Mitsubishi Montero (1991+). Manual — part 67
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1) Install pinion bearing races in carrier. For front race
use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L and
2.6L models and Race Installer (MB990935-01) for 3.0L models. For rear
race, use Handle and Race Installer (MB990936-01). Ensure races are
fully seated.
2) Install Pinion Height Gauge (MB990901-01) and pinion
bearings. See Fig. 4. DO NOT install oil seal. 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.
3) Install Cylinder Gauge (MB990903-01) in side bearing
seats. Ensure flat areas are aligned and gauge contacts side bearing
seat firmly. See Fig. 4.
4) 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 pinion bearing. Using Bearing Installer (MB990802-01),
install rear pinion bearing.
PINION ROTATING TORQUE SPECIFICATIONS
Application INCH Lbs. (N.m)
With Oil Seal
2.4L & 2.6L Engines . 3.04-3.91 (.35-.45)
3.0L Engine . . ... 5.21-6.08 (.6-.7)
Without Oil Seal
2.4L & 2.6L Engines . 1.30-2.17 (.15-.25)
3.0L Engine . . ... 3.47-4.34 (.4-.5)
Fig. 4: Setting Pinion Depth
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 at this time. Install pinion flange, washer and retaining
nut. Check pinion rotating torque without pinion oil seal.
2) Recheck rotating torque. Rotating torque must be within
specification. 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
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 thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges, measure clearance between carrier and side bearing shim
at opposite sides of bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add removed shim
thickness and 1/2 of feeler gauge clearance measurement plus .002" (.
05 mm). This is thickness of shim that should be installed on each
side of case. Select proper shims. Install equal shims on each side of
case assembly.
NOTE: Ensure no 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. 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 must be within .004-.006" (.10-.15 mm).
2) If not within specification, change side bearing adjusting
shims and recheck backlash. If backlash is too small, install thinner
shim behind ring gear and thicker shim opposite ring gear.
3) If backlash is excessive, install thicker shim behind ring
gear and thinner shim opposite ring gear. Check gear tooth contact
using paint impression method.
CAUTION: When changing shims, total thickness of all shims must
remain constant.
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. Install cover and gasket.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Bearing Cap Bolt . . . . . .. 40-47 (54-64)
Brake Caliper Bolt . . . . . 58-72 (79-98)
Carrier-to-Housing Tube Bolt . . .. 58-72 (79-98)
Cover Bolt . . . . . . . 11-16 (15-22)
Drain Plug . . . . . . . 43-51 (58-69)
Fill Plug . . . . . . . . 29-43 (39-58)
Front Crossmember Bolt . . . ... 72-87 (98-118)
Hub Cover . . . . . . . . 13-25 (18-34)
Knuckle-to-Ball Joint Nut
Upper . . . . . . . ... 43-65 (58-88)
Lower . . . . . . . 87-130 (118-176)
Mount Bracket-to-Frame Bolt . . .. 58-80 (79-108)
Mount Bracket-to-Housing Tube Bolt ... 58-72 (79-98)
Pinion Flange Nut
2.4L & 2.6L . . . . . . 116-159 (157-216)
3.0L . . . . . . . 137-181 (186-245)
Drive Shaft Flange Bolt . . . ... 36-43 (49-58)
Right Drive Axle-to-Inner Shaft Bolt .. 36-43 (49-58)
Ring Gear-to-Case Bolt . . . . 58-65 (79-88)
Tie Rod-to-Knuckle Nut . . . . . .. 33 (45)
Wheel Lug Nuts
Montero . . . . . . . 72-87 (98-188)
Pick-Up . . . . . . .. 87-101 (118-137)
INCH Lbs. (N.m)
Undercover-to-Frame
Bolts (Montero) . . . . . 84-108 (9.5-12.2)
DRIVE AXLE - REAR NON-INTEGRAL
1991 Mitsubishi Montero
1991 92 DRIVE AXLES
Differentials & Axle Shafts - Rear Non-Integral
Mitsubishi: Montero, Pickup
DESCRIPTION
Rear axle features a rigid banjo-type housing with semi-
floating axle shafts. Differential consists of hypoid reduction gears
and straight bevel differential gears. Limited Slip Differential (LSD)
is available on all models.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS
Application Ratio
Montero . . . . . . . . . . . . .. 4.63
Pickup
2WD w/Light Suspension . . . . . . . . . 3.91
2WD w/Heavy Suspension . . . . . . . . . 4.22
4WD . . . . . . . . . . . . . 4.22
LUBRICATION
CAPACITY
REAR AXLE GEAR OIL CAPACITY
Application Pts. (L)
Montero . . . . . . . . .. 5.4 (2.5)
Pickup
Conventional
2WD . . . . . . . . ... 3.2 (1.5)
4WD . . . . . . . . ... 5.5 (2.6)
LSD . . . . . . . . . 5.5 (2.6)
FLUID TYPE
Conventional differentials use API classification GL-5 SAE
80W or 90W. Limited slip differentials use Mitsubishi Gear Oil
(8149630 EX) or Mopar Gear Oil (4318058) and Mopar Friction Modifier
(4318060).
TROUBLE SHOOTING
DRIVE AXLE (RWD) TROUBLE SHOOTING
PROBLEM
Possible Cause Action
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