Mitsubishi Montero (2002-2004). Manual - part 213

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-49

LUBRICATION, SEALING AND ADHESIVE POINTS

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
Use special tools MB990938 and MB990934 to insert the oil 
seal, and then apply a thin coat of multipurpose grease to the 
lip of the oil seal.

AC102455

(APPLY ALL 
AROUND LIP)

φ

 2 - 3 mm

φ

 0.08 - 0.12 in

AB

(APPLY ALL 
AROUND 
LIP)

SEALANT:

     3M

TM

 AAD PART NO.8672, 8679, 

     8678, 8661, 8663 OR EQUIVALENT

ADHESIVE:

      3M

TM

 AAD PART NO.8730,

      8731 OR EQUIVALENT

ACX01051AB

OIL SEAL

MB990938

MB990934

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-50

.

>>B<< DRIVE PINION FRONT BEARING OUTER RACE 
INSTALLATION
Use special tools MB990938 and MB990936 to press-fit the 
drive pinion front bearing outer races into the gear carrier.

.

>>C<< DRIVE PINION REAR BEARING OUTER RACE 
INSTALLATION
Use special tools MB990938 and MB990934 to press-fit the 
drive pinion rear bearing outer races into the gear carrier.

.

>>D<< PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special tool.
2. Install the special tool, drive pinion front and rear bearing 

inner races to the gear carrier.

ACX01052AB

MB990938

MB990936

ACX01053 AB

MB990938

MB990934

ACX01054AB

MB990819

WASHER

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TSB Revision

FRONT AXLE

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3. Tighten the nut of special tool MB990819 while measuring 

the turning torque of the drive pinion. Gradually keep 
tightening the nut of special tool MB990819 until the turning 
torque of the drive pinion (without oil seal) is at the standard 
value.

Standard value: (Without oil seal)

NOTE:  The special tool cannot be turned a full revolution, 
so turn it several times within the range of movement to run 
in the bearing, and then measure the turning torque.

4. Clean the side bearing hub.

5. Install special tools MB991170 and MB990819 to the side 

bearing hub of the gear carrier, and then install the bearing 
cap.
NOTE: Always check that the notch is in the shown position 
and that special tools are touching firmly against the side 
bearing hub.

6. Use a thickness gauge to measure the clearance (A) 

between special tools MB991170 and MB990819.

7. Remove special tools (MB991170, MB990819).

8. Use a micrometer to measure the special tool in the places 

(B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge and 

micrometer to measure the inside diameter (D) of the 
bearing cap as shown in the illustration.

10.Calculate the thickness (E) of the required drive pinion front 

shim by the following formula, and then select a shim which 
most closely matches this thickness. E = A + B + C-1/2D-
100.0 mm (3.94 inches)

BEARING 
DIVISION

BEARING 
LUBRICATION

TURNING TORQUE

New

None (with anti-
rust agent)

0.83 

− 1.19 N⋅m 

(7.35 

− 10.53 in-lb)

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

ACX01057AB

THICKNESS GAUGE

MB990819

A

MB991170

NOTCH

ACX01058AB

MB991534

B

C

ACX01059AB

BEARING CAP

D

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TSB Revision

FRONT AXLE

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11.Fit the selected drive pinion front shim(s) to the drive pinion, 

and press-fit the drive pinion front bearing inner race by 
using special tool MB990802.

.

>>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT
Adjust the drive pinion rotation torque by using the following 
procedure:
1. Insert the drive pinion into the gear carrier, and then install 

the drive pinion spacer, the drive pinion rear shim, the drive 
pinion rear bearing inner race, and the companion flange in 
that order.
NOTE:  Do not install the oil seal.

2. Tighten the companion flange to the specified torque by 

using special tool MB990850.

3. Measure the drive pinion turning torque (without the oil seal) 

by using special tools MB990685 and MB990326.

Standard value: (Without oil seal)

4. If the drive pinion turning torque is not within the range of the 

standard value, adjust the preload by replacing the drive 
pinion rear shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion rear shims, if the 
number of shims is large, reduce the number of shims to a 
minimum by selecting the drive pinion spacers. Also, select 
the drive pinion spacer from the following two types.

ACX01060AB

DRIVE 
PINION
FRONT 
SHIM

MB990829

MB990829

BEARING 
DIVISION

BEARING 
LUBRICATION

TURNING 
TORQUE

New

None (with anti-
rust agent)

0.83 

− 1.19 N⋅m 

(7.35 

− 10.53 in-lb)

DRIVE PINION SPACER 
HEIGHT mm (in)

IDENTIFICATION COLOR

56.67 (2.231)

White

57.01 (2.244)

−

ACX01061AB

MB990850

216 

± 

29 N

•

m

159 

± 

22 ft-m

ACX01062AB

MB990326

MB990685

ACX01063 AB

IDENTIFICATION

COLOR