Mitsubishi Montero (2004+). Manual - part 462

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-53

3. Tighten the nut of special tool MB990819 while measuring

the turning torque of the drive pinion. Gradually keep
tightening the nut of special tool MB990819 until the turning
torque of the drive pinion (without oil seal) is at the standard
value.

Standard value: (Without oil seal)

NOTE: The special tool cannot be turned a full revolution,
so turn it several times within the range of movement to run
in the bearing, and then measure the turning torque.

4. Clean the side bearing hub.

5. Install special tools MB991170 and MB990819 to the side

bearing hub of the gear carrier, and then install the bearing
cap.
NOTE: Always check that the notch is in the shown position
and that special tools are touching firmly against the side
bearing hub.

6. Use a thickness gauge to measure the clearance (A)

between special tools MB991170 and MB990819.

7. Remove special tools (MB991170, MB990819).

8. Use a micrometer to measure the special tool in the places

(B, C) shown in the illustration.

9. Install the bearing cap, and then use a cylinder gauge and

micrometer to measure the inside diameter (D) of the
bearing cap as shown in the illustration.

10.Calculate the thickness (E) of the required drive pinion front

shim by the following formula, and then select a shim which
most closely matches this thickness. E = A + B +
C-1/2D-100.0 mm (3.94 inches)

BEARING
DIVISION

BEARING
LUBRICATION

TURNING TORQUE

New

None (with
anti-rust agent)

0.83

− 1.19 N⋅m

(7.35

− 10.53 in-lb)

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

ACX01057 AB

THICKNESS GAUGE

MB990819

MB991170

NOTCH

ACX01058AF

MB991170

ACX01059AB

BEARING CAP

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-54

11.Fit the selected drive pinion front shim(s) to the drive pinion,

and press-fit the drive pinion front bearing inner race by
using special tool MB990802.

>>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT
Adjust the drive pinion rotation torque by using the following
procedure:
1. Insert the drive pinion into the gear carrier, and then install

the drive pinion spacer, the drive pinion rear shim, the drive
pinion rear bearing inner race, and the companion flange in
that order.
NOTE: Do not install the oil seal.

2. Tighten the companion flange to the specified torque by

using special tool MB990850.

3. Measure the drive pinion turning torque (without the oil seal)

by using special tools MB990685 and MB990326.

Standard value: (Without oil seal)

4. If the drive pinion turning torque is not within the range of the

standard value, adjust the preload by replacing the drive
pinion rear shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion rear shims, if the
number of shims is large, reduce the number of shims to a
minimum by selecting the drive pinion spacers. Also, select
the drive pinion spacer from the following two types.

ACX01060AD

DRIVE
PINION
FRONT
SHIM

MB990802

BEARING
DIVISION

BEARING
LUBRICATION

TURNING
TORQUE

New

None (with
anti-rust agent)

0.83

− 1.19 N⋅m

(7.35

− 10.53 in-lb)

DRIVE PINION SPACER
HEIGHT mm (in)

IDENTIFICATION COLOR

56.67 (2.231)

White

57.01 (2.244)

−

ACX01061AB

MB990850

216

± 29 N

159

± 22 ft-m

ACX01062AB

MB990326

MB990685

ACX01063 AB

IDENTIFICATION

COLOR

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-55

NOTE: Apply gear oil around the circumference of compan-
ion flange (and the mating surface of oil seal) when press fit-
ting oil seal into companion flange.

5. Remove the companion flange and drive pinion again. Then,

after inserting the drive pinion rear bearing inner race into
the gear carrier, use special tool MB990031 or MB990699 to
press-fit the oil seal.

6. Install the drive pinion assembly and companion flange with

the mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified torque by
using special tool MB990850.

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

using special tools.

Standard value: (With oil seal)

8. If the drive pinion turning torque is not within the standard

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

>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
1. Assemble the side gears, side gear spacers, pinion gears

and pinion washers into the differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not drive in the lock pin yet.

BEARING
DIVISION

BEARING
LUBRICATION

TURNING TORQUE

New

None (with
anti-rust agent)

0.93

− 1.28 N⋅m (8.24 −

11.32 in-lb)

Gear oil applied

0.97

− 1.32 N⋅m (8.59 −

11.68 in-lb)

ACX01064 AB

MB990031
OR
MB990699

ACX01065AB

MB990850

216

± 29 N

•

159

± 22 ft-lb

ACX01062AB

MB990326

MB990685

ACX01066AB

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

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FRONT AXLE

26-56

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

lock the side gear.

4. 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)

5. If the differential gear backlash exceeds the limit, adjust the

backlash by installing thicker side gear spacers.

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

pinion gears as a set.

7. Measure the differential gear backlash once again, and

confirm that it is within the limit.

>>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 at two points.

>>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 special tool MB990813 (tap M10 x
1.25), and then clean the threaded holes by applying
compressed air.

3. Apply the specified adhesive to the threaded holes of the

drive gear.

Specified adhesive: 3M

 AAD Part number 8730, 8731

or equivalent

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: 83

± 5 N⋅m (62 ± 3 ft-lb)

AC102885

WEDGE

SIDE GEAR
SPACER

ACX01067AB

ACX01068AF

MB990813

AC000438 AB

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