Mitsubishi Montero (2004+). Manual - part 459

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-41

 <<B>> CLUTCH GEAR/BEARING REMOVAL
1. Use a press and steel plate to remove the clutch gear and 

bearing together.

2. Using a press, hold the supports against the bearing inner 

race, and separate the clutch gear and bearing.

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
Use special tool MB991168 to tap the oil seal until it is flush 
with the clutch housing.

.

 >>B<< BEARING/CLUTCH GEAR INSTALLATION
1. Use special tool MB990799 to press-fit the bearing to the 

shoulder of the clutch gear.

ACX01024 AB

METAL PLATE

ACX01025 AB

METAL PLATE

SUPPORT

ACX01026 AB

OIL SEAL

CLUTCH 
HOUSING

MB991168

ACX01027AB

MB990799

BEARING

CLUTCH 
GEAR

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-42

CAUTION

Place special tool MB990890 or MB990891 against the 
outer race of the bearing.
2. Use special tools MB990890 or MB990891 to press-fit the 

bearing to the side of the clutch housing.

.

>>C<<OIL SEAL INSTALLATION
Use special tools MB990926 and MB990938 To press-fit the oil 
seal to the clutch housing.

.

>>D<< SPRING PIN INSTALLATION
Tap the spring pin from the chamfered side of the shaft rod until 
the projection length becomes the length shown in the illustra-
tion.

.

>>E<< SPACER INSTALLATION
1. Place the current spacer in the area shown in the illustration 

to check that the dimensions shown in the illustration are 
within the standard values.

Standard Value (A): 0.05 

− 0.3 mm (0.002 − 0.012 inch)

2. If the dimensions are outside of the standard values, select 

the correct spacer type to fit in the standard values.
Spacer type 

ACX01028 AB

MB990890
OR
MB990891

CLUTCH 
HOUSING

ACX01029AC

OIL SEAL

MB990938

MB990926

CLUTCH 
HOUSING

ACX01030 AB

SPRING PIN

SHIFT ROD

0 – 1 mm
(0 – 0.03 in)

CHAMFER

Part Number Thickness 

mm (in)

Part Number Thickness 

mm (in)

MR111526

1.1 (0.04)

MR111530

2.1 (0.08)

AC101906AB

CLUTCH GEAR

MAIN SHAFT 
ASSEMBLY

SPACER

A

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-43

.

>>F<< BEARING INSTALLATION
Press-fit the bearing to the shoulder of the mainshaft.

DIFFERENTIAL CARRIER DISASSEMBLY

M1262002300124

MR111527

1.35 (0.05)

MR111531

2.35 (0.09)

MR111528

1.6 (0.06)

MR111532

2.6 (0.10)

MR111529

1.85 (0.07)

MR111533

2.85 (0.11)

Part Number Thickness 

mm (in)

Part Number Thickness 

mm (in)

ACX01031AB

MAIN SHAFT

ACX01032 AB

1

28

2

3

4

5

22

27

26

23

24

25

6

30

15 14

9

11

12

19

29

20

21

18

17

16

10 8

7

13

 

  

DISASSEMBLY 

STEPS

<<A>>  

•

INSPECTION BEFORE DISASSEMBLY

 

 

1. COVER

<<B>>  

2.  DIFFERENTIAL CASE ASSEMBLY

 

 

3.  SIDE BEARING SPACER

 

 

4.  SIDE BEARING OUTER RACE

<<C>>  

5.  SIDE BEARING INNER RACE

<<D>>  

6. DRIVE 

GEAR

<<E>>  

7. SELF-LOCKING 

NUT

 

 

8. WASHER

<<F>>  

9.  DRIVE PINION ASSEMBLY

 

 

10. COMPANION FLANGE

 

 

11.  DRIVE PINION SPACER

 

 

12.  DRIVE PINION REAR SHIM (FOR 

TURNING TORQUE ADJUSTMENT)

<<G>>  

13.  DRIVE PINION FRONT BEARING 

INNER RACE

 

 

14.  DRIVE PINION REAR SHIM (FOR 

PINION HEIGHT ADJUSTMENT)

 

 

 

DISASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-44

Required Special Tools:

• MB990810: Side Bearing Puller

• MB990811: Differential Side Bearing Cap

• MB990850: End Yoke Holder 

• MB990339: Bearing Puller

• MB990648: Bearing Remover

• MB990939: Bearing and Oil Seal Installer Set

• MB990909: Working Base

• MB991116: Adapter

DISASSEMBLY SERVICE POINTS

.

<<A>> INSPECTION BEFORE DISASSEMBLY
1. Remove the cover and gasket. 
2. Hold the special tools MB990909 and MB991116 in a vise, 

and install the differential carrier assembly to the special 
tool.

.

DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge to 

measure the drive gear backlash in four or more places on 
the drive gear. 

Standard value: 0.11 

− 0.16 mm (0.004 − 0.006 inch)

2. If the backlash is not within the standard value, adjust the 

drive gear backlash (Refer to 

P.26-49

).

3. After the adjustment, inspect the drive gear tooth contact.

.

 

 

15. DRIVE PINION

<<H>>  

16. OIL SEAL

<<H>>  

17.  DRIVE PINION REAR BEARING INNER 

RACE

<<H>>  

18.  DRIVE PINION REAR BEARING 

OUTER RACE

<<I>>  

19.  DRIVE PINION FRONT BEARING 

OUTER RACE

 

 

20. OIL SEAL

 

 

21. DIFFERENTIAL CARRIER

<<J>>  

22. LOCK PIN

 

 

23. PINION SHAFT

 

 

24. PINION GEAR

 

 

25. PINION WASHER

 

 

26. SIDE GEAR

 

 

27.  SIDE GEAR SPACER

 

 

28. FILLER PLUG

 

 

29. DRAIN PLUG

 

 

30. DIFFERENTIAL CASE

 

 

 

DISASSEMBLY STEPS (Continued)

AC102883AE

MB990909 
AND 
MB991116

ACX01034AB