Mitsubishi Montero (2002-2004). Manual - part 216

SPECIFICATIONS

TSB Revision

FRONT AXLE

26-61

DIFFERENTIAL MOUNTING BRACKET <RH-REAR>
1. Remove insulator with special tool MD999570.

2. Using special tools MB991318, MB991183 and MB990843 

with a hydraulic press, press fit each insulator to adjust until 
the hollow part faces as shown and the difference between 
C and D is 0.7 mm (0.03 inch).

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1261005400268

ACX01081 AB

MD999570

ACX01082AB

MB991183

MB990843

C

D

<RH-REAR>

MB991318

ITEM

SPECIFICATION

Drive shaft
Castle nut

255 

± 29 N⋅m (188 ± 21 ft-lb)

Drive shaft and inner shaft connection nut

60 

± 10 N⋅m (45 ± 7 ft-lb)

Upper arm and upper arm ball joint connection nut

25 

± 4 N⋅m (18 ± 3 ft-lb)

Freewheel clutch assembly, Differential carrier
Bearing cap bolt

59 

± 5 N⋅m (44 ± 3 ft-lb)

Cover bolt

18 

± 3 N⋅m (13 ± 2 ft-lb)

Differential case bolt

83 

± 5 N⋅m (62 ± 3 ft-lb)

Differential carrier and propeller shaft connection bolt

60 

± 10 N⋅m (45 ± 7 ft-lb)

Differential mount bracket bolt

69 

± 9 N⋅m (51 ± 7 ft-lb)

Differential mount bracket <LH> and differential carrier connection bolt

89 

± 9 N⋅m (65 ± 7 ft-lb)

Differential support bracket and differential carrier connection nut

59 

± 9 N⋅m (43 ± 7 ft-lb)

Drain plug

65 

± 5 N⋅m (48 ± 4 ft-lb)

Drive pinion self-locking nut

216 

± 29 N⋅m (159 ± 22 ft-lb)

Filler plug

50 

± 10 N⋅m (37 ± 7 ft-lb)

Freewheel engage switch assembly

25 

± 5 N⋅m (22 ± 4 ft-lb)

Housing tube and freewheel clutch assembly connection bolt

90 

± 10 N⋅m (67 ± 7 ft-lb)

No.2 crossmember and front frame assembly connection nut

128 

± 9 N⋅m (94 ± 7 ft-lb)

SPECIFICATIONS

TSB Revision

FRONT AXLE

26-62

GENERAL SPECIFICATIONS

M1261000200258

Front differential mount
Differential mount bracket bolt

69 

± 9 N⋅m (51 ± 7 ft-lb)

Differential mount bracket <REAR> bolt

23 

± 4 N⋅m (17 ± 3 ft-lb)

Differential mount bracket <RH> and housing tube connection nut

89 

± 9 N⋅m (65 ± 7 ft-lb)

Differential mount bracket <LH> and differential carrier connection bolt

89 

± 9 N⋅m (65 ± 7 ft-lb)

Differential support bracket and differential carrier connection nut

59 

± 9 N⋅m (43 ± 7 ft-lb)

Differential support bracket bolt

69 

± 9 N⋅m (51 ± 7 ft-lb)

No.2 crossmember and front frame assembly connection nut

128 

± 9 N⋅m (94 ± 7 ft-lb)

Hub and knuckle assembly
Brake disc and front hub assembly connection bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Caliper assembly bolt

113 

± 10 N⋅m (83 ± 7 ft-lb)

Castle nut

255 

± 29 N⋅m (188 ± 21 ft-lb)

Dust cover and front hub assembly connection bolt

8.9 

± 1.9 N⋅m (79 ± 17 in-lb)

Knuckle and front hub assembly connection bolt

88 

± 10 N⋅m (65 ± 7 ft-lb)

Lower arm ball joint and knuckle connection nut

147 

± 29 N⋅m (109 ± 21 ft-lb)

Tie rod end connection nut

39 

± 4 N⋅m (29 ± 3 ft-lb)

