Mitsubishi Montero Sport (2004+). Manual - part 431

AXLE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-25

<<B>> AXLE SHAFT REMOVAL
1. Secure special tool MB991552 to the bearing case bolts with

the nuts and adjust the height of the hanger. Then install the
washers, plate and nuts in that order.
NOTE: The washers are used to eliminate the difference in
height of the bearing case so that the plate and the bearing
case are parallel.

CAUTION

The hanger and plate should be placed so that they are
parallel.
2. Place the end of the bolt against the center of the axle shaft,

and then tighten the bolt to remove the axle shaft from the
bearing case assembly.

<<C>> OUTER BEARING INNER RACE REMOVAL
Install special tool MB990560 as shown in the illustration, and
then use a press to remove the outer bearing inner race from
the axle shaft.

<<D>> BEARING OUTER RACE REMOVAL
Reinstall the outer bearing inner race that was removed previ-
ously. Use special tool MB990799 and a press to remove the
bearing outer race.

ASSEMBLY SERVICE POINTS

>>A<< BEARING OUTER RACE INSTALLATION
Use special tool MB990890 or MB990891 to press-fit the bear-
ing outer race to the bearing case.

AC103785 AB

BOLT

WASHER

BEARING
CASE

HANGER

NUT

PLATE

WASHER

MB991552

AC004871AB

MB990560

BEARING INNER
RACE

AC004873 AB

MB990799

BEARING
OUTER RACE

AC004875AB

MB990890 OR
MB990891

AXLE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-26

>>B<< INNER BEARING INNER RACE/OUTER BEARING
INNER RACE INSTALLATION
1. Apply multipurpose grease to the roller surface and ends of

the bearing.

2. Pass the axle shaft through the bearing case and the inner

bearing inner race and outer bearing inner race.

CAUTION

Both the inner bearing inner race and outer bearing inner
race should be press-fitted together.
3. Use special tool MB990799 to press-fit the inner bearing

inner race and outer bearing inner race to the axle shaft.

>>C<< OIL SEAL INSTALLATION
1. Apply multipurpose grease to the outside of the oil seal.
2. Using special tools MB990936 and MB990938, press-fit the

oil seal into the bearing case until it is flush with the face of
the bearing case.

3. Apply multipurpose grease to the lips of the oil seal.

>>D<< RETAINER INSTALLATION
Use special tool MB990799 to press-fit the retainer to the axle
shaft. Check that the press-fitting force is at the standard value.
If the initial press-fitting force is less that the standard value,
replace the axle shaft.

Standard value:

AC004876 AB

AXLE SHAFT

BEARING CASE

OUTER
BEARING
INNER RACE

INNER
BEARING
INNER RACE

MB990799

AC004896 AB

MB990936

MB990938

AC004880AC

RETAINER

MB990799

Initial press-fitting force N (lb) 49,000 (11,016) or more

Final press-fitting force N (lb) 98,000

− 108,000 (22,032 −

24,281)

AXLE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-27

>>E<< SNAP RING INSTALLATION
1. After installing the snap ring, measure clearance (A)

between the snap ring and the retainer with a feeler gauge.
Check that it is within the standard value.

Standard value (A): 0

− 0.166 mm (0 − 0.0065 inch)

2. If the clearance exceeds the standard value, change the

snap ring so that the clearance is at the standard value.

Example:
Clearance 2.0 mm (0.08 inch)
Standard value 0

− 0.166 mm (0 − 0.0065 inch)

Thickness of snap ring 2.01 mm (0.079 inch)

>>F<< ABS ROTOR INSTALLATION
Use special tool MB990787 to press-fit the ABS rotor so that
the distance (A) to the bearing case is at the standard value.

Standard value (A): 19.4

− 20.0 mm (0.76 − 0.79 inch)

INSPECTION

M1271002800127

• Check the dust cover for deformation and damage.

• Check the inner and outer bearings for seizure, discolora-

tion and rough raceway surface.

• Check the axle shaft for cracks, wear and damage.

THICKNESS OF SNAP
RING mm (in)

IDENTIFICATION COLOR

2.17 (0.085)

−

2.01 (0.079)

Yellow

1.85 (0.073)

Blue

1.69 (0.067)

Purple

1.53 (0.060)

Red

AC004897 AB

SNAP RING

RETAINER RING

AC004882

ABS ROTOR

MB990787

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-28

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL AND INSTALLATION

M1272002000276

REMOVAL SERVICE POINTS

<<A>> PROPELLER SHAFT REMOVAL

CAUTION

Suspend the propeller shaft from the body with wire, etc.
to avoid spilling transmission fluid and to avoid injury
from falling propeller shaft when not secured.
Make the mating marks on the flange yoke of the propeller
shaft and the companion flange of the differential case.

Pre-removal Operation
• Differential Gear Oil Draining

• Axle Shaft Assembly Removal <Vehicles with drum

brakes> (Refer to

P.27-21

.) <Vehicles with disc brakes>

(Refer to

P.27-21

Post-installation Operation
• Axle Shaft Assembly Installation <Vehicles with drum

brakes> (Refer to

P.27-21

.) <Vehicles with disc brakes>

(Refer to