Mitsubishi Montero Sport (2004+). Manual - part 415

 

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Mitsubishi Montero Sport (2004+). Manual - part 415

 

 

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-41

REMOVAL SERVICE POINT

.

<<A>> FRONT PROPELLER SHAFT REMOVAL 
Make mating marks on the flange yoke and the differential car-
rier companion flange. Remove the front propeller shaft.

INSTALLATION SERVICE POINTS

.

>>A<< FRONT PROPELLER SHAFT INSTALLATION
Install the front propeller shaft so that the mating marks of the 
flange yoke and the differential carrier companion flange are 
aligned.

DISASSEMBLY

M1262002300102

AC003833 AB

MATING MARKS

AC004731AB

17

18 19 20

27 21

22

3

4

5

6

13

12

11

10

11

12

8

9

13

7

14

6

5

4

30

1

29

2

26

24 23 16

15

28

25

N

N

N

 

  

DISASSEMBLY 

STEPS

<<A>>  

INSPECTION BEFORE DISASSEMBLY 

1. COVER
2. BEARING CAP

<<B>>

3. DIFFERENTIAL CASE ASSEMBLY

 

 

4.  SIDE BEARING SPACER
5.  SIDE BEARING OUTER RACE

<<C>>  

6.  SIDE BEARING INNER RACE

<<D>>  

7. DRIVE 

GEAR

<<E>>  

8. LOCK 

PIN

9. PINION SHAFT
10. PINION GEAR
11. PINION WASHER

12. SIDE GEAR
13. SIDE GEAR SPACER
14. DIFFERENTIAL CASE

<<F>>  

15. SELF-LOCKING NUT
16. WASHER

<<G> 

17.  DRIVE PINION ASSEMBLY
18. DRIVE PINION
19. DRIVE PINION FRONT SHIM (FOR 

PINION HEIGHT ADJUSTMENT)

<<H>>

20. DRIVE PINION FRONT BEARING 

INNER RACE

21. DRIVE PINION SPACER

 

 

 

DISASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-42

Required Special Tools:

• MB990909: Working Base

• MB990939: Brass Bar

• MB991116: Adapter 

• MB990339: Bearing Puller

• MB990590: Rear Axle Shaft Oil Seal Remover

• MB990648: Bearing Remover

• MB990767: End Yoke Holder

• MB990810: Side Bearing Puller

• MB990811: Differential Side Bearing Cap

DISASSEMBLY SERVICE POINTS

.

<<A>> INSPECTION BEFORE DISASSEMBLY
1. Remove the cover and gasket.
2. Hold special tools MB990909 and MB99116 in a vise, and 

install the differential carrier assembly to it.

.

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, insert side 

bearing adjustment spacers, and then inspect the drive gear 
tooth contact.

.

22. DRIVE PINION REAR SHIM (FOR 

TURNING TORQUE ADJUSTMENT)

23. COMPANION FLANGE
24. OIL SEAL
25. DRIVE PINION REAR BEARING INNER 

RACE

<<I>>

26. DRIVE PINION REAR BEARING 

OUTER RACE

<<J>>

27. DRIVE PINION FRONT BEARING 

OUTER RACE

<<K>>  

28. OIL SEAL

 

 

29. GEAR CARRIER

 

 

30. VENT PLUG

 

 

 

DISASSEMBLY STEPS (Continued)

ACX01033

MB990909 AND
MB991116

AB

ACX01034AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-43

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 the runout exceeds the limit value, check for foreign 

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

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

and differential case and remeasure.

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

replace 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 (0.08 inch)

2. Repeat the same procedure for both pinion gears.
3. If the backlash exceeds the limit, adjust by using the side 

gear thrust spacers.

4. 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.

ACX01036 AB

ACX01035 AB

WEDGE

SIDE GEAR
THRUST
SPACER

SIDE GEAR
THRUST 
SPACER

ACX01037 AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-44

CAUTION

If the drive gear is rotated too much, the tooth contact pat-
tern will become unclear and difficult to check.
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 [approximate 2.5 

− 3.0 

N

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

3. Check the tooth contact condition of the drive gear and drive 

pinion.

AC004730 AB

MB990939

 

 

 

 

 

 

 

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