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Mitsubishi Montero (1998+). Manual - part 97

Fig. 17: Checking Differential Starting Torque

Courtesy of Mitsubishi Motor Sales of America.

13) Ensure starting torque is within specification. See

STARTING TORQUE table. Ensure adhesive is removed from ring gear

mounting bolts and gear mounting surface. Clean internal threads with

tap.

14) Ensure alignment marks on differential case and ring gear

align. Apply Loctite 271 to bolts, and install ring gear on

differential case. Tighten bolts in diagonal sequence to

specification. See TORQUE SPECIFICATIONS.

STARTING TORQUE

Application Ft. Lbs. (N.m)

Used Clutch Plates ................................... 29-54 (40-75)

New Clutch Plates .................................... 18-54 (25-75)

Carrier Assembly & Drive Pinion Installation

1) Install pinion bearing races in differential housing.

Ensure races are fully seated. Install Pinion Height Gauge (MB990901)

and pinion bearings. See Fig. 18. DO NOT install oil seal.

Fig. 18: Setting Pinion Height

Courtesy of Mitsubishi Motor Sales of America.

2) Using torque wrench, measure pinion rotating torque.

Gradually tighten pinion height gauge to increase rotating torque. See

PINION ROTATING TORQUE SPECIFICATIONS table.

PINION ROTATING TORQUE SPECIFICATIONS

Application INCH Lbs. (N.m)

Oil Seal Not Installed

With Lubrication ................................. 3.5-4.3 (.4-.5)

Without Lubrication .............................. 5.2-7.8 (.6-.9)

Oil Seal Installed

With Lubrication ............................... 5.6-6.5 (.65-.75)

Without Lubrication .......................... 7.4-10.0 (.85-1.15)

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

areas align, and gauge contacts side bearing seat firmly. 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 and press, install rear pinion bearing.

5) Install drive pinion in differential housing. Install

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

oil seal. Install pinion companion flange, washer and retaining nut.

Tighten nut to specification. See TORQUE SPECIFICATIONS.

6) Check pinion rotating torque. 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.

Install pinion companion flange so alignment marks are correct. Apply

light coat of grease to contact area of pinion flange washer.

7) Install NEW retaining nut. Recheck pinion rotating torque.

Ensure rotating torque is within specification. Press side bearings

onto differential case. Install outer races. Install differential

carrier into differential housing. Align bearing cap index marks, and

snug carrier cap bolts. Ensure outer races and bearing caps are

installed in original location.

8) Install side bearing nuts. Tighten bearing cap bolts to

specification. See TORQUE SPECIFICATIONS. Tighten bearing nuts until

bearing outer races are seated against bearings. Adjust ring gear

backlash.

Ring Gear Backlash

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

ring gear backlash at heel of ring gear tooth. See Fig. 6. Measure at

4 locations of ring gear. Gear backlash must be within specification.

Backlash should be .005-.007" (.13-.18 mm).

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 exceeds

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 2 adjacent holes on side bearing nut.

Recheck backlash. Ensure bearing cap bolts are tightened to

specification. See TORQUE SPECIFICATIONS.

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. Check gear tooth contact

pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL

INFORMATION.

Ring Gear Runout

Using dial indicator, measure runout at back side of ring

gear. See Fig. 7. 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)

Bearing Cap Bolt

Montero ............................................ 40-47 (54-64)

Montero Sport ...................................... 37-48 (51-65)

Bearing Case-To-Axle Housing Bolt

Montero .................................................. 35 (47)

Montero Sport ...................................... 40-47 (54-64)

Brake Tube Flare Nut ....................................... 11 (15)

Differential Carrier-To-Axle Housing Nut

Montero .................................................. 35 (47)

Montero Sport

2.4L ............................................. 18-21 (24-28)

3.0L ................................................... 35 (47)

Drain Plug (Montero Sport) ................................. 44 (60)

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

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

Pinion Flange Nut ........................................ 159 (216)

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

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

Wheel Lug Nut

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

Montero Sport

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

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

Content .. 95 96 97 98 ..