Mitsubishi Montero (1991+). Manual - part 71

Fig. 10:  Checking Differential Starting Torque

Courtesy of Chrysler Motors.

         14) Starting torque must be within specification. See

STARTING TORQUE SPECIFICATIONS table. Ensure adhesive is removed from

ring gear mounting bolts and gear mounting surface. Clean internal

threads with tap.

         15) Ensure alignment marks on differential case and ring gear

are aligned. Apply Loctite 271 to bolts and install ring gear on

differential case. Tighten bolts in diagonal sequence to

specification. See TORQUE SPECIFICATIONS table.

STARTING TORQUE SPECIFICATIONS

Application                            Ft. Lbs. (N.m)

Used Clutch Plates  ..................  25-72 (34-98)

New Clutch Plates  ...................  47-72 (64-98)

         DRIVE PINION HEIGHT

         1) Install pinion bearing races in carrier. Ensure races are

fully seated. Install pinion height gauge and pinion bearings. Use

Pinion Height Gauge (MB990901) for all others. See  Fig. 10. DO NOT

install oil seal.

         2) Using torque wrench, measure pinion rotating torque.

Gradually tighten pinion height gauge to increase rotating torque to

3.5-4.3 INCH lbs. (.40-.48 N.m).

         3) Install cylinder gauge in side bearing seats. Ensure flat

areas are aligned and gauge contacts side bearing seat firmly. See

Fig. 11. Select adjusting shim with same thickness as gap between

cylinder gauge and pinion height gauge.

         4) Use minimum amount of adjusting shims. Install selected

adjusting shims between drive pinion gear and rear pinion bearing.

Using bearing installer, install rear pinion bearing.

Fig. 11:  Setting Pinion Height

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. Install pinion flange, washer and retaining nut. Tighten nut

to specification. See TORQUE SPECIFICATIONS table.

         2) Check pinion rotating torque. Rotating torque must be

within specification. Correct specification is 3.5-4.3 INCH lbs. (.40-

.48 N.m) without oil seal. Adjust rotating torque by replacing drive

pinion front shims or spacer.

         3) Once correct rotating torque is obtained, install oil

seal. Coat seal lip with grease. Install pinion flange so alignment

marks are correct. Apply light coat of grease to contact area of

pinion flange washer.

         4) Install new retaining nut. Recheck pinion rotating torque.

Rotating torque must be within specification.

         SIDE BEARING

         1) Press side bearings onto differential case. Install outer

races. Install differential case into differential carrier. Align

bearing cap index marks, and snug carrier cap bolts. Ensure outer

races and bearing caps are installed in original location. Tighten

bearing cap bolts finger tight.

         2) Install side bearing nuts. Tighten bearing cap bolts. See

TORQUE SPECIFICATIONS table. Rotate bearing nuts in and out until

rotation is smooth. Temporarily tighten side bearing nuts to preload

side bearings. See TORQUE SPECIFICATIONS table. Adjust 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 specification. See RING

GEAR BACKLASH SPECIFICATIONS table.

RING GEAR BACKLASH SPECIFICATIONS

Application                                   In. (mm)

2.4L  .......................  .0043-.0063 (.109-.160)

3.0L  .......................  .0051-.0071 (.130-.180)

         2) If backlash is less than specification, loosen side

bearing nut at back of ring gear and tighten side bearing nut on tooth

side of ring gear by same amount. If backlash is beyond specification,

loosen side bearing nut at tooth side of ring gear and tighten side

bearing nut at back of ring gear by same amount.

         3) After adjusting backlash, tighten both side bearing nuts

half the distance between center of 2 neighboring holes on side

bearing nut. Recheck backlash. Ensure bearing cap bolts are tightened

to specification. See TORQUE SPECIFICATIONS table.

         4) Lock plates are of 2 designs for hole location of side

bearing nuts. Install proper type lock plate. Tighten lock plate bolt

to specification. See TORQUE SPECIFICATIONS table. Check gear tooth

contact using paint impression method. See GEAR TOOTH CONTACT PATTERNS

in this article.

         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.

         TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application                                             Ft. Lbs. (N.m)

Axle Bearing Lock Nut (Montero)  ..................  130-159 (176-216)

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

Bearing Case-To-Axle Housing Bolt  ....................  36-43 (49-58)

Brake Tube Flare Nut  .................................  10-12 (14-16)

Differential Carrier-To-Axle Housing Nut

  2.4L (2WD)  .........................................  18-22 (24-30)

  3.0L (4WD)  .........................................  29-40 (39-54)

Drain Plug  ...........................................  43-50 (58-68)

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

Lock Plate Bolt  ......................................  11-16 (15-22)

Pinion Flange Nut  ................................  137-181 (186-245)

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

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

Side Bearing Lock Plate Bolts  ........................  11-16 (15-22)

Wheel Lug Nut

  Montero  ...........................................  72-87 (98-118)

  Pickup  ..........................................  87-101 (118-137)