Content .. 64 65 66 67 ..

Mitsubishi Montero (1991+). Manual - part 66

INNER SHAFT SPECIFICATIONS

Application In. (mm)

Shaft O.D.

Bearing Area ................ 1.38 (35.0)

Center Area ................. 1.24 (31.4)

INSTALLATION

1) If oil seal replacement is necessary, install new oil seal

in differential carrier using Oil Seal Installer (MB990934-01) and

Handle (MB990938-01). Coat seal lips with grease. Install housing

tube. Using Seal Installer (MB990955) and Handle (C-4171), install new

dust seal in housing tube. Dust seal must be even with housing tube.

Coat seal lip with grease.

2) Using a pipe with O.D. of 2.95" (74.3 mm), wall thickness

of .16" (4.0 mm) and with overall length of 1.97" (50.0 mm), install

dust cover on shaft. Coat inside of dust cover with grease. Press

bearing on shaft. Install new circlip on inner shaft. Drive inner

shaft into differential. Use care not to damage oil seal.

DRIVE AXLES & BEARINGS OVERHAUL

NOTE: References to BJ refer to Birfield Joint and DOJ to Double

Offset Joint.

DISASSEMBLY

1) Remove boot bands. Remove circlip from DOJ outer race.

Separate drive axle from DOJ outer race. Remove balls from DOJ cage.

Remove DOJ cage from DOJ inner race in direction of BJ. See Fig. 2.

Fig. 2: Exploded View of Drive Axles

Courtesy of Chrysler Motors.

2) Remove snap ring from drive axle shaft. Remove DOJ inner

race from shaft. Remove circlip from shaft. Wrap tape around splines

of shaft to prevent boot damage during removal.

3) Remove DOJ boot. Note size of boot. Remove dust cover from

shaft. Straighten BJ boot protector and remove protector band. Move

boot protector toward BJ side of shaft and remove. Remove BJ boot.

CAUTION: Drive axle and BJ are serviced as a unit. DO NOT

disassemble BJ and drive axle.

REASSEMBLY

1) Coat shaft with light coat of grease. Wrap splines with

tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct

size boot is installed in proper location.

2) Boot bands must be installed so lever is pulled toward

rear of vehicle when band is tightened. Pack proper amount of grease

in BJ and BJ boot. See GREASE APPLICATION table.

3) Place DOJ cage on shaft with smaller diameter installed

first. Install circlip, DOJ inner race, and snap ring on shaft. Apply

grease to DOJ inner race and cage. Install balls into cage.

4) Apply proper amount of grease to outer DOJ race. Install

shaft into DOJ outer race. Apply proper amount of grease to DOJ outer

race and install circlip. See GREASE APPLICATION table.

5) Place DOJ boot over DOJ outer race. Install boot bands so

lever is pulled toward rear of vehicle when band is tightened. Adjust

DOJ boot bands to have proper distance between centerline of boot

bands. See BOOT BAND SPECIFICATIONS table. This distance is necessary

to control air in DOJ boot. Tighten boot bands.

6) Install boot protector and band. Install dust cover on

shaft. Use a pipe with O.D. of 2.68" (68.0 mm), wall thickness of .09"

(2.3 mm) and with overall length of 6.70" (170.1 mm) to install dust

cover.

GREASE APPLICATION

Application Ozs. (g)

BJ Boot

Montero

3.0L Engine .................. 4.6 (130)

All Others .................... 3.9 (110)

DOJ Outer Race

Montero

3.0L Engine ................... 2.3 (60)

All Others ..................... 1.9 (55)

BOOT BAND SPECIFICATIONS

Application In. (mm)

All Models .......... 3.03-3.27 (76.9-83.0)

DIFFERENTIAL DISASSEMBLY

1) Remove differential carrier from vehicle. See DIFFERENTIAL

CARRIER R & I in this article. Remove cover. Mark bearing caps for

reassembly reference. Remove bearing caps. Remove differential case

assembly from carrier.

CAUTION: Ensure adjusting spacers, bearing caps, gears and side

bearings are marked for reassembly reference. Components

must be installed in original location.

2) Using bearing puller, remove differential case side

bearings. Loosen ring gear retaining bolts in diagonal sequence.

Remove ring gear.

3) Remove drive pinion shaft lock pin from ring gear side.

Remove pinion shaft and pinion gears. Remove side gears and thrust

spacers.

DRIVE PINION

1) Remove pinion flange nut. Scribe alignment mark on pinion

flange and pinion. Remove flange. Using soft-faced hammer, drive out

pinion. Remove rear bearing and oil seal from carrier. Remove rear

adjusting shim from pinion.

2) Press front bearing from pinion. Remove front adjusting

shim and spacer from pinion. Inspect all components for unusual wear

or damage. Replace as necessary.

DIFFERENTIAL REASSEMBLY & ADJUSTMENTS

CASE REASSEMBLY

1) Place side gear thrust spacers behind side gears in

original position. Assemble side gears in differential case. Install

pinion gears and washers. Rotate pinion gears to mesh with side gears.

2) Install pinion shaft without lock pin. Check pinion and

side gear backlash. Install wooden wedge to lock side gears. Using

dial indicator, measure gear backlash. See Fig. 3.

3) Backlash must be within specification. See PINION & SIDE

GEAR BACKLASH SPECIFICATIONS table. Adjust backlash by using different

side gear spacers. Ensure both sides are equally shimmed.

4) Install pinion shaft lock pin. Securely stake in 2 places.

Ensure adhesive is removed from ring gear mounting bolts and gear

mounting surface. Clean internal threads with tap.

5) Install ring gear on differential case. Ensure alignment

marks on differential case and ring gear are aligned. Apply Loctite

271 to bolts and install. Tighten bolts alternately in diagonal

sequence to specification. See TORQUE SPECIFICATIONS table at the end

of this article.

PINION & SIDE GEAR BACKLASH SPECIFICATIONS

Application In. (mm)

Standard ....................... .003 (.08)

Wear Limit ..................... .008 (.20)

Fig. 3: Checking Pinion & Side Gear Backlash

Courtesy of Chrysler Motors.

DRIVE PINION DEPTH

Content .. 64 65 66 67 ..