Mitsubishi Montero (1991+). Manual — part 65

determine location of open circuit.

WIRING DIAGRAMS

See appropriate chassis wiring diagram in the WIRING DIAGRAMS

Section.

DRIVE AXLE - FRONT

1991 Mitsubishi Montero

1990-92 DRIVE AXLES

Differentials & Axle Shafts - Front

Montero, Pickup 4WD

DESCRIPTION

Front axle assembly consists of differential carrier, housing

tube, inner shaft and drive axles. A full-floating axle design is

used. Drive axles are flexible assemblies made up of inner and outer

CV joints. Birfield Joints (BJ) and Double Offset Joints (DOJ) are

used at opposite ends of each drive axle.

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 . . . . . . . 4.63:1

Pickup . . . . . . . . 4.22:1

NOTE: References to BJ refer to Birfield Joint and DOJ to Double

Offset Joint.

TESTING

TOTAL ASSEMBLY BACKLASH

Place transfer case in "4H" position. Raise and support

vehicle. Check total backlash at flange. If backlash at flange exceeds

.55" (14.0 mm), check assembly for wear and proper adjustment.

DRIVE AXLES R & I

REMOVAL

1) Remove undercover on Montero. Place hub in free-wheeling

position. Place transfer case in 2H position. Remove drive hub cover,

snap ring and shim from drive axle. Remove brake calipers and wire out

of way.

2) Using dial indicator, check drive axle end play. Rotate

drive axle forward and rearward until maximum end play is obtained.

End play must be adjusted during reassembly if not within .008-.020"

(.20-.50 mm). Disconnect tie rod assembly. Support lower control arm

with jack.

3) Separate ball joints from knuckle. Remove knuckle and

front hub assembly. Remove left drive axle from differential carrier.

Use care not to damage oil seal. On right drive axle, remove drive

axle-to-inner shaft retaining bolts. Remove right drive axle.

CAUTION: Support lower control arm during drive axle removal and

installation.

CAUTION: Always replace circlips on BJ splines of left drive axle

and splines of inner shaft.

INSTALLATION

1) Install right drive axle on inner shaft. Install new

circlip on BJ side of left drive axle. Drive left drive axle into

differential. Use care not to damage oil seal.

2) Reinstall knuckle with front hub assembly. If drive axle

end play requires adjustment, select proper shim to obtain proper end

play. Shim is located behind snap ring on end of drive axle. Install

shim and recheck axle end play. Install remaining components in

reverse of removal procedure.

DIFFERENTIAL CARRIER R & I

REMOVAL

1) Raise and support vehicle. Drain gear oil. Support

differential carrier. Remove drive axles and inner shaft. See DRIVE

AXLES R & I and INNER SHAFT & BEARING R & I in this article. Place

alignment mark on drive shaft and pinion flange for reassembly

reference.

2) Remove drive shaft. Remove differential mounting brackets

at differential and frame. See Fig. 1. Disconnect front crossmember

from frame. Remove differential carrier assembly and front

crossmember. Remove differential carrier from front crossmember.

INSTALLATION

To install, reverse removal procedure. Align marks on drive

shaft and pinion flange.

Fig. 1: Front Drive Axle & Suspension

Courtesy of Chrysler Motors.

INNER SHAFT & BEARING R & I

REMOVAL

1) Remove right drive axle. See DRIVE AXLES R & I in this

article. Remove inner shaft from differential carrier. Pry dust seal

from housing tube assembly using a screwdriver if replacement is

required. See Fig. 1.

2) If oil seal replacement is required, remove housing tube.

Using slide hammer, remove oil seals. Bend outer area of dust cover

inward on inner shaft. Press bearing from shaft. Remove dust cover

from shaft.

INSPECTION

Inspect inner shaft for damaged splines or threads. Inspect

bearing for roughness or damage. Measure shaft O.D. Replace shaft if

not within specification. See INNER SHAFT SPECIFICATIONS table.