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Mitsubishi Montero (2002-2004). Manual - part 226

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-37

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

verify that the drive pinion turning torque complies with the
standard value.

Standard value:

8. If the turning torque is not within the standard value, check

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

>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear thrust spacers, pinion

gears, and pinion washers into the differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not assemble the thrust block and lock pin yet.

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

lock the side gear.

4. While locking the side gear with the wedge, 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 (0.01 inch)

5. Measure by the same procedure for the other pinion gear.
6. If the backlash exceeds the limit value, replace side bearing

adjustment spacers.

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

pinion gears as a set.

8. Check that the backlash is within the limit value and that the

differential gear turns smoothly.

BEARING
DIVISION

COMPANION
FLANGE
LUBRICATION

TURNING
TORQUE

New

None (with anti-rust
agent)

2.03

− 2.34 N⋅m

18.0

− 20.7 in-lb

Gear oil applied

2.10

− 2.40 N⋅m

18.6

− 21.2 in-lb

ACX01062AB

MB990326

MB990685

ACX01066

AC102885

WEDGE

SIDE GEAR
SPACER

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-38

>>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 on both sides.

>>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 tap (M10 x 1.25). Clean the
threaded holes by applying compressed air.

3. Apply 3M

ä stud locking 4170 or equivalent to the threaded

holes of the drive gear.

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: 152

± 15 N⋅m (112 ± 10 ft-lb)

>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tools MD998812 and MD998829 to press-fit the
side bearing inner races into the differential case.

ACX02429

ACX01068AB

TAP

ACX02430

ACX02431AB

MD998812

MD998829

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-39

>>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR
BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Assemble the differential case with the side bearing outer

race to the gear carrier.

2. Press the differential case to one side to measure the

clearance of the side bearing outer race and the gear carrier.

3. Select two pairs of side bearing spacer. Determine the

thickness by adding 1/2 of the clearance to the pre-load
0.05mm (0.002 inch).

4. Remove the side bearing, using special tools MB990810

and MB991407.
NOTE: Hook the claws of the special tool MB990810 with
the side bearing inner race by using the notches (two areas)
of the differential case side.

5. Assemble the selected side bearing spacers to each side.

6. Use special tool MB990802 to press-fit the side bearing

inner case into the differential case. After installing the outer
race, assemble the differential case to the gear carrier.

7. Align the mating marks of differential carrier and the bearing

cap with each other and tighten to the specified torque.

Tightening torque: 74

± 5 N⋅m (55 ± 3 ft-lb)

8. Measure the drive gear backlash.

NOTE: Measure at four points or more on the circumference
of the drive gear.

Standard value: 0.13

− 0.18 mm (0.005 − 0.007 inch)

ACX01071

ACX01041AB

MB990810

MB991407

ACX02432

DRIVE
PINION
REAR
SHIM

MB990802

ACX01034

SPECIFICATIONS

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REAR AXLE

27-40

9. If the backlash is not within the standard value, move the

side bearing spacer as shown in the illustration to adjust the
backlash.
NOTE: The increment of side bearing spacer must be the
same as the decreased amount.

10.Inspect the tooth condition at the final drive gear and adjust

if required. (Refer to GROUP 26, Inspection Before
Disassembly

P.26-41

11.Measure the drive gear runout.

Limit: 0.05 mm (0.002 inch)

12.If drive gear runout exceeds the limit, remove the differential

case and then the drive gears, moving them to different
positions and reinstall them.

13.If adjustment is not possible, replace the differential case or

drive gear and drive pinion as a set.

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1271004000257

ACX02433AB

WHEN THE BACKLASH IS SMALL

WHEN THE BACKLASH IS LARGE

DECREASED

INCREASED

ACX01036

ITEM

SPECIFICATION

Rear axle hub assembly, drive shaft assembly
Backing plate bolt

133

± 14 N⋅m (98 ± 10 ft-lb)

Lower arm and knuckle connection nut

152

± 25 N⋅m (113 ± 18 ft-lb)

Rear brake caliper bolt

100

± 10 N⋅m (74 ± 7 ft-lb)

Rear drive shaft and companion shaft connection nut

113

± 14 N⋅m (84 ± 10 ft-lb)

Rear drive shaft nut

255

± 29 N⋅m (188 ± 21 ft-lb)

Knuckle
Toe-control arm and knuckle connection nut

± 7 N⋅m (50 ± 5 ft-lb)

Trailing arm and knuckle connection bolt

231

± 34 N⋅m (170 ± 25 ft-lb)

Upper arm and knuckle connection nut

150

± 30 N⋅m (111 ± 22 ft-lb)

Differential carrier assembly
Bearing cap bolt

± 5 N⋅m (55 ± 3 ft-lb)

Differential cover bolt

± 5 N⋅m (25 ± 4 ft-lb)

Dynamic damper bolt

± 12 N⋅m (61 ± 9 ft-lb)

Drain plug

± 4 N⋅m (47 ± 2 ft-lb)

Drive gear bolt

152

± 15 N⋅m (112 ± 10 ft-lb)

Drive pinion self-locking nut

216

± 29 N⋅m (159 ± 22 ft-lb)

Filler plug

± 9 N⋅m (37 ± 6 ft-lb)

Lower arm and knuckle connection nut

152

± 25 N⋅m (113 ± 18 ft-lb)

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