Mitsubishi Montero (1998+). Manual — part 93

DIFFERENTIAL & AXLE SHAFTS REAR

1998 Mitsubishi Montero

1997-98 DRIVE AXLES

Mitsubishi Differentials & Axle Shafts - Rear Non-Integral

Montero, Montero Sport

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 some models. Locking rear differential is available on

1997-98 Montero and 1998 Montero Sport. See DIFFERENTIAL LOCK - REAR

article.

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 . . . . . . . . . . . . . . 4.27:1

Montero Sport

With Wide Fender

2WD . . . . . . . . . . . . . . 4.22:1

4WD . . . . . . . . . . . . . . 4.27:1

Without Wide Fender . . . . . . . . . ... 4.64:1

LUBRICATION

CAPACITY

REAR AXLE GEAR OIL CAPACITY

Application Pts. (L)

Montero . . . . . . . . . . . . .. 6.8 (3.2)

Montero Sport

Conventional & Locking . . . . . . . . . 3.2 (1.5)

Limited Slip . . . . . . . . . . ... 5.5 (2.6)

FLUID TYPE

Conventional differentials use SAE 80W or SAE 90W API GL-5.

Limited slip differentials use Mitsubishi Gear Oil (8149630 EX), or

Mopar Gear Oil (4318058) and Mopar Friction Modifier (4318060).

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the

GENERAL TROUBLE SHOOTING section.

TESTING & INSPECTION

AXLE SHAFT END PLAY

Montero & Montero Sport

Using dial indicator, check axle shaft end play. End play

should be .010" (.25 mm). If end play is not within specification,

replace axle bearing. See AXLE SHAFT OVERHAUL under OVERHAUL.

AXLE TOTAL BACKLASH

1) Raise and support rear axle. Place transmission in

Neutral. Apply parking brake. Rotate drive shaft clockwise. Place

reference marks on pinion dust cover and differential housing.

2) Rotate drive shaft counterclockwise, and measure distance

between reference marks. Differential must be removed and backlash

adjusted if distance exceeds 0.2" (5 mm). See RING GEAR BACK-LASH

procedure under DIFFERENTIAL ASSEMBLY (LIMITED SLIP) under OVERHAUL.

LIMITED SLIP DIFFERENTIAL PRELOAD

1) Place transmission in Neutral. Block front wheels. Raise

one rear wheel off ground and remove wheel. Release parking brake.

2) Using torque wrench and axle puller adapter, measure

starting torque while rotating wheel in forward direction. See Fig. 1.

Differential must be repaired if torque is less than 18 ft. lbs. (25

N.m).

Fig. 1: Testing Limited Slip Differential Preload

Courtesy of Mitsubishi Motor Sales of America.

LOCKING DIFFERENTIAL (MONTERO)

Air Pump

Connect air pressure gauge in-line to air hose from air pump.

Air pump is located in right storage area, under rear seat. Connect

battery voltage to air pump (positive lead to Red wire). The air pump

is operating correctly when the following sequences occur;

* Pump should operate for no more than 5 seconds.

* Pressure should be 4-6 psi (.28-.41 kg/cm

) within 10-20

seconds after pump has stopped.

* After air pump has stopped operating, it should not restart

operating for 5 minutes.

Center Differential Lock Operation Switch

See ANTI-LOCK BRAKE SYSTEM article in BRAKES.

Differential Lock Switch

Remove switch from center console. To test switch operation,

see Fig. 2. Replace switch as needed.

Differential Lock Control Unit

See ANTI-LOCK BRAKE SYSTEM article in BRAKES.

Lock Detection Switch

1) Raise and support vehicle. Disconnect air hose connection

near rear differential. Connect air source with pressure regulator and

pressure gauge. Apply 4 psi (.28 kg/cm

) pressure. Disconnect lock

detection switch harness connector.

2) Using ohmmeter, check if continuity exists with air

pressure applied. Continuity should exist with air pressure applied.

If continuity exists, ensure axle is locked by attempting to turn rear

wheels separately of each other.

3) If continuity does not exist, go to step 4). If continuity

does exist but axles are not locked, see CARRIER ASSEMBLY under

REMOVAL & INSTALLATION and inspect locking assembly.

4) Remove detection switch from housing. Using ohmmeter,

check continuity of switch. Continuity should exist with switch

plunger extended. With plunger in neutral position, continuity should

not exist. Replace switch as needed.

Fig. 2: Checking Differential Lock Switch Continuity

Courtesy of Mitsubishi Motor Sales of America.

REMOVAL & INSTALLATION

AXLE SHAFT R & I

Removal (Montero & Montero Sport)

Block front wheels. Raise and support rear axle housing.

Remove brake caliper and rotor. See Fig. 3. Remove parking brake cable

attaching bolts. Remove connection for parking brake cable end from

rear brake assembly. Remove ABS speed sensor (if equipped). Unbolt

backing plate with bearing housing from rear axle housing. Using

Puller (MB990241) and Slide Hammer (MB990211), remove axle assembly.

DO NOT damage oil seal. Remove "O" ring. Replace if necessary.

Installation

Install NEW oil seal in axle housing as needed. To install

axle assembly, reverse removal procedure.

Fig. 3: Exploded View Of Typical Axle Shaft

Courtesy of Mitsubishi Motor Sales of America.

Installation

1) Insert new "O" ring and shim of .04" (1.0 mm) thickness