Mitsubishi Montero (1991+). Manual — part 55

oil seal using seal driver. Apply grease to outside circumference of

bearing outer race. Apply grease to lip of oil seal and to roller

surfaces of bearing inner race.

2) Press bearing onto axle shaft. Install rear brake assembly

and bearing case. Pack bearing case and axle threads with grease.

Install lock washer (tab aligned with axle slot) and lock nut (chamfer

toward lock washer). Tighten lock nut to 130-159 ft. lbs. (176-216 N.

m).

3) Bend tabs on lock washer into slots of lock nut. Apply

grease to oil seal area of rear axle housing. Adjust clearance between

bearing case and rear axle by inserting .04" (1.0 mm) shim and "O"

ring into left rear axle housing.

4) Apply semi-drying sealant to mating surface of bearing

case. Install left axle shaft into rear housing. Tighten nuts

diagonally to 36-43 ft. lbs. (49-58 N.m).

5) Install right axle shaft without shims and "O" ring.

Temporarily tighten to about 53 INCH lbs. (6 N.m). Using a feeler

gauge, measure clearance between bearing case and rear axle housing.

6) Remove right axle shaft. Install shims to equal bearing

case-to-axle housing clearance plus .002-.008" (.05-.20 mm). Install

"O" ring to right rear axle housing. Apply sealant to mating surfaces

of bearing case and shim. See Fig. 10.

7) Install axle into housing, tightening nuts diagonally to

36-43 ft. lbs. (50-58 N.m). Check axle shaft for .002-.008" (.05-.20

mm) end play using dial indicator.

Fig. 10: Applying Sealant (Montero, Pickup & Ram-50)

Courtesy of Mitsubishi Motor Sales of America.

Removal (Pickup & Ram-50)

1) With drum removed, disconnect brake line from wheel

cylinder. Disconnect parking brake cable end, and remove cable

attaching bolts. Remove brake backing plate, bearing case and axle

shaft as an assembly. If axle shaft binds, use slide hammer with

puller to remove.

2) Remove shims, "O" ring and snap ring. Retain shims for

reassembly. Secure axle shaft assembly in a vise, and remove one

retainer bolt from backing plate. Push bearing case completely to side

of dust cover. Place adhesive tape around edge of bearing case at

retainer bolt hole to prevent damage.

3) Secure axle shaft, and grind retainer ring until retainer

ring wall thickness is .04-.06" (1.0-1.5 mm) on axle shaft side and

retainer ring wall thickness is .08" (2.0 mm) on bearing side. See

Fig. 11.

CAUTION: DO NOT damage bearing case or axle shaft when grinding or

chiseling retainer ring.

4) Change angle of grind, and remove remaining .08" (2.0 mm)

of retainer ring wall on bearing side. See Fig. 11. Using a chisel,

cut retainer ring, and remove. DO NOT damage axle shaft.

Fig. 11: Grinding Bearing Retainer Ring (Pickup & Ram-50)

Courtesy of Mitsubishi Motor Sales of America.

5) Install Puller (MB990787-01) to remove bearing case from

axle shaft. Rotate nuts with equal force to remove wheel bearing.

Remove bearing outer race using a hammer and drift. Remove oil seal

from axle housing using a slide hammer and hook.

Installation

1) Apply Multipurpose Grease (SAE J310) to oil seal. Install

oil seal using seal driver. Apply grease to outside circumference of

oil seal lip. Install backing plate and bearing case. Apply grease to

oil seal.

2) Press new oil seal into bearing case until it is flush

with face of bearing case. Apply grease to lip of oil seal and to

external surfaces of bearing outer race. Press bearing outer race into

bearing case.

3) Apply grease to roller surfaces of bearing inner race.

Install rear brake assembly and bearing case. Pack bearing case and

axle threads with grease. Install new retainer ring.

4) Adjust clearance between bearing case and rear axle by

inserting .04" (1.0 mm) shim and "O" ring into left rear axle housing.

Apply semi-drying sealant to mating surface of bearing case. Install

left axle shaft into rear housing. Tighten nuts diagonally to 36-43

ft. lbs. (50-58 N.m).

5) Install right axle shaft without shims and "O" ring.

Temporarily tighten to about 53 INCH lbs. (6 N.m). Using a feeler

gauge, measure clearance between bearing case and rear axle housing.

6) Remove right axle shaft. Install shims to equal bearing

case-to-axle housing clearance plus .002-.008" (.05-.20 mm). Install

"O" ring to right rear axle housing. Apply sealant to mating surface

of bearing case. See Fig. 10.

7) Install axle into housing, tightening nuts diagonally to

36-43 ft. lbs. (49-58 N.m). Check axle shaft for .002-.008" (.05-.20

mm) end play using dial indicator.

OVERHAUL

NOTE: For exploded views of front disc brake caliper, see Fig. 12.

For exploded view of master cylinder, see Fig. 13.

Fig. 12: Exploded View of Front Disc Brake Caliper (Typical)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Exploded View of Master Cylinder (Typical)

Courtesy of Mitsubishi Motor Sales of America.

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS TABLE

Application In. (mm)

Disc Diameter

Montero

2.6L . . . . . . . . . .. 10.2 (259)

3.0L . . . . . . . . . .. 10.9 (277)

Pickup & Ram-50

2WD . . . . . . . . . ... 10.2 (259)

4WD . . . . . . . . . ... 10.9 (277)

Lateral Runout . . . . . . . . .006 (.15)

Parallelism . . . . . . . . . . .. ( 1)

Original Thickness . . . . . . . .. .87 (22)

Master Cylinder Diameter . . . . . .938 (23.83)

Minimum Refinish Thickness . . . . . .80 (20.4)

Discard Thickness . . . . . . . . .78 (19.8)

(1) - Information is not available.

DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS TABLE

Application In. (mm)

Drum Diameter . . . . . . . . . 10.0 (254)

Drum Width . . . . . . . . . . ... ( 1)

Master Cylinder Diameter . . . . . .938 (23.83)