Mitsubishi Montero (1991+). Manual - part 68

KNOCKING OR CLUNKING

Differential Side Gear Clearance  ..............  Check Clearance

Worn Pinion Shaft  ........................  Replace Pinion Shaft

Axle Shaft End Play  ............................  Check End Play

Missing Gear Teeth  ...................  Check Diff./Replace Gear

Wrong Axle Backlash  ............................  Check Backlash

Misaligned Driveline  ........................  Realign Driveline

CLUNKING DURING ENGAGEMENT

Side Gear Clearance  .................  Check Side Gear Clearance

Ring and Pinion Backlash  .......................  Check Backlash

Worn/Loose Pinion Shaft  .................  Replace Shaft/Bearing

Bad "U" Joint  ...............................  Replace "U" Joint

Sticking Slip Yoke  .............................  Lube Slip Yoke

Broken Rear Axle Mount  ..........................  Replace Mount

Loose Drive Shaft Flange  .........................  Check Flange

CLICK/CHATTER ON TURNS

Differential Side Gear Clearance  ..............  Check Clearance

Worn Clutch Plates (1)  ..................  Replace Clutch Plates

Wrong Diff. Lubricant (1)  ....................  Change Lubricant

RHYTHMIC KNOCK OR CLICK

Flat Spot on Rear Wheel Bearing  .........  Replace Wheel Bearing

HUM/LOW VIBRATION AT ALL SPEEDS

Faulty Wheel Bearings  ........................  Replace Bearings

Faulty "U" Joint  ............................  Replace "U" Joint

Faulty Drive Shaft  ........................  Balance Drive Shaft

Faulty Companion Flange  ........................  Replace Flange

Faulty Slip Yoke Flange  ........................  Replace Flange

(1) - Limited slip differential only.

         DRIVE AXLE (FWD)

DRIVE AXLE (FWD) TROUBLE SHOOTING

PROBLEM

Possible Cause                                             Action

GREASE LEAKING

Ripped CV Boot  ...................................  Replace Boot

CLICKING NOISE WHILE CORNERING

Dry/Worn CV Joints  ....................  Replace Outer CV Joints

CLUNK ON ACCELERATION

Dry/Worn CV Joints  ....................  Replace Inner CV Joints

Worn Trans. Gears/Bearings  .....................  Inspect Trans.

VIBRATION/SHUDDER ON ACCELERATION

Dry/Worn CV Joints  ..........................  Replace CV Joints

Alignment Out  .................................  Check Alignment

Incorrect Spring Height  ...................  Check Spring Height

SQUEALING OR HUMMING

Dry/Worn CV Joints  .....................  Lube/Replace CV Joints

Faulty Wheel Bearing  ....................  Replace Wheel Bearing

         TESTING & INSPECTION

         AXLE SHAFT END PLAY

         Using dial indicator, check axle shaft end play. End play

must be .0020-.0079" (.05-.20 mm). If end play is not within

specification, change shims to obtain correct end play. See AXLE

SHAFTS under REMOVAL & INSTALLATION.

         AXLE TOTAL BACKLASH

         1) Raise and support rear axle. Place transmission in

Neutral. Apply parking brake. Rotate drive shaft clockwise. Place

reference marks on pinion dust cover and differential housing.

         2) Rotate drive shaft counterclockwise and measure distance

between reference marks. Differential must be removed and backlash

adjusted if distance exceeds 0.2" (5.0 mm).

         LIMITED SLIP DIFFERENTIAL PRELOAD

         1) Place transmission in Neutral. Block front wheels. Raise

one rear wheel free of ground and remove wheel. Use Axle Puller

Adapter (MB990241) for Montero and Pickup models. Install adapter on

wheel studs. Release parking brake.

         2) Using torque wrench, measure starting torque on Pickup

models while rotating wheel in forward direction. On Montero models,

measure rotating torque. This measurement is read once axle is

turning. Differential must be repaired if torque is less than

specification. See TESTING SPECIFICATIONS table.

TESTING SPECIFICATIONS

Application                              Ft. Lbs. (N.m)

Montero & Pickup  ............................  25 (34)

         REMOVAL & INSTALLATION

         AXLE SHAFTS

         Removal

         1) Block front wheels. Raise and support rear axle housing.

Remove brake drum. See Fig. 1. Remove parking brake cable attaching

bolts. Remove connection for parking brake cable end and rear brake

assembly. Drain brake fluid from bleeder screw at left side of rear

brake and disconnect brake tubes.

         2) On all models, remove flange nuts and rear axle shaft

assembly. Use Puller (MB990241) and Slide Hammer (MB990211) if

necessary. DO NOT damage oil seal. Remove shim(s) and "O" ring.

Replace if necessary.

Fig. 1:  Exploded View of Axle Shaft

Courtesy of Chrysler Motors.

         Installation

         1) Insert a new "O" ring and a shim of .04" (1.0 mm)

thickness into left side axle housing. Install left axle shaft

assembly into axle housing and tighten nuts to specification. See

TORQUE SPECIFICATIONS table at the end of this article.

         2) Install right axle shaft assembly into axle housing

WITHOUT a shim or "O" ring. Temporarily tighten nuts in diagonal

sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance

between bearing case and rear axle housing end with a feeler gauge.

         3) Select shims equal to the sum of the thickness of the

measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle

shaft and install the selected shim(s) and "O" ring into right axle

housing end. Install right axle shaft assembly into rear axle housing.

Tighten nuts in diagonal sequence to specification. See TORQUE

SPECIFICATIONS table.

         4) Using dial indicator, check end play of axle shaft. End

play must be .0020-.0079" (.05-.20 mm). If end play is not within

specification, change shim(s) to obtain correct end play. Reverse

removal procedure to install remaining components. Adjust parking

brake and bleed brake system.

         DIFFERENTIAL CARRIER

         Removal

         Raise and support vehicle. Drain gear oil. Mark drive shaft

flange-to-pinion flange position. Remove drive shaft. Remove axle

shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support

differential carrier with jack. Remove differential carrier retaining

nuts. Remove differential carrier.

         Inspection

         Inspect for leakage at vent plug, differential carrier

companion flange and where carrier joins axle housing.

         Installation

         Apply sealant to axle housing surface. To install, reverse

removal procedure. Align marks on drive shaft and pinion flange.

         DRIVE SHAFT

         Removal

         Make match marks on drive shaft yoke flange and pinion

flange. Remove bolts. Remove drive shaft from vehicle.

         Installation

         To install, reverse removal procedure. Ensure match marks are

aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS

table at end of article.

         OVERHAUL

         AXLE SHAFTS

         Disassembly

         1) Mount backing plate and axle shaft assembly in soft-jawed

vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench

(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall

lock nut on axle shaft approximately 3 turns.

         2) Attach Bearing Puller (MB990787-01) to rear of backing

plate to remove bearing case from axle shaft. See  Fig. 2. Using equal

pressure to avoid binding, tighten puller nuts diagonally to remove

bearing case. Using hammer and drift, remove bearing outer race from

bearing case. Remove oil seal from end of axle housing with Slide

Hammer and Adapter (MB990211).