Mitsubishi Montero (2002-2004). Manual - part 209

INNER SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-33

2. After special tool MB990560 has been installed as shown, 

tighten the nut of special tool MB990560 until the portion of 
special tool MB990560 touches the bearing outer race.

3. Press out the inner shaft from the bearing.

ASSEMBLY SERVICE POINTS

.

>>A<< DUST SEAL INSTALLATION
Press-fit the new dust seal into the housing tube by using spe-
cial tools MB990938 and MB990955, until it is flush with the 
housing tube end face.

.

>>B<< DUST COVER INSTALLATION
Using a steel pipe, install a new dust cover onto the inner shaft.

.

ACX01003AB

A

MB990560

ACX01013 AB

MB990560

ACX01014 AB

MB990955

MB990938

STEEL PIPE

mm (in)

Overall length

50 (2.0)

Outside diameter

75 (3.0)

Wall thickness

4 (0.16)

ACX01015 AB

STEEL PIPE

INNER SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-34

>>C<< BEARING INSTALLATION
Use special tool MB990560 to press-fit the bearing onto the 
inner shaft.

ACX01016AB

MB990560

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-35

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

REMOVAL AND INSTALLATION

M1262001800063

Pre-removal and Post-installation Operation
• Under Cover Removal and Installation

• Skid Plate Removal and Installation (Refer to GROUP 51- 

Front Bumper 

P.51-3

.)

• Gear Oil Draining and Refill (Refer to 

P.26-15

.)

• Driveshaft Removal and Installation (Refer to 

P.26-23

.)

• Inner Shaft Removal and Installation (Refer to 

P.26-30

.)

AC102456AB

8

2

7

6

5

9

2

10

11

1

4

4

3

12

9

11

69 

± 

9 N

·

m *

51 

± 

7 ft-lb *

25 

± 

5 N

·

m

22 

± 

4 ft-lb

69 

± 

9 N

·

m *

51 

± 

7 ft-lb *

128 

± 

9 N

·

m

  94 

± 

7 ft-lb

89 

± 

9 N

·

m

65 

± 

7 ft-lb

59 

± 

9 N

·

m

43 

± 

7 ft-lb

60 

± 

10 N

·

m

45 

± 

7 ft-lb

69 

± 

9 N

·

m *

51 

± 

7 ft-lb *

90 

± 

10 N

·

m

67 

± 

7 ft-lb

SEALANT:

     3M

TM

 AAD PART NO.8672, 8679,

     8678, 8661, 8663 OR EQUIVALENT

 

  

REMOVAL 

STEPS

<<A>>  

>>B<<

1.  FRONT PROPELLER SHAFT 

CONNECTION

 

 

2.  FRONT FRAME AND DIFFERENTIAL 

BRACKET CONNECTION

 

 

3. FRONT FRAME AND NO.2 

CROSSMEMBER ASSEMBLY 
CONNECTION

 

 

4. VACUUM 

HOSE

 

 

5. COLLAR

<<B>>  

6. PIN

 

 

7. FREEWHEEL 

ENGAGE 

SWITCH 

CONNECTION

 >>A<<

8. DIFFERENTIAL 

MOUNTING 

BRACKET <RH> AND HOUSING 
TUBE ASSEMBLY

 

 

9.  FREEWHEEL CLUTCH ASSEMBLY

 >>A<< 

10. DIFFERENTIAL MOUNTING 

BRACKET <LH>

 

 

11. DIFFERENTIAL CARRIER

 

 

12.  NO.2 CROSSMEMBER ASSEMBLY

 

 

 

REMOVAL STEPS (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

TSB Revision

FRONT AXLE

26-36

REMOVAL SERVICE POINTS

.

<<A>> FRONT PROPELLER SHAFT REMOVAL

CAUTION

• Be careful not to damage joint boot by crimping with 

the bent propeller shaft joint.

• Hang propeller shaft with wires to prevent it from fall-

ing.

Make mating marks on the flange yoke and the differential car-
rier companion flange. Remove the front propeller shaft.

.

<<B>> PIN REMOVAL
1. Remove one side of dust cover mounting part on the 

vacuum actuator assembly.

2. Match a pin with a pin hole and remove the pin with a punch.

INSTALLATION SERVICE POINTS

.

>>A<< DIFFERENTIAL MOUNTING BRACKET ASSEMBLY
Tighten differential mounting insulator in the order of A, B, C, D 
or A, C, B, D as shown, in the left diagram.

.

AC000430AB

JOINT ASSEMBLY (BJ)

CLOTH

PROPELLER
SHAFT

JOINT BOOT

ACX01018 AB

MATING 
MARKS

ACX01019 AB

COLLAR

DUST COVER

PIN

ACX01020 AB

C

B

D

A