Mitsubishi Montero Sport (2004+). Manual - part 434

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-37

>>B<< DRIVE PINION FRONT BEARING OUTER RACE 
PRESS-FITTING
Use special tools MB990938 and MB990934 to press-fit the 
drive pinion front bearing outer race.

.

>>C<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool 

MB990819.

2. Install special tool MB990819, MB991169 and drive pinion 

front and rear bearing inner races to the gear carrier as 
shown in the illustration.

3. Tighten the nut of special tool MB990819 a little at a time 

while measuring the turning torque of the drive pinion. Then 
confirm that the turning torque (without the oil seal) is at the 
standard value.

Standard value:

4. Clean the side bearing hub.

ACX01107AB

MB990938

MB990934

BEARING TYPE BEARING

LUBRICATION

TURNING 
TORQUE

New

None (with 
anti-rust agent)

0.6 

− 0.9 N⋅m

5.3 

− 8.0 in-lb

New or reuse

Gear oil applied

0.4 

− 0.5 N⋅m

3.5 

− 4.4 in-lb

(

)

AC004937AB

WASHER

MB991169

DRIVE PINION
ATTACHMENT

MB990819

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-38

5. Place special tool MB991534 between the side bearing hub 

of the gear carrier, and position the notch as shown in the 
illustration. Then tighten side bearing mounting bolt.

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

special tools MB991169 and MB991534.

7. Remove special tool MB991169.

8. Use a micrometer to measure the shown dimensions (B, C) 

of special tools MB991169 and MB991534.

9. Install the bearing cap, and then use a cylinder gauge to 

measure the inside diameter (D) of the bearing cap.

10.Calculate thickness (F) of the required drive pinion rear 

shim twice by the following formula. Select a shim which 
most closely matches this thickness.
F = A + B + C 

− 1/2D − 120.00 mm (4.724 inches)

11.Fit the selected drive pinion rear shim(s) to the drive pinion, 

and press-fit the drive pinion rear bearing inner race by 
using special tool MB990802.

.

>>D<< DRIVE PINION PRELOAD ADJUSTMENT
1. Insert the drive pinion into the gear carrier, and then install 

the following parts in sequence from the carrier rear side. 
Drive pinion spacer, drive pinion front shim and drive pinion 
front bearing inner race, companion flange.
NOTE: Do not install the oil seal.

ACX01109AE

FEELER
GAUGE

MB991169

NOTCH

MB991534

A

ACX01058AD

MB991534

B

C

MB991169

AC102914

CYLINDER GAUGE

AC

D

ACX02428 AE

DRIVE PINION
REAR SHIM

MB990802

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-39

2. Tighten the companion flange to the specified torque by 

using special tool MB990850.

Tightening torque: 216 N

⋅m (159 ft-lb)

3. Measure the drive pinion turning torque (without the oil 

seal).

Standard value:

4. If the drive pinion turning torque is not within the standard 

value, adjust the turning torque by replacing the drive pinion 
front shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion front shims, if the 
number of shims is large, reduce the number of shims to a 
minimum by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following two 
types.

5. Remove the companion flange and drive pinion again. Then 

insert the drive pinion front bearing inner race into the gear 
carrier. Use special tool MB991168 to press-fit the oil seal.

BEARING TYPE BEARING 

LUBRICATION

TURNING 
TORQUE

New

None (with 
anti-rust agent)

0.6 

− 0.9 N⋅m

5.3 

− 8.0 in-lb

New or reuse

Gear oil applied

0.4 

− 0.5 N⋅m

3.5 

− 4.4 in-lb

ACX01065 AC

216 N·m
159 ft-lb

MB990850

ACX01062AB

MB990326

MB990685

HEIGHT OF DRIVE PINION 
SPACER mm (in)

IDENTIFICATION 
COLOR

52.50 (2.067)

Yellow

52.84 (2.080)

Red

ACX01063 AB

IDENTIFICATION

COLOR

ACX01064 AD

MB991168

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-40

6. Install the drive pinion assembly and companion flange with 

mating marks properly aligned. Tighten the companion 
flange self-locking nut to the specified torque using special 
tool MB990850.

Tightening torque: 216 N

⋅m (159 ft-lb)

7. Measure the drive pinion turning torque (with oil seal) to 

verify that the drive pinion turning torque complies with the 
standard value.

Standard value:

8. If the turning torque is not within the standard value, check 

the tightening torque of the companion flange self-locking 
nut, and the installation of the oil seal.

.

>>E<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear thrust spacers, pinion 

gears, and pinion washers into the differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not assemble the thrust block and lock pin yet.

3. Insert a wedge between the side gear and the pinion shaft to 

lock the side gear.

4. 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)

5. Measure by the same procedure for the other pinion gear.

Limit: 0.2 mm (0.01 inch)

6. If the backlash exceeds the limit value, replace side bearing 

adjustment spacers.

7. If adjustment is not possible, replace the side gears and 

pinion gears as a set.

BEARING 
DIVISION

COMPANION FLANGE 
LUBRICATION

TURNING 
TORQUE

New

None (with anti-rust 
agent)

0.85 

− 1.15 N⋅m

7.52 

− 10.18 in-lb

Gear oil applied

0.65 

− 0.75 N⋅m

5.75 

− 6.64 in-lb

ACX01065 AC

216 N·m
159 ft-lb

MB990850

ACX01062AB

MB990326

MB990685

ACX01066

ACX01035 AB

WEDGE

SIDE GEAR
THRUST
SPACER

SIDE GEAR
THRUST 
SPACER