Mitsubishi Montero Sport (2004+). Manual - part 435

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-41

8. Check that the backlash is within the limit value and that the 

differential gear turns smoothly.

.

>>F<< 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 on both sides.

.

>>G<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the 

drive gear by turning the tap (M10 x 1.25). Clean the 
threaded holes by applying compressed air.

3. Apply 3M

 AAD Part No. 8730, 8731 or equivalent to the 

threaded holes of the drive gear.

4. Install the drive gear onto the differential case with the 

mating marks properly aligned. Tighten the bolts to the 
specified torque in a diagonal sequence.

Tightening torque: 137 

− 167 N⋅m (101 − 123 ft-lb)

.

ACX02429

ACX01068AB

TAP

ACX02430

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-42

>>H<< SIDE BEARING INNER RACE INSTALLATION
Use special tool MD998812, MD998829 to press-fit the side 
bearing inner races into the differential case.

.

>>I<< BEARING CAP INSTALLATION
Align the mating marks on the gear carrier and the bearing cap, 
and then tighten the bearing cap.

.

>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Using special tools MB991367 and MB991385, temporarily 

tighten the side bearing nut to just before preloading of the 
side bearing.

2. Measure the drive gear backlash.

Standard value: 0.13 

− 0.18 mm (0.005 − 0.007 inch)

ACX02431AB

MD998812

MD998829

AC004945 AB

69 - 78 N·m
51 - 58 ft-lb

AC004921AB

MB991385

MB991367

AC004946 AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-43

3. Using special tools MB991367, MB991385, adjust the 

backlash to standard value by moving the side bearing nut 
as shown.
NOTE: First loosen the side bearing nut then tighten the 
side bearing nut the same amount as when it was loosened.

4. Using special tools MB991367 and MB991385, apply the 

preload, turn down both right and left side bearing nuts on 
half the distance between centers of two neighboring holes.

5. Choose and install the lock plate (two kinds).
6. Check the final drive gear tooth contact. If poor contact is 

evident, make adjustment. (Refer to GROUP 26, Inspection 
Before Disassembly 

P.26-41

.)

7. Measure the drive gear runout.

Limit: 0.05 mm (0.002 inch)

8. When drive gear runout exceeds the limit, remove the 

differential case and then the drive gears, moving them to 
different positions and reinstall them.

9. If adjustment is not possible, replace the differential case or 

drive gear and drive pinion as a set.

AC004947AB

WHEN BACKLASH
IS INSUFFICIENT

WHEN BACKLASH
IS EXCESSIVE

LOOSEN

LOOSEN

TIGHTEN

TIGHTEN

AC004948 AB

MB991385

MB991367

AC004949 AB

MB092153

MB092154

AC004950 AB

SPECIFICATIONS

TSB Revision

REAR AXLE

27-44

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1271004000354

GENERAL SPECIFICATIONS

M1271000200141

ITEM

SPECIFICATION

Axle assembly and backing plate connection nut

49 

− 59 N⋅m (36 − 44 ft-lb)

Bearing cap bolt

69 

− 78 N⋅m (51 − 58 ft-lb)

Brake tube connection

15 N

⋅m (11 ft-lb)

Differential carrier assembly nut

47 N

⋅m (35 ft-lb)

Conventional differential case bolt

137 

− 167 N⋅m (101 − 123 ft-lb)

Limited slip differential case bolt

137 

− 167 N⋅m (101 − 123 ft-lb)

Drain plug

59 N

⋅m (44 ft-lb)

Drive pinion self-locking nut

216 N

⋅m (159 ft-lb)

Filler plug

49 N

⋅m (36 ft-lb)

Lateral rod mounting nut

216 

− 245 N⋅m (159 − 181 ft-lb)

Lock plate bolt

19 N

⋅m (14 ft-lb)

Lower arm bolt assembly

17 N

⋅m (12 ft-lb)

Lower arm nut

216 

− 245 N⋅m (159 − 181 ft-lb)

Rear propeller shaft connection nut

98 

− 108 N⋅m (72− 80 ft-lb)

Stabilizer bracket bolt

34 N

⋅m (25 ft-lb)

Shock absorber nut (lower)

216 

− 245 N⋅m (159 − 181 ft-lb)

ITEM

RWD

4WD

Axle housing type

Banjo type

Banjo type

Axle shaft Supporting type

Semi-floating type

Semi-floating type

Differential Reduction gear type

Hypoid gear

Hypoid gear

Reduction ratio

4.636

4.900

Pinion gear type

2-pinion

2-pinion