Mitsubishi Montero (2002-2004). Manual - part 204

 

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Mitsubishi Montero (2002-2004). Manual - part 204

 

 

SPECIAL TOOLS

TSB Revision

FRONT AXLE

26-13

MD999547 Oil 
seal installer

−

Removal of front differential mount 
insulator <Front side, Rear side (LH)>

MD999570 
Crankshaft front 
oil seal insulator 

−

Removal of front differential mount 
insulator <Rear side (RH)>

MB990947 
Lower arm 
bushing arbor 

MB990947

Press fitting of front differential mount 
insulator <Front side, Rear side (LH)>

MB990847 Rear 
suspension 
bushing remover 
and installer 
base 

MB990847 

MB990981 
Mount bushing 
remover and 
installer 

−

MB991318 
Lower arm 
bushing arbor 

−

Press fitting of front differential mount 
insulator <Rear side (RH)>

MB991183 
Bushing arbor 

−

MB990843 
Draglink bushing 
remover and 
installer 

−

TOOLS

TOOL NUMBER 
AND NAME

SUPERSESSION APPLICATION

MB990947

MB990847

MB990981

MB991318

MB991183

MB990843

ON-VEHICLE SERVICE

TSB Revision

FRONT AXLE

26-14

ON-VEHICLE SERVICE

WHEEL BEARING PLAY CHECK

M1261001100094

1. Remove caliper assembly and suspend it with wire to 

prevent it from falling.

2. Remove brake disc from hub.
3. Set dial gauge as shown in the diagram and move hub in the 

axis to measure backlash.

Limit: 0 mm (0 inch)

4. If the play exceeds the limit value, disassemble hub knuckle 

to check each component. If the front hub assembly bearing 
is faulty, replace the front hub assembly.

FRONT AXLE TOTAL BACKLASH CHECK

M1261001300043

When the ignition switch is in "LOCK" (OFF) position, the front 
wheel comes to a stop after turning the propeller shaft by hand 
due to the force applied to front wheel actuator. Inspect the 
vehicle as follows:
1. Turn the ignition switch to "LOCK" (OFF) position, and then 

put the transfer shift lever to the "2H" position.

TOOL

TYPE

TOOL NUMBER

O D mm (in)

A

MB990926

39.0 (1.54)

MB990927

45.0 (1.77)

MB990928

49.5 (1.95)

MB990929

51.0 (2.00)

MB990930

54.0 (2.13)

MB990931

57.0 (2.24)

MB990932

61.0 (2.40)

MB990933

63.5 (2.50)

MB990934

67.5 (2.66)

MB990935

71.5 (2.81)

MB990936

75.5 (2.97)

MB990937

79.0 (3.11)

B

MB990938

-

C

MB990939

-

ACX02372

A

B

C

BRASS BAR

BAR (SNAP-IN TYPE)

TOOL BOX

MB990925

AB

INSTALL ADAPTER

ACX00961AB

ON-VEHICLE SERVICE

TSB Revision

FRONT AXLE

26-15

CAUTION

Do not jack up the vehicle.
2. Turn the propeller shaft until a click is heard.
3. Turn the companion flange clockwise until all play is 

eliminated, and then align the mating mark on the dust cover 
with the mating mark on the differential carrier.

4. Turn the companion flange counterclockwise until all play is 

eliminated and measure the distance through which the 
mating marks moved.

Limit: 11 mm (0.4 inch)

5. If the amount of movement exceeds the limit value, check 

the following.

• Final drive gear backlash

• Differential gear backlash

• Play in the serrations and splines of the side gears, drive 

shaft, and drive flange

FRONT AXLE GEAR OIL LEVEL CHECK

M1262000900045

Remove the filler plug and check the gear oil level. Check that 
the gear oil level is not more than 8 mm (0.3 inch) below the 
bottom of the filler plug hole.

Specified gear oil: Hypoid gear oil API classification 
GL-5 or higher, SAE viscosity Number 90, 80W [1.15 
dm

3

 (1.22 quart)]

DIFFERENTIAL CARRIER OIL SEAL 
REPLACEMENT

M1262001000045

Required Special Tools:

• MB990590: Rear Axle Shaft Oil Seal Remover

• MB990934: Bearing and Oil Seal Installer Set 

• MB990938: Bearing and Oil Seal Installer Set

1. Remove the drive shaft <LH> (Refer to 

P.26-23

.)

2. Remove the oil seal with special tools.

ACX00962AB

MATING MARKS

ACX00964 AB

AC000439

UPPER LIMIT

LOWER LIMIT

AB

8 mm (0.3 in)

ACX00965AB

MB990590

ON-VEHICLE SERVICE

TSB Revision

FRONT AXLE

26-16

3. Install new oil seal with the special tools.

4. Apply multipurpose grease to the oil seal to lip before 

installing the drive shaft <LH> (Refer to 

P.26-23

.)

CAUTION

• Be careful not damage the lip of oil seal.
• Replace the circlip attached to the spline of <LH> DOJ 

side of driveshaft with a new one.

SOLENOID VALVE OPERATION CHECK

M1261001500058

1. Remove the vacuum hoses (blue stripe, yellow stripe) from 

the solenoid valves.

2. Disconnect the harness connectors.

ACX00966AB

MB990938

MB990934

ACX00967AB

ACX00968AB

SOLENOID
VALVE B

SOLENOID 
VALVE A

 

 

 

 

 

 

 

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