Mitsubishi Montero (1998+). Manual - part 92

Check ring gear, pinion and side gears for wear or damage. Replace

components as necessary.

         Reassembly & Adjustments

         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. 5.

         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. If backlash cannot be adjusted within specifications, replace

side and pinion gears as matched set.

         4) Install pinion shaft lock pin. Using a punch, securely

stake lock pin 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 bolts. Tighten bolts alternately in diagonal

sequence to specification. See TORQUE SPECIFICATIONS.

PINION & SIDE GEAR BACKLASH SPECIFICATIONS

Application                                                   In. (mm)

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

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

Fig. 5:  Checking Pinion & Side Gear Backlash

Courtesy of Mitsubishi Motor Sales of America.

         Drive Pinion Depth

         1) Install pinion bearing races in carrier housing. Ensure

races are fully seated. Install Pinion Height Gauge (MB990901-01) with

pinion bearings. See Fig. 6. DO NOT install oil seal.

         2) 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. Install Cylinder Gauge

(MB990903-01). Ensure flat areas are aligned and that gauge contacts

carrier bearing bores firmly. See Fig. 6.

         3) 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 drive pinion bearing. Using Bearing Installer (MB990802-

01), install rear pinion bearing.

PINION ROTATING TORQUE SPECIFICATIONS

Application                                            INCH Lbs. (N.m)

Oil Seal Not Installed

  With Lubrication  ...............................  1.3-2.2 (.15-.25)

  Without Lubrication  ............................  2.6-4.3 (.30-.50)

Oil Seal Installed

  With Lubrication  ...............................  3.1-3.9 (.35-.45)

  Without Lubrication  ............................  4.3-6.1 (.50-.70)

Fig. 6:  Setting Drive Pinion Depth

Courtesy of Mitsubishi Motor Sales of America.

         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 companion flange, washer and

retaining nut. Tighten nut to 137 ft. lbs. (190 N.m).

         2) Using INCH-lb. torque wrench, check pinion rotating torque

without pinion oil seal. 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 Installation

         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 in thickness on both sides. Install

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

differential carrier housing.

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

feeler gauges (feeler gauges 180 degrees opposed), measure clearance

between carrier and side bearing. Remove shims from one side of

differential carrier.

         3) Measure thickness of shims removed. Add .002" (.05 mm) to

50% of measured clearance and then add thickness measurement of

removed shim. This is thickness of new shim that should be installed

on each side of case. Install equal thickness shims on each side of

case assembly.

NOTE:    Ensure zero 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. Tighten bolts to

specification. See TORQUE SPECIFICATIONS. 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 should be .004-.006" (.10-.15 mm).

         2) If backlash is not within specification, change side

bearing adjusting shims and recheck backlash. See

GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Check gear

tooth contact using Prussian Blue.

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

         remain constant to ensure correct bearing preload.

         Ring Gear Runout

         Using dial indicator, measure runout at back side of ring

gear. Runout should not exceed .002" (.05 mm). If runout is excessive,

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

gear mounting bolts are tightened to correct specification. Recheck

runout. Install cover and gasket.

         TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application                                             Ft. Lbs. (N.m)

Brake Caliper Bolt  .........................................  65 (88)

Carrier-To-Housing Tube Bolt

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

  Montero Sport  ......................................  58-72 (79-98)

Differential

  Cover Bolt  ...............................................  14 (19)

  Drain Plug

    Montero  ..........................................  43-51 (58-69)

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

  Fill Plug

    Montero  ................................................  39 (53)

    Montero Sport  ..........................................  36 (49)

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

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

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

Knuckle-To-Ball Joint Nut

  Upper

    Montero  ................................................  54 (73)

    Montero Sport  ....................................  44-65 (60-88)

  Lower

    Montero  ..............................................  108 (146)

    Montero Sport  .............  ..................  87-130 (118-176)

Mounting Bracket-To-Frame Bolt  ......................  58-80 (79-108)

Mounting Bracket-To-Housing Tube Bolt  ................  58-72 (79-98)

Pinion Flange Nut

  Montero

    A/T  ..................................................  137 (186)

    M/T  ..................................................  159 (216)

  Montero Sport  ..........................................  159 (216)

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

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

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

Tie Rod-To-Knuckle Nut

  Montero  ..................................................  33 (45)

  Montero Sport  ............................................  32 (43)

Wheel Lug Nuts

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

  Montero Sport

    Aluminum Wheel  ..................................  73-86 (99-117)

    Steel Wheel  ...................................  87-101 (118-137)

                                                        INCH Lbs. (N.m)

Undercover-To-Frame Bolts (Montero)  ..............  84-108 (9.5-12.2)

(1) - Information is not available from manufacturer.