Mitsubishi Montero Sport (2004+). Manual - part 429

ON-VEHICLE SERVICE

TSB Revision

REAR AXLE

27-17

ON-VEHICLE SERVICE

REAR AXLE TOTAL BACKLASH CHECK

M1271001200122

1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position. 

Apply the parking brake. Raise the vehicle on a jack.

3. Turn the companion flange clockwise as far as it will go. 

Make the mating mark on the dust cover of the companion 
flange and on the differential carrier.

4. Turn the companion flange counterclockwise as far as it will 

go, and measure the amount of distance the mating marks 
moved.

Limit: 5 mm (0.2 inch)

5. If the backlash exceeds the limit value, remove the 

differential carrier assembly and check the following.

• Final drive gear backlash

• Differential gear backlash

AXLE SHAFT END PLAY CHECK

M1271001300077

1. Measure the axle shaft end play by using a dial indicator.

Standard value: 0 

− 0.25 mm (0 − 0.010 inch)

2. If within specifications, return vehicles to original condition. If 

not within specifications, replace the axle shaft assembly.

AXLE SHAFT END PLAY ADJUSTMENT

M1271001400074

The axle shaft end play is preset at factory. It can not be 
adjusted.

ACX00962 AB

MATING MARKS

ACX00964

AC004839 AB

ON-VEHICLE SERVICE

TSB Revision

REAR AXLE

27-18

GEAR OIL LEVEL CHECK

M1272001200222

Check that gear oil level is not 8 mm (0.3 inch) below the bot-
tom of filler plug hole.

Specified gear oil:
<Conventional differential>
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

<Limited slip differential>
Hypoid gear oil MITSUBISHI Genuine Gear Oil Part 
Number 8149630 EX or equivalent

ACX01083 AC

8 mm (0.3 in)

UPPER
LIMIT

LOWER
LIMIT

AXLE ASSEMBLY

TSB Revision

REAR AXLE

27-19

AXLE ASSEMBLY

REMOVAL AND INSTALLATION

M1271001700172

CAUTION

*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on 
the ground in an unladen condition.

Pre-removal Operation
• Brake Fluid Draining

Post-installation Operation
• Brake Fluid Filling and Air Bleeding (Refer to GROUP 

35A, On-vehicle Service 

P.35A-19

.)

• Parking Brake Lever Stroke Adjustment (Refer to GROUP 

36, On-vehicle Service 

P.36-2

.)

AC309200

AB

17 N·m
12 ft-lb

216 - 245 N·m*
159 - 181 ft-lb*

216 - 245 N·m*
159 - 181 ft-lb*

216 - 245 N·m*
159 - 181 ft-lb*

216 - 245 N·m*
159 - 181 ft-lb*

216 - 245 N·m*
159 - 181 ft-lb*

34 N·m
25 ft-lb

15 N·m
11 ft-lb

4

5

6

7

12

13

1

2

3

8

11

10

14

9

98 - 108 N·m
72 - 80 ft-lb

REMOVAL STEPS

1. BRAKE DRUM
2. SHOE AND LINING ASSEMBLY 

(REFER TO GROUP 35A, REAR 
DRUM BRAKE 

P.35A-37

.)

3. PARKING BRAKE CABLE 

CONNECTION

4. SPEED SENSOR CONNECTION 

<VEHICLES WITH ABS>

5. BRAKE HOSE AND TUBE 

CONNECTION

6. BREATHER HOSE

<<A>> >>B<<

7. PROPELLER SHAFT

<<B>> >>A<<

8. STABILIZER BAR MOUNTING BOLT
9. LOWER ARM
10. LATERAL ROD
11. SHOCK ABSORBER MOUNTING 

BOLT (LOWER SIDE ONLY)

<<C>>

12. AXLE ASSEMBLY
13. COIL SPRING
14. STABILIZER BAR

REMOVAL STEPS (Continued)

AXLE ASSEMBLY

TSB Revision

REAR AXLE

27-20

REMOVAL SERVICE POINTS

.

<<A>> PROPELLER SHAFT REMOVAL

CAUTION

Suspend the propeller shaft from the body with wire, etc. 
to prevent it from falling.
Place mating marks on the companion flange and flange yoke. 
Disconnect the propeller shaft from the companion flange.

.

<<B>> STABILIZER BAR MOUNTING BOLT REMOVAL
Support the axle housing with a jack before removing the stabi-
lizer bar mounting bolt.

.

<<C>> AXLE ASSEMBLY REMOVAL

WARNING

Secure the axle assembly to the jack or equivalent. 
The axle assembly is heavy and unstable and may fall 
causing damage to the assembly, surrounding equip-
ment, or injuring the installer.

Take out the axle assembly from the rear of the vehicle.

INSTALLATION SERVICE POINTS

.

>>A<< STABILIZER BAR MOUNTING BOLT INSTALLATION
When installing the stabilizer bar to the stabilizer bar bracket, 
check that the amount of projection of the stabilizer bar installa-
tion bolt is within the standard value range.

Standard value (A): 15 

− 17 mm (0.6 − 0.7 inch)

.

AC003833 AB

MATING MARKS

AC004846AB

AC004847 AB

JOINT CUP

STABILIZER
BAR
INSTALLATION
BOLT

RUBBER
BUSHING

JOINT CUP

RUBBER
BUSHING

JOINT CUP

JOINT CUP

STABILIZER BAR

COLLAR

A