Upper arm ball joint and knuckle connection nut

74 

± 14 N⋅m (55 ± 3 ft-lb)

Inner shaft, Housing tube
Actuator bolt

17 

± 3 N⋅m (13 ± 2 ft-lb)

Breather pipe bolt

12 

± 2 N⋅m (107 ± 17 in-lb)

Differential mount bracket <RH> and housing tube connection nut

89 

± 9 N⋅m (65 ± 7 ft-lb)

Differential mount bracket bolt

69 

± 9 N⋅m (51 ± 7 ft-lb)

Freewheel engage switch assembly

25 

± 5 N⋅m (22 ± 4 ft-lb)

Housing tube and differential carrier connection bolt

90 

± 10 N⋅m (67 ± 7 ft-lb)

Vacuum tank bolt

12 

± 2 N⋅m (107 ± 17 in-lb)

Solenoid valve, Vacuum pipe
Actuator bolt

17 

± 3 N⋅m (13 ± 2 ft-lb)

Solenoid valve assembly bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Vacuum pipe bolt

12 

± 2 N⋅m (107 ± 17 in-lb)

ITEM

SPECIFICATION

ITEM

SPECIFICATION

Front axle hub bearing

Type

Taper roller type nut bearing

Driveshaft

Joint type

Outer

Under cut joint

Inner

Double-offset joint

Differential

Final drive gear type

Hypoid gear

Reduction ratio

4.300

Pinion gear type

2 pinion

SPECIFICATIONS

TSB Revision

FRONT AXLE

26-63

SERVICE SPECIFICATIONS

M1261000300299

LUBRICANTS

M1261000400296

SEALANTS AND ADHESIVES

M1261000500099

ITEM

STANDARD VALUE

LIMIT

Wheel bearing axis backlash mm (in)

-

0 (0)

Front axle total backlash mm (in)

-

11 (0.4)

Solenoid valve resistance [at 20

°C (68°F)] Ω

36 

− 46

-

Hub rotation starting torque N

⋅m (ft-lb)

-

1.75 (15.48)

Hub rotary rotation starting torque N

⋅m (ft-lb)

80 

± 5 (3.2 ± 0.1)

-

Opening dimension of the 
special tool (MB991561) mm (in)

When the BJ boot 
band (small) is 
crimped

2.9 (0.11)

-

When the BJ boot 
band (large) is 
crimped

3.2 (0.13)

-

Crimped width of the BJ boot band mm (in)

2.4 

− 2.8 (0.09 − 0.11)

-

Crimped height of BJ boot band (larger) mm (in)

-

9.5 (0.37)

FInal drive gear backlash mm (in)

0.11 

− 0.160 (0.004 − 0.006)

-

Drive gear runout mm (in)

-

0.05 (0.002)

Differential gear backlash mm (in)

0 

− 0.076 (0 − 0.003)

0.2 (0.007)

Drive pinion 
turning torque 
N

⋅m (in-lb)

Without oil seal

0.83 

− 1.19 (7.35 − 10.53)

-

With oil seal

With anti-rust agent 0.93 

− 1.128 (8.24 − 11.32)

-

With gear oil 
applied

0.97 

− 1.32 (8.59 − 11.68)

-

Drive gear runout mm (in)

-

0.05 (0.002)

ITEM

SPECIFIED LUBRICANT

QUANTITY

Front differential gear oil

Hypoid gear oil API classification 
GL-5 or higher SAE viscosity No. 
90, 80W

1.2 dm

3

(1.3qt)

DOJ boot grease

Repair kit grease

Approximately 120 g (4.2 oz) 

UJ boot grease

Repair kit grease

Approximately 140 g (4.9 oz)

ITEM

SPECIFIED SEALANTS AND ADHESIVES

Contact surface of differential cover and differential 
carrier

3M

TM

 AAD Part No.8672, 8679, 8678, 8661, 8663 or 

equivalent

Vent plug
Free-wheeling clutch assembly
Drive gear threaded hole

3M

TM

 AAD Part No.8730, 8731 or equivalent

NOTES