Mitsubishi Montero (1991+). Manual - part 69

Fig. 2:  Removing Bearing Case from Axle Shaft

Courtesy of Chrysler Motors.

         Inspection

         Inspect bearings for roughness, pitting or damage. Inspect

axle shaft for damaged splines or flange. Inspect bearing case for

cracks or damage. Measure axle shaft O.D. in bearing area. Correct O.

D. is 1.57" (39.8 mm). Axle shaft must be replaced if O.D. is not to

specification.

         Reassembly

         1) Apply grease to outer surface of bearing outer race and

oil seal.Install outer race in bearing case. Install oil seal in

bearing case until it is even with bearing case surface. Apply grease

to bearing rollers. Install brake assembly, bearing case and bearing

onto axle shaft.

         2) Apply grease to bearing rollers. Press inner bearing onto

axle shaft. Pack bearing case with grease. Coat lock nut threads with

grease. Install washer, NEW lock washer and lock nut. Lock nut must be

installed with chamfered edge toward axle shaft flange. Tighten lock

nut to specification. See TORQUE SPECIFICATIONS table at end of

article. Bend tab on lock washer into groove on lock nut.

         DIFFERENTIAL

NOTE:    Check pinion and side gear backlash, ring gear backlash and

         ring gear runout before disassembly.

         Disassembly

         1) Remove differential carrier from axle housing. Remove lock

plates and side bearing nuts. See Fig. 3. Mark bearing caps for

location. Remove bearing caps. Remove differential case assembly from

differential carrier.

CAUTION:  Ensure side bearing nuts, bearing caps and side bearings

          are marked for location. Components must be installed in

          original location.

Fig. 3:  Exploded View of Conventional Rear Differential

Courtesy of Chrysler Motors.

         2) Using bearing puller, remove differential case side

bearings. Place alignment marks on ring gear and differential case for

reassembly. Loosen ring gear bolts in diagonal sequence. Remove ring

gear.

         3) On conventional axles, remove drive pinion shaft lock pin

from differential case. Remove differential pinion shaft and thrust

block (if equipped). Remove pinion gears and washers. Remove side

gears and thrust spacers. Mark components for reassembly reference.

         4) On limited slip units, mark differential case and

differential case cover for reassembly reference. Remove differential

case retaining screws. Separate differential case and cover. Remove

components from case. See Fig. 4. Mark components for location.

Fig. 4:  Exploded View of Typical Limited Slip Differential

Courtesy of Chrysler Motors.

         Drive Pinion

         1) Remove pinion flange retaining nut. Scribe alignment marks

on drive pinion and pinion flange for reassembly. Using soft-faced

hammer, drive out pinion. Remove front adjusting shim and spacer from

pinion.

         2) Using bearing puller, remove rear bearing from pinion.

Remove rear adjusting shim from pinion. Remove oil seal and bearing

races from differential carrier.

         Inspection

         1) Inspect all gears for cracked or flaking teeth. Inspect

pinion shaft for wear. Inspect pinion flange and drive pinion for

damaged splines.

         2) Inspect bearings and races for roughness or flaking.

Replace worn components. On limited slip axles, inspect clutch

components and contact areas for wear or overheating. Inspect friction

plates, friction discs, spring plates and pressure rings for signs of

seizure, excessive heat, severe friction or nicks.

NOTE:    Outer areas of friction surfaces will wear heavier due to

         clutch plate and preload spring.

         3) Using dial indicator, check friction plate and friction

disc for warpage. Replace components if beyond specification. See

FRICTION PLATE & DISC SPECIFICATIONS table.

         4) Measure friction plates and disc thickness at projection

areas not within wear area. Measure plate and disc thickness in

friction surface. Difference between thickness of projections and

friction surface indicates amount of wear. Replace components if not

within specification. See FRICTION PLATE & DISC SPECIFICATIONS table.

FRICTION PLATE & DISC SPECIFICATIONS

Application                                 In. (mm)

Warpage Limit  .........................  .003 (.08)

Wear Limit  ............................  .004 (.10)

         DIFFERENTIAL OVERHAUL

         CASE ASSEMBLY (CONVENTIONAL)

         1) Install thrust spacers, side gears, pinion washers and

pinion gears in differential case. DO NOT install thrust block (if

equipped) at this time.

         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.

PINION & SIDE GEAR BACKLASH SPECIFICATIONS

Application                                    In. (mm)

4-Cylinder Engine

  Standard  ..................  .0004-.0030 (.010-.076)

  Wear Limit  .............................  .008 (.20)

V6 Engine

  Standard  .........................  0-.0030 (0-.076)

  Wear Limit  .............................  .008 (.20)

Fig. 5:  Checking Pinion & Side Gear Backlash

Courtesy of Chrysler Motors.

         4) Install thrust block (if equipped) once correct backlash

is obtained. Install pinion shaft lock pin from back side of ring