Mitsubishi Montero (1998+). Manual - part 94

into left side axle housing. Install left axle shaft assembly into

axle housing, and tighten nuts to specification. See

TORQUE SPECIFICATIONS.

         2) Install right axle shaft assembly into axle housing

without shim or "O" ring. Temporarily tighten nuts in diagonal

sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance

between bearing case of right axle and rear axle housing end with

feeler gauge.

         3) Select shims equal to sum of measured clearance plus .002-

.008" (.05-.20 mm). Remove right axle shaft, and install selected

shim(s) and "O" ring into right axle housing end. Install right axle

shaft assembly into rear axle housing. Tighten nuts in diagonal

sequence to specification. See TORQUE SPECIFICATIONS.

         4) Using dial indicator, check end play of axle shaft. End

play should be .002-.008" (.05-.20 mm). If end play is not within

specification, change shim(s) to obtain correct end play. Reverse

removal procedure to install remaining components. Adjust parking

brake, and bleed brake system.

         CARRIER ASSEMBLY

         Removal

         Raise and support vehicle. Drain gear oil. Mark drive shaft

flange-to-pinion flange position. Remove drive shaft. Remove axle

shafts. See AXLE SHAFT R & I. Support differential carrier with jack.

Remove differential carrier retaining nuts. Remove differential

carrier.

         Inspection

         Check for leaks at vent plug, differential carrier companion

flange and where carrier joins axle housing.

         Installation

         Apply sealant to axle housing surface. To install, reverse

removal procedure. Align marks on drive shaft and pinion flange.

         DRIVE SHAFT

         Removal

         Make match marks on drive shaft yoke flange and pinion

flange. Remove bolts and drive shaft from vehicle.

         Installation

         To install, reverse removal procedure. Ensure match marks are

aligned. Tighten bolts to specification. See  TORQUE SPECIFICATIONS.

         OVERHAUL

         AXLE SHAFT OVERHAUL

         Removal

         1) 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.

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

         chiseling retainer ring.

         2) 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 .

08" (2.0 mm) on bearing side. See Fig. 4.

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

of retainer ring wall on bearing side. Using a chisel, cut retainer

ring. Remove ring. DO NOT damage axle shaft.

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

axle shaft. See Fig. 5. 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.

Fig. 4:  Grinding Bearing Retainer Ring

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5:  Removing Bearing Case From Axle Shaft

Courtesy of Mitsubishi Motor Sales of America.

         Inspection

         Inspect bearings for roughness, pitting or damage. Inspect

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

cracks or damage.

         Installation

         1) Apply Multipurpose Grease (SAE J310) to oil seal, oil seal

cavity and contact surfaces. Install oil seal using seal driver. Press

new oil seal into bearing case until it is flush with face of bearing

case. Install backing plate and bearing case.

         2) Apply grease to external surfaces of bearing outer race.

Press bearing outer race into bearing case. Install bearing on axle

shaft. Install rear brake assembly with bearing case onto axle.

Install inner bearing on axle. Install NEW retainer ring. Do not

exceed 22,046 lbs. (100,00 N) when pressing on retainer ring. Install

NEW snap ring.

         3) Using a feeler gauge, measure clearance between snap ring

and NEW retainer ring. Clearance should be less than .007" (.17 mm).

If clearance exceeds specification, install correct snap ring. See

SNAP RING THICKNESS SPECIFICATION table.

SNAP RING THICKNESS SPECIFICATION

Thickness: In. (mm)                                              Color

.060 (1.52)  ....................................................  Red

.067 (1.70)  .................................................  Purple

.073 (1.85)  ...................................................  Blue

.079 (2.01)  .................................................  Yellow

.085 (2.16)  ................................................  Neutral

         DIFFERENTIAL ASSEMBLY (CONVENTIONAL)

         Pre-Disassembly Inspection

         1) Secure differential assembly in appropriate holder. Secure

drive pinion from turning. Mount dial indicator on case and check ring

gear backlash at 4 positions. See Fig. 6. Backlash should be .005-.

007" (.13-.18 mm).

         2) Remount dial indicator and measure ring gear runout. See

Fig. 7. On all models, runout should not exceed .002" (.05 mm).

Remount  dial indicator and measure pinion gear backlash on models

without limited slip differential. See Fig. 8. Secure side gear from

turning with wedge. Backlash should be 0-.003" (0-.08 mm). Pinion gear

backlash service limit is .008" (.20 mm).

         3) Check gear tooth contact pattern between ring gear and

drive pinion gear. Apply Prussian Blue to both surfaces of ring gear

teeth. Insert brass rod between differential housing and carrier

assembly to provide resistance while turning drive pinion.

         4) Turning resistance of drive pinion should be 28-33 INCH

lbs. (2.5-3.0 N.m). Rotate drive pinion until ring gear completes one

revolution. Reverse direction of rotation and return to original

starting point. Check wear pattern. See GEAR TOOTH CONTACT PATTERNS

article in GENERAL INFORMATION.

         5) On Montero models with differential lock, connect air

supply hose with pressure gauge and regulator to actuator air pipe.

Apply 4 psi (.28 kg/cm



) of pressure. Using Adapter Shaft (MB990992),

turn side gear on one side of carrier assembly only. Locking mechanism

should engage. To disengage, release air pressure and turn side gear

1/4-1/2 turn.

         6) With lock mechanism engaged, measure turning torque of

drive pinion. Turning torque should not be less than 36 ft. lbs. (50

N.m). With lock mechanism disengaged, turning torque should not be

more than 36 ft. lbs. (50 N.m).

Fig. 6:  Measuring Ring Gear Backlash

Courtesy of Mitsubishi Motor Sales of America.