Mitsubishi Montero (1998+). Manual - part 91

AXLE RATIO SPECIFICATIONS

Application                                                      Ratio

Montero  .....................................................  4.27:1

Montero Sport  ..................................................  ( 1)

(1) - On vehicles equipped with wide fender, ratio is 4.64:1. On

      vehicles with narrow fender, ratio is 4.27:1.

         LUBRICATION

         CAPACITY

DIFFERENTIAL FLUID CAPACITY

Application                                              Specification

Montero & Montero Sport  ............................  2.4 Pts. (1.1L)

         FLUID TYPE

         All models use fluid type SAE 80W-90/API GL-5.

         TROUBLE SHOOTING

NOTE:    See TROUBLE SHOOTING - BASIC PROCEDURES article in the

         GENERAL TROUBLE SHOOTING section.

         REMOVAL & INSTALLATION

         AXLE SHAFTS R & I

         Removal

         1) Raise and support vehicle. Remove wheels and undercover.

Ensure hub is in free-wheeling position. Place transfer case in 2H

position. Remove drive hub cover, snap ring and shim from axle shaft.

See Fig. 3. Remove brake calipers and support aside.

         2) Disconnect tie rod assembly. Support lower control arm

with jack. Separate ball joints from knuckle. Remove knuckle and front

hub assembly. Using flat-blade pry bar, carefully remove left axle

shaft from differential carrier. DO NOT damage oil seal. On right axle

shaft, remove axle shaft-to-inner shaft flange retaining bolts. Remove

right axle shaft.

CAUTION: Replace circlips on BJ/DOJ splined shaft end.

         Installation

         1) Install right axle shaft on inner shaft flange. Install

new circlip on DOJ side of left axle shaft. Carefully install left

axle shaft into differential. DO NOT damage oil seal.

         2) Reinstall knuckle with front hub assembly. To complete

installation, reverse removal procedure. Install shim and snap ring.

Check axle end play. See Fig. 4. End play should be .016-.028" (.4-.7

mm). If end play is not within specification, install correct shim.

Fig. 3:  Exploded View Of Auto-Locking Hub Assembly (Typical)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4:  Measuring Axle Shaft End Play

Courtesy of Mitsubishi Motor Sales of America.

         DIFFERENTIAL CARRIER ASSEMBLY

         Removal

         1) Raise and support vehicle. Drain gear oil. Support

differential carrier. Remove axle shafts and inner shaft. See

AXLE SHAFTS R & I and

INNER SHAFT & BEARING. Place alignment mark on drive shaft and pinion

companion flange for reassembly reference.

         2) Remove drive shaft. Remove differential mounting brackets

at differential and frame. See Fig. 1. Disconnect front crossmember

from frame. Remove differential carrier assembly and front

crossmember. Remove differential carrier from front crossmember.

         Installation

         To install, reverse removal procedure. Align marks on drive

shaft and pinion companion flange.

         INNER SHAFT & BEARING

         Removal

         Remove right axle shaft. See AXLE SHAFTS R & I. Using slide

hammer, remove inner shaft from differential carrier. See  Fig. 1. If

dust seal replacement is required, pry dust seal from housing tube

assembly using a screwdriver. To remove bearing, bend outer area of

dust cover inward on inner shaft. Press shaft out of bearing. Remove

dust cover from shaft.

         Inspection

         Inspect inner shaft for damaged splines or threads. Inspect

bearing for roughness or damage.

         Installation

         1) 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 2.00" (75.0 mm), wall thickness

of .16" (4.0 mm) and overall length of 2.00" (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. Carefully drive inner

shaft into differential. DO NOT damage oil seal. To complete

installation, reverse removal procedure.

         OVERHAUL

         AXLE SHAFTS & BEARINGS

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

         Offset Joint, respectively.

         Disassembly

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

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

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

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

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

of shaft to prevent boot damage during removal. Remove DOJ boot. Note

size of boot. Remove dust cover from shaft. Move boot protector toward

BJ side of shaft and remove. Remove BJ boot.

CAUTION: Axle shaft and BJ are serviced as a unit. DO NOT attempt to

         disassemble BJ and axle shaft.

         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) Pack proper amount of grease in BJ and BJ boot. See

CV JOINT GREASE CAPACITY table. Boot bands must be installed so lever

is pulled toward rear of vehicle when band is tightened.

         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. Apply

proper amount of grease to outer DOJ race. See

CV JOINT GREASE CAPACITY table. Install shaft into DOJ outer race.

Install circlip.

         4) 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 center line of boot

bands. Distance should be 3.03-3.27" (76.9-83.0 mm). This distance is

necessary to control air in DOJ boot. Tighten boot bands. Install boot

protector and band. Install dust cover on shaft.

CV JOINT GREASE CAPACITY

Application                                               ( 1) Ozs. (g)

BJ Boot & Joint

  Montero  ................................................  4.6 (130)

  Montero Sport  ..........................................  4.2 (120)

DOJ Boot & Joint

  Montero  ................................................  3.5 (100)

  Montero Sport  ..........................................  4.9 (140)

(1) - Apply 1/2 of the amount of grease specified to joint, the other

      half to inside of CV boot.

         DIFFERENTIAL ASSEMBLY

         Disassembly

         1) Remove differential carrier from vehicle. See

DIFFERENTIAL CARRIER ASSEMBLY under REMOVAL & INSTALLATION. 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. Remove drive pinion shaft lock pin from ring gear

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

thrust spacers.

         Drive Pinion Removal

         Remove pinion flange nut. Scribe alignment mark on pinion

companion flange and drive pinion. Remove flange. Using soft-faced

hammer, drive out pinion. Remove rear bearing and oil seal from

carrier. Remove rear adjusting shim from pinion. See  Fig. 1. Press

front bearing from pinion. Remove front adjusting shim and spacer from

pinion.

         Cleaning & Inspection

         Use cleaning solvent to rinse gears and components. Check

bearings for wear or discoloration. Check gear carrier for cracks or

damage. Check pinion, side gear and flange splines for excessive wear.