Mitsubishi Montero (2004+). Manual - part 458

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-37

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

REMOVAL AND INSTALLATION

M1262001800074

Pre-removal and Post-installation Operation
• Under Cover Removal and Installation

• Skid Plate Removal and Installation (Refer to GROUP 51- 

Front Bumper 

P.51-3

).

• Gear Oil Draining and Refill (Refer to 

P.26-15

).

• Driveshaft Removal and Installation (Refer to 

P.26-24

).

• Inner Shaft Removal and Installation (Refer to 

P.26-32

).

AC309396AB

8

2

7

6

5

9

2

10

11

1

4

4

3

12

9

11

69 

± 9 N

·

m *

51 

± 7 ft-lb *

25 

± 5 N

·

m

22 

± 4 ft-lb

69 

± 9 N

·

m *

51 

± 7 ft-lb *

128 

± 9 N

·

m

  94 

± 7 ft-lb

89 

± 9 N

·

m

65 

± 7 ft-lb

59 

± 9 N

·

m

43 

± 7 ft-lb

60 

± 10 N

·

m

45 

± 7 ft-lb

69 

± 9 N

·

m *

51 

± 7 ft-lb *

90 

± 10 N

·

m

67 

± 7 ft-lb

SEALANT:

     3M

TM

 AAD PART NO.8672, 8679,

     8678, 8661, 8663 OR EQUIVALENT

 

  

REMOVAL 

STEPS

<<A>>  

>>B<<

1.  FRONT PROPELLER SHAFT 

CONNECTION

 

 

2.  FRONT FRAME AND DIFFERENTIAL 

MOUNTING BRACKET 
CONNECTION

 

 

3. FRONT FRAME AND NO.2 

CROSSMEMBER ASSEMBLY 
CONNECTION

 

 

4. VACUUM 

HOSE

 

 

5. COLLAR

<<B>>   

6. PIN

 

 

7. FREEWHEEL 

ENGAGE 

SWITCH 

CONNECTION

 

>>A<<

8. DIFFERENTIAL 

MOUNTING 

BRACKET <RH> AND HOUSING 
TUBE ASSEMBLY

 

 

9.  FREEWHEEL CLUTCH ASSEMBLY

 

>>A<< 

10. DIFFERENTIAL MOUNTING 

BRACKET <LH>

 

 

 

REMOVAL STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-38

REMOVAL SERVICE POINTS

.

<<A>> FRONT PROPELLER SHAFT REMOVAL

CAUTION

• Be careful not to damage joint boot by crimping with 

the bent propeller shaft joint.

• Hang propeller shaft with wires to prevent it from fall-

ing.

Make mating marks on the flange yoke and the differential car-
rier companion flange. Remove the front propeller shaft.

.

<<B>> PIN REMOVAL
1. Remove one side of dust cover mounting part on the 

vacuum actuator assembly.

2. Match a pin with a pin hole and remove the pin with a punch.

 

 

11. DIFFERENTIAL CARRIER

 

 

12.  NO.2 CROSSMEMBER ASSEMBLY

 

 

 

REMOVAL STEPS (Continued)

AC000430AB

JOINT ASSEMBLY (BJ)

CLOTH

PROPELLER
SHAFT

JOINT BOOT

ACX01018 AB

MATING 
MARKS

ACX01019 AB

COLLAR

DUST COVER

PIN

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-39

INSTALLATION SERVICE POINTS

.

>>A<< DIFFERENTIAL MOUNTING BRACKET ASSEMBLY
Tighten differential mounting insulator in the order of A, B, C, D 
or A, C, B, D as shown, in the left diagram.

.

>>B<< FRONT PROPELLER SHAFT INSTALLATION

CAUTION

Remove grease from fastener threads before tightening. 
Fastener threads covered with oily products could become 
loose.
Install the front propeller shaft so that the mating marks of the 
flange yoke and the differential carrier companion flange are 
aligned.

DIFFERENTIAL CARRIER AND FREE 
WHEELING CLUTCH INSPECTION

INSPECTION

M1262001900048

FREEWHEEL ENGAGE SWITCH CHECK

ACX01020 AB

C

B

D

A

SHAFT(SWITCH)
POSITION

TESTER 
CONNECTION

SPECIFIED 
CONDITION

PRESSED(ON)

1-2

Less than 2 ohms

RELEASED(OFF) -

Open circuit

ACX01021AB

OFF

ON

1 2

BALL

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-40

FREE WHEELING CLUTCH DISASSEMBLY AND ASSEMBLY

M1262002900074

Required Special Tools:

• MB990560: Bearing Remover

• MB990799: Ball Joint Remover and Installer

• MB990890 or MB990891: Rear Suspension 

Bushing Base

• MB990926: Bearing and Oil Seal Installer Set

• MB990938: Bearing and Oil Seal Installer Set

• MB991168: Differential Oil Seal Installer

DISASSEMBLY SERVICE POINTS

.

<<A>> MAIN SHAFT/BEARING REMOVAL
1. After special tool MB990560 has been installed as shown, 

tighten the nut of special tool MB990560 until portion "A" of 
special tool MB990560 touches the bearing outer race.

CAUTION

Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing.

.

AC101907AB

12

10

9

12

11

10

4

13

7

3

2

1

6

5

8

9

FREE WHEELING CLUTCH 
DISASSEMBLY STEPS

<<A>>

1.

MAIN SHAFT ASSEMBLY

<<A>>

>>F<<

2.

BEARING

>>E<<

3.

SPACER

4.

CLUTCH SLEEVE

>>D<<

5.

SPRING PIN

6.

SNAP RING

7.

SHIFT FORK

8.

SHIFT ROD

>>C<<

9.

OIL SEAL

<<B>>

>>B<<

10. CLUTCH GEAR

<<B>>

>>B<<

11. BEARING

>>A<<

12. OIL SEAL
13. CLUTCH HOUSING

FREE WHEELING CLUTCH 
DISASSEMBLY STEPS 
(Continued)

ACX01023 AB

A

MB990560