Mitsubishi Montero (2002-2004). Manual - part 224

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-29

<<D>> DRIVE GEAR REMOVAL
1. Make 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>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.

.

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

.

<<G>> DRIVE PINION ASSEMBLY/COMPANION FLANGE 
REMOVAL

CAUTION

Do not make mating marks on the contact surfaces of the 
companion flange and propeller shaft.
1. Make mating marks to the drive pinion and companion 

flange.

ACX01042AB

MATING 
MARKS

ACX01048AB

PUNCH

ACX01043AB

MB990850

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-30

2. Use special tool MB990810 to pull out the companion 

flange.

.

<<H>> DRIVE PINION REAR BEARING INNER RACE 
REMOVAL
Use special tool MD998801 to pull out the front bearing inner 
race.

.

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

.

<<J>> DRIVE PINION REAR BEARING OUTER RACE 
REMOVAL
Use special tool MB990939 to remove the drive pinion rear 
bearing outer race.

ACX01044 AB

MB990810

COMPANION
FLANGE

ACX02423

MD998801

AB

ACX01101AB

DRIVE PINION 
FRONT BEARING 
OUTER RACE

DRIVE PINION 
FRONT
BEARING 
OUTER RACE

OIL SEAL

DRIVE PONION 
REAR BEARING 
OUTER RACE

MB990939

ACX01102 AB

MB990939

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-31

ASSEMBLY

M1272002300125

AC203534AB

35 ± 5 N·m
25 ± 4 ft-lb

15

5

23

17

18

20

20

18 17

FINAL DRIVE GEAR SET

DIFFERENTIAL GEAR SET

12

32

2

31

15

14 13

19

20

26 25

24

17

18

21

20

27

29

30

18

11

4

1

28

9

8

7

10

3

6 5

26

25

24

23

17

N

N

N

N

N

N

N

N

152 ± 15 N·m
112 ± 10 ft-lb

74 ± 5 N·m
55 ± 3 ft-lb

49 ± 9 N·m
37 ± 6 ft-lb

63 ± 4 N·m
47 ± 2 ft-lb

216 ± 29 N·m
159 ± 22 ft-lb

22

19

16

N

ASSEMBLY STEPS

1. DIFFERENTIAL CARRIER

>>A<<

2. OIL SEAL

>>B<<

3. DRIVE PINION REAR BEARING 

OUTER RACE

>>C<<

4. DRIVE PINION FRONT BEARING 

OUTER RACE

>>D<<

• DRIVE PINION HEIGHT 

ADJUSTMENT

5. DRIVE PINION
6. DRIVE PINION REAR SHIM (FOR 

ADJUSTING DRIVE PINION 
HEIGHT)

7. DRIVE PINION REAR BEARING 

INNER RACE

8. DRIVE PINION SPACER

>>E<<

• DRIVE PINION TURNING TORQUE 

ADJUSTMENT

9. DRIVE PINION FRONT SHIM (FOR 

ADJUSTING DRIVE PINION 
PRELOAD)

10. DRIVE PINION ASSEMBLY
11. DRIVE PINION FRONT BEARING 

INNER RACE

>>E<<

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
26. SIDE BEARING SHIM
27. DIFFERENTIAL CASE ASSEMBLY

>>J<<

28. BEARING CAP
29. VENT PLUG
30. DIFFERENTIAL COVER
31. DRAIN PLUG
32. FILLER PLUG

>>J<<

• FINAL DRIVE GEAR BACKLASH 

ADJUSTMENT

ASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-32

Required Special Tools:

• MB991168: Drive Pinion Oil Seal Installer

• MB990938: Bar

• MB991445: Bushing Remover and Installer Base

• MB990934: Installer Adapter

• MB991770: Head

• MB990819: Drive Pinion Gauge

• MB990326: Preload Socket

• MB990685: Torque Wrench

• MB991169: Drive Pinion Gauge

• MB991534: Cylinder Gauge

• MB990802: Bearing Installer

• MB990850: End Yoke Holder

• MB990727: Drive Pinion Oil Seal Installer

• MD998812: Installer Cap

• MD998829: Installer Adapter

• MB990810: Side Bearing Puller

• MB991407: Differential Rear Support Arbor

LUBRICATION AND ADHESIVE POINTS

ACX01104 AC

2    3 mm (0.08    0.12 in)
(BEAD DIAMETER)

–

–

TM

TM

ADHESIVE: 
3M     PART NO. 8730, 
8731 OR EQUIVALENT

SEMI-DRYING SEALANT: 
3M     AAD PART NO. 8672, 8679,
8678, 8661, 8663 OR EQUIVALENT