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Mitsubishi Montero (1991+). Manual - part 67

1) Install pinion bearing races in carrier. For front race

use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L and

2.6L models and Race Installer (MB990935-01) for 3.0L models. For rear

race, use Handle and Race Installer (MB990936-01). Ensure races are

fully seated.

2) Install Pinion Height Gauge (MB990901-01) and pinion

bearings. See Fig. 4. DO NOT install oil seal. Using INCH lb. torque

wrench, measure pinion rotating torque. Gradually tighten pinion

height gauge to increase rotating torque to proper specification. See

PINION ROTATING TORQUE SPECIFICATIONS table.

3) Install Cylinder Gauge (MB990903-01) in side bearing

seats. Ensure flat areas are aligned and gauge contacts side bearing

seat firmly. See Fig. 4.

4) Select adjusting shim with same thickness as gap between

cylinder gauge and pinion height gauge. Use minimum amount of

adjusting shims. Install selected adjusting shims between drive pinion

gear and rear pinion bearing. Using Bearing Installer (MB990802-01),

install rear pinion bearing.

PINION ROTATING TORQUE SPECIFICATIONS

Application INCH Lbs. (N.m)

With Oil Seal

2.4L & 2.6L Engines . 3.04-3.91 (.35-.45)

3.0L Engine ........... 5.21-6.08 (.6-.7)

Without Oil Seal

2.4L & 2.6L Engines . 1.30-2.17 (.15-.25)

3.0L Engine ........... 3.47-4.34 (.4-.5)

Fig. 4: Setting Pinion Depth

Courtesy of Chrysler Motors.

DRIVE PINION PRELOAD

1) Install drive pinion in differential carrier. Install

spacer, pinion front shim(s) and front pinion bearing. DO NOT install

oil seal at this time. Install pinion flange, washer and retaining

nut. Check pinion rotating torque without pinion oil seal.

2) Recheck rotating torque. Rotating torque must be within

specification. See PINION ROTATING TORQUE SPECIFICATIONS table. Adjust

rotating torque by replacing drive pinion front shims or spacer. Once

correct rotating torque is obtained, install oil seal. Coat seal lip

with grease.

3) Install pinion flange so alignment marks are correct.

Apply light coat of grease to flange washer contact area. Install new

retaining nut. Check pinion rotating torque with pinion oil seal

installed. Rotating torque must be within specification. See PINION

ROTATING TORQUE SPECIFICATIONS table.

SIDE BEARING

1) Using Bearing Installer (MB990802-01), install bearings on

differential case. Select 2 side bearing adjusting shims thinner than

those removed. Shims must be equal thickness on both sides. Install

shims on each side of case assembly. Install case assembly in

differential carrier.

2) Push case assembly fully to one side of carrier. Using 2

feeler gauges, measure clearance between carrier and side bearing shim

at opposite sides of bearing. Remove shims from one side of

differential carrier.

3) Measure thickness of shims removed. Add removed shim

thickness and 1/2 of feeler gauge clearance measurement plus .002" (.

05 mm). This is thickness of shim that should be installed on each

side of case. Select proper shims. Install equal shims on each side of

case assembly.

NOTE: Ensure no clearance exists between gear carrier and

adjusting shim.

4) Install side bearing shims and differential case assembly

in differential carrier. Using brass drift, tap shims to fit them to

side bearing outer race. Install bearing caps. Check ring gear

backlash.

RING GEAR BACKLASH

1) Lock drive pinion in place. Using dial indicator, check

ring gear backlash at heel of ring gear tooth. Measure at 4 locations

of ring gear. Gear backlash must be within .004-.006" (.10-.15 mm).

2) If not within specification, change side bearing adjusting

shims and recheck backlash. If backlash is too small, install thinner

shim behind ring gear and thicker shim opposite ring gear.

3) If backlash is excessive, install thicker shim behind ring

gear and thinner shim opposite ring gear. Check gear tooth contact

using paint impression method.

CAUTION: When changing shims, total thickness of all shims must

remain constant.

RING GEAR RUNOUT

Using dial indicator, measure runout at back side of ring

gear. Runout must be within .002" (.05 mm). If runout is excessive,

change ring gear-to-differential case mounting position. Recheck

runout. Install cover and gasket.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)

Bearing Cap Bolt ...................... 40-47 (54-64)

Brake Caliper Bolt .................... 58-72 (79-98)

Carrier-to-Housing Tube Bolt .......... 58-72 (79-98)

Cover Bolt ............................ 11-16 (15-22)

Drain Plug ............................ 43-51 (58-69)

Fill Plug ............................. 29-43 (39-58)

Front Crossmember Bolt ............... 72-87 (98-118)

Hub Cover ............................. 13-25 (18-34)

Knuckle-to-Ball Joint Nut

Upper ............................... 43-65 (58-88)

Lower ............................ 87-130 (118-176)

Mount Bracket-to-Frame Bolt .......... 58-80 (79-108)

Mount Bracket-to-Housing Tube Bolt ... 58-72 (79-98)

Pinion Flange Nut

2.4L & 2.6L ..................... 116-159 (157-216)

3.0L ............................ 137-181 (186-245)

Drive Shaft Flange Bolt ............... 36-43 (49-58)

Right Drive Axle-to-Inner Shaft Bolt .. 36-43 (49-58)

Ring Gear-to-Case Bolt ................ 58-65 (79-88)

Tie Rod-to-Knuckle Nut ...................... 33 (45)

Wheel Lug Nuts

Montero ............................ 72-87 (98-188)

Pick-Up .......................... 87-101 (118-137)

INCH Lbs. (N.m)

Undercover-to-Frame

Bolts (Montero) ................. 84-108 (9.5-12.2)

DRIVE AXLE - REAR NON-INTEGRAL

1991 Mitsubishi Montero

1991 92 DRIVE AXLES

Differentials & Axle Shafts - Rear Non-Integral

Mitsubishi: Montero, Pickup

DESCRIPTION

Rear axle features a rigid banjo-type housing with semi-

floating axle shafts. Differential consists of hypoid reduction gears

and straight bevel differential gears. Limited Slip Differential (LSD)

is available on all models.

AXLE RATIO & IDENTIFICATION

Ratio is determined by dividing number of ring gear teeth by

number of drive pinion teeth.

AXLE RATIO SPECIFICATIONS

Application Ratio

Montero .................................................. 4.63

Pickup

2WD w/Light Suspension ................................. 3.91

2WD w/Heavy Suspension ................................. 4.22

4WD .................................................... 4.22

LUBRICATION

CAPACITY

REAR AXLE GEAR OIL CAPACITY

Application Pts. (L)

Montero .................................. 5.4 (2.5)

Pickup

Conventional

2WD ................................... 3.2 (1.5)

4WD ................................... 5.5 (2.6)

LSD .................................... 5.5 (2.6)

FLUID TYPE

Conventional differentials use API classification GL-5 SAE

80W or 90W. Limited slip differentials use Mitsubishi Gear Oil

(8149630 EX) or Mopar Gear Oil (4318058) and Mopar Friction Modifier

(4318060).

TROUBLE SHOOTING

DRIVE AXLE (RWD) TROUBLE SHOOTING

PROBLEM

Possible Cause Action

Content .. 65 66 67 68 ..