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Mitsubishi Montero (2004+). Manual - part 460

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-45

DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.

Limit: 0.05 mm (0.002 inch)

2. When runout exceeds the limit value, check for foreign

material between drive gear rear side and differential case,
or for loose drive gear installation bolts.

3. When step (2) gives normal results, reposition the drive gear

and differential case and remeasure.

4. If adjustment is impossible, replace the differential case, or

replace the drive gear and pinion as a set.

DIFFERENTIAL GEAR BACKLASH
1. 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 (0.007 inch)

Use the measurement procedure for both pinion gears.
2. If the backlash exceeds the limit, adjust by using the side

gear thrust spacers.

3. If adjustment is impossible, replace the side gear and pinion

gear as a set.

DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces

of the drive gear teeth.

2. Insert special tool MB990939 between the differential carrier

and the differential case, and then rotate the companion
flange by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque [approximately 2.5

− 3.0

⋅m (22.1 − 26.6 in-lb)] is applied to the drive pinion.

CAUTION

If the drive gear is rotated too much, the tooth contact pat-
tern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and drive

pinion.

AC102886

AC102885

WEDGE

SIDE GEAR
SPACER

ACX01037 AB

ACX01038 AB

MB990939

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

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NOTE: Check the tooth contact pattern to confirm that the
adjustments of the pinion height and backlash have been
done properly. Continue to adjust the pinion height and
backlash until the tooth contact pattern resembles the stan-
dard pattern. If, even after adjustments have been made, the
correct tooth contact pattern cannot be obtained, it means
that the drive gear and the drive pinion have become worn
beyond the allowable limit. Replace the gear set.

<<B>> DIFFERENTIAL CASE ASSEMBLY REMOVAL

CAUTION

When taking out the differential case assembly, be careful
not to drop and damage the bearing outer races.
NOTE: Keep the right and left side bearings and side bearing
adjusting spacers separate, so that they do not become mixed
during reassembly.

STANDARD TOOTH CONTACT PATTERN PROBLEM

SOLUTION

1. Narrow tooth side
2. Drive-side tooth surface (the side
applying power during forward movement)
3. Wide tooth side
4. Coast-side tooth surface (the side
applying power during reverse movement)

Tooth contact pattern resulting
from excessive pinion
height

The drive pinion is positioned too
far from the center of the drive
gear.

Increase the thickness of
the drive pinion rear shim,
and position the drive pinion
closer to the center of the
drive gear. Also, for
backlash adjustment,
position the drive gear
farther from the drive
pinion.

Tooth contact pattern resulting
from insufficient pinion
height.

The drive pinion is positioned too
close to the center of the drive
gear.

Decrease the thickness of
the drive pinion rear shim,
and position the drive pinion
farther from the center of
the drive gear. Also, for
backlash adjustment,
position the drive gear
closer to the drive pinion.

ACX01039 AF

AC107260

AC107261AB

AC107262

AC107263

ACX01040AB

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

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<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and MB990811 to pull out the side
bearing inner races.
NOTE: There are two notches provided (at the differential case
side) for the claw part of the special tools; use special tools
MB990810 and MB990811 at that position.

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

<<F>> DRIVE PINION ASSEMBLY REMOVAL

CAUTION

The mating mark made on the companion flange must not
be on the coupling surface of the flange yoke and the front
propeller shaft.
1. Make mating marks on the drive pinion and companion

flange.

AC102890AE

MB990810

MB990811

ACX01042AB

MATING
MARKS

ACX01043AB

MB990850

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FRONT AXLE

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2. Pull out the drive pinion together with special tool

MB990810.

<<G>> DRIVE PINION FRONT BEARING INNER RACE
REMOVAL
Use special tools MB990339 and MB990648 to pull out the
front bearing inner race.

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

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

ACX01044 AB

MB990810

COMPANION
FLANGE

ACX01045 AB

MB990339

MB990648

ACX01046AB

MB990939

ACX01047 AB

MB990939

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