Mitsubishi Montero Sport (2004+). Manual - part 417

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-49

ASSEMBLY

M1262002500140

AC004795 AB

DIFFERENTIAL GEAR SET

FINAL DRIVE GEAR SET

24

6

16

21

18

21

18

19

19

18

23

18

1920 20

2119

2526

27

22

24

17

25

26

27

13

12 11

4

8

7

6

2

29

3

5

10

9

14 15

16

30

1

19 N·m
14 ft-lb

49 N·m
36 ft-lb

78 - 88 N·m
58 - 65 ft-lb

54 - 64 N·m
40 - 47 ft-lb

216 N·m
159 ft-lb

N

N

N

28

ASSEMBLY STEPS

1. VENT 

PLUG

2. GEAR CARRIER

>>A<<

3. OIL SEAL

>>B<<

4.  DRIVE PINION FRONT BEARING 

OUTER RACE

>>C<<

5.  DRIVE PINION REAR BEARING 

OUTER RACE

>>D<<

•

PINION HEIGHT ADJUSTMENT

6. DRIVE 

PINION

7.  DRIVE PINION FRONT SHIM (FOR 

PINION HEIGHT ADJUSTMENT)

8.  DRIVE PINION FRONT BEARING 

INNER RACE

>>E<<

•

DRIVE PINION TURNING TORQUE 
ADJUSTMENT

9. DRIVE PINION REAR BEARING INNER 

RACE

10. OIL SEAL
11. DRIVE PINION REAR SHIM (FOR 

TURNING TORQUE ADJUSTMENT)

12. DRIVE PINION SPACER

13. DRIVE PINION ASSEMBLY
14. COMPANION FLANGE
15. WASHER
16. SELF-LOCKING NUT

 

17. DIFFERENTIAL CASE
18. SIDE GEAR SPACER
19. SIDE GEAR
20. PINION WASHER
21. PINION GEAR

>>F<<

•

DRIVE GEAR BACKLASH 
ADJUSTMENT

22. PINION SHAFT

>>G<<

23. LOCK PIN

>>H<<

24. DRIVE GEAR

>>I<<

25. SIDE BEARING INNER RACE
26. SIDE BEARING OUTER RACE
27. SIDE BEARING ADJUSTING SPACER

>>J<<

•

DRIVE GEAR BACKLASH 
ADJUSTMENT

28.  DIFFERENTIAL CASE ASSEMBLY

ASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-50

Required Special Tools:

• MB990031 or MB990699: Drive Pinion Oil Seal 

Installer

• MB990326: Preload Socket

• MB990767: End Yoke Holder

• MB990802: Bearing Installer

• MB990819: Drive Pinion Gauge Assembly

• MB990934: Installation Adapter

• MB990936: Installation Adapter

• MB990938: Bar

• MB990939: Brass Bar

• MB991170: Cylinder Gauge

• MB990685: Torque Wrench

29. BEARING CAP
30. COVER

ASSEMBLY STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-51

LUBRICATION, SEALING AND ADHESIVE POINTS

AC004796 AB

ADHESIVE:
3M™ AAD PART NO. 8730 OR AAD PART
NO. 8731 OR EQUIVALENT

SEALANT: 3M™ AAD PART NO.8672, 8679, 8678, 8661,
8663 OR EQUIVALENT 

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-52

ASSEMBLY SERVICE POINTS

.

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

.

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

.

>>D<< PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height as follows:

ACX01051AB

OIL SEAL

MB990938

MB990934

AC004801 AB

MB990938

MB990936

AC004802

MB990938

MB990934

AB