Mitsubishi Montero (2002-2004). Manual - part 214

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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26-53

NOTE: Apply gear oil around the circumference of compan-
ion flange (and the mating surface of oil seal) when press fit-
ting oil seal into companion flange.

5. Remove the companion flange and drive pinion again. Then,

after inserting the drive pinion rear bearing inner race into
the gear carrier, use special tool MB990031 or MB990699 to
press-fit the oil seal.

6. Install the drive pinion assembly and companion flange with

the mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified torque by
using special tool MB990850.

7. Measure the drive pinion turning torque (with the oil seal) by

using special tools.

Standard value: (With oil seal)

8. If the drive pinion turning torque is not within the standard

value, check the tightening torque of the companion flange
self-locking nut and the oil seal.

>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
1. Assemble the side gears, side gear spacers, pinion gears

and pinion washers into the differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not drive in the lock pin yet.

BEARING
DIVISION

BEARING
LUBRICATION

TURNING TORQUE

New

None (with anti-
rust agent)

0.93

− 1.28 N⋅m (8.24 −

11.32 in-lb)

Gear oil applied

0.97

− 1.32 N⋅m (8.59 −

11.68 in-lb)

ACX01064AB

MB990031
OR
MB990699

ACX01065AB

MB990850

216

29 N

•

159

22 ft-lb

ACX01062AB

MB990326

MB990685

ACX01066AB

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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3. Insert a wedge between the side gear and the pinion shaft to

lock the side gear.

4. Measure the differential gear backlash with a dial indicator

on the pinion gear.

Standard value: 0

− 0.076 mm (0 − 0.0030 inch)

Limit: 0.2 mm (0.007 inch)

5. If the differential gear backlash exceeds the limit, adjust the

backlash by installing thicker side gear spacers.

6. If adjustment is not possible, replace the side gears and

pinion gears as a set.

7. Measure the differential gear backlash once again, and

confirm that it is within the limit.

>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the differential case

lock pin hole, and drive in the lock pin.

2. Stake the lock pin with a punch at two points.

>>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 special tool MB990813 (tap M10 x
1.25), and then clean the threaded holes by applying
compressed air.

3. Apply the specified adhesive to the threaded holes of the

drive gear.

Specified adhesive: 3M

ä AAD Part number 8730, 8731

or equivalent

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: 83

± 5 N⋅m (62 ± 3 ft-lb)

AC102885

WEDGE

SIDE GEAR
SPACER

ACX01067AB

ACX01068AB

TAP

AC000438 AB

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>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tool MB990802 to press-fit the side bearing inner
races into the differential case.

>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than

those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE: Select side bearing spacers with the same thickness
for both the drive pinion side and the drive gear side.

2. Push the differential case assembly to one side, and

measure the clearance between the gear carrier and the
side bearing adjusting spacer with a feeler gauge.

3. Measure the thickness of the side bearing adjusting spacers

on one side, select two pairs of spacers which correspond to
that thickness plus one half of the clearance plus 0.05 mm
(0.002 inch), and then install one pair each to the drive
pinion side and the drive gear side.

ACX01069AB

MB990829

PIECE
OF
METAL

MB990829

PIECE OF
METAL

ACX01070AB

ACX01071AB

ACX01072 AB

CLEARANCE / 2 + 0.05 mm
= THICKNESS OF THE
SPACER ON ONE SIDE

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4. Install the side bearing adjusting spacers and differential

case assembly, as shown in the illustration, to the gear
carrier.

5. Tap the side bearing adjusting spacers with the special tool

to fit them to the side bearing outer race.

6. Align the mating marks on the gear carrier and the bearing

cap, and then tighten the bearing cap.

7. With the drive pinion locked in place, measure the drive gear

backlash with a dial indicator on the drive gear.
NOTE: Measure at four points or more on the circumference
of the drive gear.

Standard value: 0.11

− 0.16 mm (0.004 − 0.006 inch)

8. Change the side bearing adjusting spacers as illustrated,

and then adjust the drive gear backlash between the drive
gear and the drive pinion.
NOTE: When increasing the number of side bearing adjust-
ing spacers, use the same number for each, and as few as
possible.

9. Check the drive gear and drive pinion for tooth contact. If

poor contact is evident, make adjustment. (Refer to

P.26-

ACX01070AB

ACX01073 AB

MB990939

ACX01074AB

ACX01034AB

ACX01075

IF BACKLASH IS TOO SMALL

IF BACKLASH IS TOO LARGE

THINNER
SPACER

THICKER
SPACER

THINNER
SPACER

THICKER
SPACER

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