Mitsubishi Montero Sport (2004+). Manual - part 418

 

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Mitsubishi Montero Sport (2004+). Manual - part 418

 

 

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-53

1. Apply multipurpose grease to the washer of special tool 

MB990819.

2. Install special tool MB990819, drive pinion front and rear 

bearing inner races to the gear carrier.

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:

NOTE: The special tools MB990326, MB990819 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 tool MB991170 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 MB991170 are touching firmly against 
the side bearing hub.

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

special tools MB991170, MB990819.

7. Remove special tools MB991170, MB990819.

BEARING 
DIVISION

BEARING 
LUBRICATION

TURNING 
TORQUE

New

None (with 
anti-rust agent)

0.83 

− 1.19 N⋅m 

7.35 

− 10.53 in-lb

ACX01054 AB

MB990819

WASHER

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

ACX01057 AC

FEELER GAUGE

MB990819

A

MB991170

NOTCH

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-54

8. Use a micrometer to measure special tools MB991170, 

MB990819 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)

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 turning 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 MB990767.

ACX01058

MB991170

B

C

AE

MB990819

ACX01059AB

BEARING CAP

D

ACX01060

DRIVE
PINION
FRONT
SHIM

MB990802

MB990802

AC

AC004803 AB

MB990767

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-55

3. Use special tools MB990685, MB990326 to measure the 

drive pinion turning torque (without the oil seal).

Standard value:

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.

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 tools MB990031 or MB990699 
press-fit the oil seal.

6. Install the drive pinion assembly and companion flange with 

mating marks properly aligned, and tighten the companion 
flange self-locking nut to the specified torque by using 
special tool MB990767.

7. Use special tools MB990685, MB990326 to measure the 

drive pinion turning torque (with the oil seal).

Standard value:

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)

−

BEARING 
DIVISION

BEARING 
LUBRICATION

TURNING 
TORQUE

New

None (with 
anti-rust agent)

0.93 

− 1.28 N⋅m 

8.23 

− 11.33 in-lb

Gear oil applied

0.97 

− 1.32 N⋅m 

8.59 

− 11.68 in-lb

ACX01062AB

MB990326

MB990685

ACX01063 AB

IDENTIFICATION

COLOR

ACX01064 AB

MB990031
OR
MB990699

AC004803 AB

MB990767

ACX01062AB

MB990326

MB990685

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

FRONT AXLE

26-56

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.

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 (0.08 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.

.

ACX01066AB

ACX01035 AB

WEDGE

SIDE GEAR
THRUST
SPACER

SIDE GEAR
THRUST 
SPACER

ACX01067AB

 

 

 

 

 

 

 

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