Mitsubishi Montero (2002-2004). Manual - part 223

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-25

REMOVAL SERVICE POINTS

.

<<A>> KNUCKLE AND LOWER ARM DISCONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to remove the lower arm mounting 
bolt by compressing the coil spring.

.

<<B>> DIFFERENTIAL CARRIER ASSEMBLY REMOVAL
Support the differential carrier assembly lower part by jacking 
to remove the joint bolt and the differential carrier assembly.

INSTALLATION SERVICE POINT

.

>>A<< KNUCKLE AND LOWER ARM CONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to install the lower arm mounting 
bolt by compressing the coil spring.

ACX01086 AB

WOODEN 
BLOCK

ACX01086 AB

WOODEN 
BLOCK

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-26

REAR SUSPENSION CROSSMEMBER BUSHING 
(FOR REAR DIFFERENTIAL MOUNT) 
REPLACEMENT

1. Remove the rear differential.
2. Use special tools MB991050, MB991218, MB991162 and 

MB991816 to remove the bushing.
NOTE: When removing the bushing, insert special tool 
MB991162 from the forward of vehicle and fix the nut with a 
wrench.

3. Use special tools MB991816, MB991218, MB991162 and 

MB990955 to press-fit the bushing.
NOTE: When installing the bushing, insert special tool 
MB991162 from the forward of vehicle and fix the nut with a 
wrench. Press-fit the bushing until the bushing end face is 
flush with the rear suspension crossmember.

4. Install the rear differential.

AC206040

REAR 
SUSPENSION
CROSSMEMBER

MB991050

WRENCH

BUSHING

MB991050

NUT

REAR 
SUSPENSION
CROSSMEMBER

MB991162

MB991816

MB991218

AB

AC206041

MB991050

WRENCH

BUSHING

MB991050

NUT

REAR 
SUSPENSION
CROSSMEMBER

MB991162

MB991816

MB991218

AB

REAR 
SUSPENSION
CROSSMEMBER

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-27

DISASSEMBLY

M1272002200117

CAUTION

Do not disassemble the limited slip differential case assembly.

AC203533 AB

1

2

20

22

23

24

30

25 26

7

9

8

17

10

16

15

18

19

21

27

28

29

32

5

13

14

7 8

9

1615

16

4

13

12

11

14

3

31

N

N

N

N

N

N

N

N

N

DISASSEMBLY STEPS

<<A>>

• INSPECTION BEFORE 

DISASSEMBLY

1. FILLER PLUG
2. DRAIN PLUG
3. DIFFERENTIAL COVER
4. VENT PLUG
5. BEARING CAP

<<B>>

6. DIFFERENTIAL CASE ASSEMBLY

<<B>>

7. DIFFERENTIAL SIDE SHIM

<<B>>

8. SIDE BEARING OUTER RACE

<<C>>

9. SIDE BEARING INNER RACE

<<D>>

10. DRIVE GEAR

<<E>>

11. LOCK PIN
12. PINION SHAFT
13. PINION GEAR
14. PINION WASHER
15. SIDE GEAR
16. SIDE GEAR SPACER
17. DIFFERENTIAL CASE

<<F>>

18. SELF-LOCKING NUT
19. WASHER

<<G>>

20. DRIVE PINION ASSEMBLY

<<G>>

21. COMPANION FLANGE
22. DRIVE PINION FRONT SHIM (FOR 

ADJUSTING PRELOAD OF DRIVE 
PINION)

23. DRIVE PINION SPACER

<<H>>

24. DRIVE PINION REAR BEARING 

INNER RACE

25. DRIVE PINION REAR SHIM (FOR 

ADJUSTING DRIVE PINION 
HEIGHT)

26. DRIVE PINION

<<I>>

27. OIL SEAL

<<I>>

28. DRIVE PINION FRONT BEARING 

INNER RACE

<<I>>

29. DRIVE PINION FRONT BEARING 

OUTER RACE

<<J>>

30. DRIVE PINION REAR BEARING 

OUTER RACE

31. OIL SEAL
32. DIFFERENTIAL CARRIER

DISASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-28

Required Special Tools:

• MB990810: Side Bearing Puller

• MB991407: Differential Rear Support Arbor

• MB990850: End Yoke Holder

• MD998801: Bearing Remover

• MB990939: Brass Bar

DISASSEMBLY SERVICE POINTS

.

<<A>> INSPECTION BEFORE DISASSEMBLY
Except for the following standard values, inspection procedure 
is the same as GROUP 26, inspection before disassembly 

P.26-41

.

DRIVE GEAR BACKLASH

Standard value: 0.13 

− 0.18 mm (0.005 − 0.007 inch)

DIFFERENTIAL GEAR BACKLASH

Standard value: 0 

− 0.076 mm (0 − 0.003 inch)

Limit: 0.07mm (0.007 inch)

.

<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL 
SIDE SHIM/SIDE BEARING OUTER RACE REMOVAL

CAUTION

When taking out the differential case assembly, be careful 
not to drop and damage the differential side shims or the 
side bearing outer races.
Use the wooden handle of a hammer to remove the differential 
case assembly, differential side shims and side bearings.
NOTE: Keep the right and left side bearings and side bearing 
outer race separated, so that they do not become mixed during 
assembly.

.

<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and MB991407 to pull out the side 
bearing inner race.
NOTE: Attach the prongs of special tools to the inner race of 
the side bearing through the openings in the differential case.

.

ACX02422

ACX01041AB

MB990810

MB991407