION SHAFT

 >>G<<

22. LOCK PIN

 >>H<<

23. DRIVE GEAR

 >>I<<

24.  SIDE BEARING INNER RACE

 

 

25.  SIDE BEARING OUTER RACE

 >>J<<

•

DRIVE GEAR BACKLASH 
ADJUSTMENT

 

 

26.  SIDE BEARING SPACER

 

  

ASSEMBLY 

STEPS 

(Continued)

 

 

27.  DIFFERENTIAL CASE ASSEMBLY

 

 

29. COVER

 

 

30. DRAIN PLUG

 

 

31. FILLER PLUG

 

  

ASSEMBLY 

STEPS 

(Continued)