Mitsubishi Montero (1998+). Manual — part 92
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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
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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.
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