Mitsubishi Montero (2004+). Manual - part 475

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-39

>>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 tap (M10 x 1.25). Clean the
threaded holes by applying compressed air.

3. Apply 3M

 stud locking 4170 or equivalent to the threaded

holes of the drive gear.

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: 152

± 15 N⋅m (112 ± 10 ft-lb)

>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tools MD998812 and MD998829 to press-fit the
side bearing inner races into the differential case.

>>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR
BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Assemble the differential case with the side bearing outer

race to the gear carrier.

2. Press the differential case to one side to measure the

clearance of the side bearing outer race and the gear carrier.

3. Select two pairs of side bearing spacer. Determine the

thickness by adding 1/2 of the clearance to the pre-load
0.05mm (0.002 inch).

ACX01068AB

TAP

ACX02430

ACX02431AB

MD998812

MD998829

ACX01071

DIFFERENTIAL CARRIER ASSEMBLY

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REAR AXLE

27-40

4. Remove the side bearing, using special tools MB990810

and MB991407.
NOTE: Hook the claws of the special tool MB990810 with
the side bearing inner race by using the notches (two areas)
of the differential case side.

5. Assemble the selected side bearing spacers to each side.

6. Use special tool MB990802 to press-fit the side bearing

inner case into the differential case. After installing the outer
race, assemble the differential case to the gear carrier.

7. Align the mating marks of differential carrier and the bearing

cap with each other and tighten to the specified torque.

Tightening torque: 74

± 5 N⋅m (55 ± 3 ft-lb)

8. Measure the drive gear backlash.

NOTE: Measure at four points or more on the circumference
of the drive gear.

Standard value: 0.13

− 0.18 mm (0.005 − 0.007 inch)

9. If the backlash is not within the standard value, move the

side bearing spacer as shown in the illustration to adjust the
backlash.
NOTE: The increment of side bearing spacer must be the
same as the decreased amount.

10.Inspect the tooth condition at the final drive gear and adjust

if required. (Refer to GROUP 26, Inspection Before
Disassembly

P.26-43

11.Measure the drive gear runout.

Limit: 0.05 mm (0.002 inch)

12.If drive gear runout exceeds the limit, remove the differential

case and then the drive gears, moving them to different
positions and reinstall them.

13.If adjustment is not possible, replace the differential case or

drive gear and drive pinion as a set.

ACX01041AB

MB990810

MB991407

ACX02432

DRIVE
PINION
REAR
SHIM

MB990802

ACX01034

ACX02433AB

WHEN THE BACKLASH IS SMALL

WHEN THE BACKLASH IS LARGE

DECREASED

INCREASED

ACX01036

SPECIFICATIONS

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REAR AXLE

27-41

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1271004000257

GENERAL SPECIFICATIONS

M1271000200130

ITEM

SPECIFICATION

Rear axle hub assembly, drive shaft assembly
Backing plate bolt

133

± 14 N⋅m (98 ± 10 ft-lb)

Lower arm and knuckle connection nut

152

± 25 N⋅m (113 ± 18 ft-lb)

Rear brake caliper bolt

100

± 10 N⋅m (74 ± 7 ft-lb)

Rear drive shaft and companion shaft connection nut

113

± 14 N⋅m (84 ± 10 ft-lb)

Rear drive shaft nut

255

± 29 N⋅m (188 ± 21 ft-lb)

Knuckle
Toe-control arm and knuckle connection nut

± 7 N⋅m (50 ± 5 ft-lb)

Trailing arm and knuckle connection bolt

231

± 34 N⋅m (170 ± 25 ft-lb)

Upper arm and knuckle connection nut

150

± 30 N⋅m (111 ± 22 ft-lb)

Differential carrier assembly
Bearing cap bolt

± 5 N⋅m (55 ± 3 ft-lb)

Differential cover bolt

± 5 N⋅m (25 ± 4 ft-lb)

Dynamic damper bolt

± 12 N⋅m (61 ± 9 ft-lb)

Drain plug

± 4 N⋅m (47 ± 2 ft-lb)

Drive gear bolt

152

± 15 N⋅m (112 ± 10 ft-lb)

Drive pinion self-locking nut

216

± 29 N⋅m (159 ± 22 ft-lb)

Filler plug

± 9 N⋅m (37 ± 6 ft-lb)

Lower arm and knuckle connection nut

152

± 25 N⋅m (113 ± 18 ft-lb)

Rear drive shaft and companion shaft connection nut

113

± 14 N⋅m (84 ± 10 ft-lb)

Rear differential mount member nut

152

± 25 N⋅m (113 ± 18 ft-lb)

Toe-control tower bar bolt and nut

± 8 N⋅m (34 ± 6 ft-lb)

ITEM

SPECIFICATION

Reduction gear type

Hypoid gear

Reduction ratio

4.300

Differential gear type (Type

× number

of gears)

Side gear

Straight bevel gear

× 2

Pinion gear

Straight bevel gear

× 2

Number of teeth

Drive gear

Drive pinion

Side gear

Pinion gear

SPECIFICATIONS

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REAR AXLE

27-42

SERVICE SPECIFICATIONS

M1271000300308

LUBRICANTS

M1271000400242

SEALANT AND ADHESIVE

M1271000500142

Bearings (Outside diameter

× Inside

diameter) mm (in)

Side

90.0

× 55.0 (3.54 × 2.17)

Front

68.3

× 30.2 (2.69 × 1.19)

Rear

79.4

× 36.5 (3.13 × 1.44)

ITEM

SPECIFICATION

ITEM

STANDARD VALUE

LIMIT

Rear axle total backlash mm (in)

−

5 (0.2)

Wheel bearing end play mm (in)

−

0 (0)

Wheel bearing rotation starting torque N

⋅m (in-lb)

−

1.76 (15.6)

DOJ boot assembly dimension mm (in)

110

± 3 (4.3 ± 0.1)

−

Drive gear backlash mm (in)

0.13

− 0.18 (0.005 − 0.007)

−

Drive gear runout mm (in)

0.05 (0.002)

−

Differential gear backlash mm (in)

− 0.076 (0 − 0.0030)

0.2 (0.01)

Drive pinion
turning torque
N

⋅m (in-lb)

Without oil seal

1.94

− 2.25 (17.2 − 19.9)

−

With
oil seal

Companion flange (oil seal
contacting area) with anti-rust
agent

2.03

− 2.34 (18.0 − 20.7)

−

Companion flange (oil seal
contacting area) with gear oil
applied

2.10

− 2.40 (18.6 − 21.2)

−

ITEM

SPECIFIED LUBRICANT

QUANTITY

Rear differential gear oil Hypoid gear oil API classification GL-5 or

higher

• Above −23°C(−10°F): SAE 90, 85W-90,

80W-90

• From −34 to −23°C(−30 to −10°F): SAE

80W, 80W-90

• Below −34°C(−30°F): SAE 75W

Approximately 1.6 dm

(1.7 qt)

BJ joint

Repair kit grease

245

± 10 g (8.7 ± 0.3 oz)

DOJ joint

Repair kit grease

295

± 10 g (10.5 ± 0.3 oz)

ITEM

SPECIFIED SEALANT AND ADHESIVE

Differential cover

 AAD Part No. 8672, 8679, 8678, 8661, 8663 or

equivalent

Drive gear and differential case mounting part

 AAD Part No. 8730, 8731 or equivalent

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