Mitsubishi Montero (2004+). Manual - part 461

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-49

<<J>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.

ASSEMBLY

M1262002500151

ACX01048AB

PUNCH

AC204225AB

83 

± 5 N

·

m

62 

± 3 ft-lb

18 

± 3 N

·

m

13 

± 2 ft-lb

50 

± 10 N

·

m

37 

± 7 ft-lb

216 

± 29 N

·

m

159 

± 22 ft-lb

65 

± 5 N

·

m

48 

± 4 ft-lb

59 

± 5 N

·

m *

44 

± 3 ft-lb *

28

30

27

16

23

19

20 21

17

18 22

24

25 26

5 6

7

8

9

10

29

2

1

4

11

12

14

13

15

23

5

15

17

17

18

18

20

20

3

DIFFERENTIAL GEAR SET

FINAL DRIVE GEAR SET

 

  

ASSEMBLY 

STEPS

 

 

1. DIFFERENTIAL 

CARRIER

 

>>A<<

2. OIL 

SEAL

 

>>B<<

3. DRIVE PINION FRONT BEARING 

OUTER RACE

 

>>C<<

4.  DRIVE PINION REAR BEARING 

OUTER RACE

 

>>D<<

•

PINION HEIGHT ADJUSTMENT

 

 

5. DRIVE 

PINION

 

 

6.  DRIVE PINION FRONT SHIM (FOR 

PINION HEIGHT ADJUSTMENT)

 

 

7.  DRIVE PINION FRONT BEARING 

INNER RACE

 

 

8.  DRIVE PINION SPACER

 

>>E<<

•

DRIVE PINION TURNING TORQUE 
ADJUSTMENT

 

 

9.  DRIVE PINION REAR SHIM (FOR 

TURNING TORQUE ADJUSTMENT)

 

 

10.  DRIVE PINION ASSEMBLY

 

  

ASSEMBLY 

STEPS 

(Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-50

NOTE: Specified torque with asterisks means that it 
is covered with oil.

Required Special Tools:

• MB990031 or MB990699: Drive Pinion Oil Seal 

Installer

• MB990326: Preload Socket

• MB990685: Torque Wrench

• MB990802: Bearing Installer

• MB990819: Drive Pinion Gauge Assembly

• MB990934: Installation Adapter

• MB990936: Installation Adapter

• MB990938: Bar

• MB990939: Brass Bar

• MB991170: Cylinder Gauge

• MB990850: End Yoke Holder

• MB990813: Tap

 

 

11.  DRIVE PINION REAR BEARING INNER 

RACE

 

 

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

 

>>J<<

•

DRIVE GEAR BACKLASH 
ADJUSTMENT

 

 

26.  SIDE BEARING SPACER

 

 

27.  DIFFERENTIAL CASE ASSEMBLY

 

  

ASSEMBLY 

STEPS 

(Continued)

 

 

28. COVER

 

 

29. DRAIN PLUG

 

 

30. FILLER PLUG

 

  

ASSEMBLY 

STEPS 

(Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-51

LUBRICATION, SEALING AND ADHESIVE POINTS

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
Use special tools MB990938 and MB990934 to insert the oil 
seal, and then apply a thin coat of multipurpose grease to the 
lip of the oil seal.

AC102455

(APPLY ALL 
AROUND LIP)

φ 2 - 3 mm

φ 0.08 - 0.12 in

AB

(APPLY ALL 
AROUND 
LIP)

SEALANT:

     3M

TM

 AAD PART NO.8672, 8679, 

     8678, 8661, 8663 OR EQUIVALENT

ADHESIVE:

      3M

TM

 AAD PART NO.8730,

      8731 OR EQUIVALENT

ACX01051AB

OIL SEAL

MB990938

MB990934

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-52

.

>>B<< DRIVE PINION FRONT BEARING OUTER RACE 
INSTALLATION
Use special tools MB990938 and MB990936 to press-fit the 
drive pinion front bearing outer races into the gear carrier.

.

>>C<< DRIVE PINION REAR BEARING OUTER RACE 
INSTALLATION
Use special tools MB990938 and MB990934 to press-fit the 
drive pinion rear bearing outer races into the gear carrier.

.

>>D<< PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedure.
1. Apply multipurpose grease to the washer of the special tool.
2. Install the special tool, drive pinion front and rear bearing 

inner races to the gear carrier.

ACX01052AB

MB990938

MB990936

ACX01053 AB

MB990938

MB990934

ACX01054 AB

MB990819

WASHER