differential MITSUBISHI ECLIPSE 1991 User Guide

REAR AXLE - Service Adjustment Procedures3-9
14A0521
IncorrectREAR WHEEL BEARING ROTATION SLIDING
RESISTANCE CHECKNOOFJAA
(1) Remove the drive shaft from the companion flange.
(2) Remove the brake pad or caliper assembly.
(3) Attach a spring balance to the hub bolt, then, pulling the
balance at a right angle to the hub bolt, measure the
rotation sliding resistance (rotation starting torque) to see
whether it is within the standard value.
Standard value: 12
N (2.6 Ibs.) [rotation starting tor-
que 0.7 Nm (6 in
Ibs.)] or less
(4) If the rotation starting torque exceeds the standard value,
check the tightening torque of the axle shaft companion
flange. If it is normal, replace the bearing.
LIMITED-SLIP DIFFERENTIAL CHECKNOJFIAA(1) Block the front wheels and move the shift lever to neutral.
(2) Completely release the parking brake.
(3) Jack up the rear wheels and place a rigid rack at the
specified part of the side sill.
(4) Disconnect the coupling of the differential and propeller
shaft.(5) When one wheel is slowly rotated, check whether or not
the wheel on the other side turns in the same direction.
(6) If it turns in the opposite direction, replace the viscous unit.
_--

3-‘14REAR AXLE - Drive Shaft
REMOVAL AND INSTALLATION55-65
N.m40-47 ft.lbs.
Removal steps
1. Bolt+e l 42. Drive shaft3. Circlip
l * 4. Oil seal
NOTE(1) Reverse the removal procedures to reinstall.(2) l * : Refer to “Service Points of Removal”.<-,(3) ii : Refer to “Service Points of Installation”.
(4) q : Non-reusable partsllA0324
SERVICE POINTS OF REMOVALNO3JEAD2. REMOVAL OF DRIVE SHAFT
Using a tire lever, etc. remove the drive shaft from the
differential carrier.
INSPECTIONNOJJHAA
lCheck the drive shaft boots for damage or deterioration.
lCheck the ball joints (B.J. and D.O.J.) for excessive play orcheck operation.
l Check the drive shaft spline for wear or damage.
SERVICE POINTS OF INSTALLATIONN03JCAE4. INSTALLATION OF OIL SEAL
(1)If the oil seal is to be replaced because of damage, driveit in by using the special tool.
(2) Apply the specified grease to the oil seal lip.
Specified grease:MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalant
,-
-
llK110llK610

REAR AXLE - Drive Shaft
Boot band
CTwo-part serration
llA02802. INSTALLATION OF DRIVE SHAFT
I_ ,T
Caution
1.Be cautious to ensure that the differential carrier oil
seal is not damaged by the drive shaft spline.
2. The drive shafts for models equipped with the
limited-slip differential are of different length and,
in addition, the right drive shaft has a two-part
serration; be very careful to install each one on the
correct side.
NOTE
The left and right drive shafts can also be distinguishedfrom each other by the identification color of boot band
C.
IItemDrive shaftDrive shaft
(left)(right)IIIBoot band
C identification color YellowBlueI
3.Be sure to thoroughly remove any oil or grease, etc.from the threaded part of the bolt and nut used for
installation to the companion flange,
because any
oil, grease, etc. on these parts might cause later
loosening even though tightening is at the specifiedtorque.

REAR AXLE - Differential Carrier
DIFFERENTIAL CARRIER
3-19
lEMOVAL AND INSTALLATIONN03lA--Pre-removal Operation
@Drainage of Differential Gear Oil (Refer toP.3-8.)*Removal of Center Exhaust Pipe (Refer
to GROUP 1 l-Exhaust Pipe and Main
Muffler.)
loo-120 Nm
72-87 ft.lbs.
\9-14 Nm7-10 ft.lbs.
80-100 Nm
58-72 ft.lbs.
loo-120 Nm
72-87 ftlbs.\/*
91hl A-55-65 Nm-/40-47 ftilis.22-25
ft.lbs.
Removal steps
4*I. Drive shaft
2. Circlip~~ ++ 3. Propeller shaft connection
4. Differential support member installation
nut
5. Stopper (lower)
6. Differential support member installation
llA0358
I Ibolts
7. Differential support member
8. Differential support member installation
bolts
9. Differential carrier
NOTE(I) Reverse the removal procedures to reinstall(2) +I) : Refer to “Service Points of Removal”.(2) W : Refer to “Service Points of Installation”.
(3) m : Non-reusable parts.

3-20REAR AXLE - Differential CarrierMating marks
’
lODSO5
Beveled place
1 lA0274
SERVICE POINTS OF REMOVALN031BAL1. REMOVAL OF DRIVE SHAFT
With a tyre lever, etc.,remove the drive shaft from the
differential carrier.
NOTEBe cautious to ensure that the differential carrier oil seal is
not damaged by the drive shaft spline.
3. DISCONNECTION OF PROPELLER SHAFT
(1) Place mating marks on the differential companion
flange and flange yoke for reference during reassembly.(2) Remove the differential carrier and propeller shaft
connection.(3) Support the propeller shaft with wire.
DIFFERENTIAL SUPPORT MEMBER BUSHING RE-
PLACEMENT
NOBIYAAUse the special tool to pull out and press in the differential
support member bushing.
NOTEPress in the bushing from the beveled part of the differential
support member; press in until the end surface of the bushing
outer cylinder is flush with the support member.
SERVICE POINTS OF INSTALLATIONN03lDAK3. CONNECTION OF PROPELLER SHAFT
Align the mating marks on the flange yoke and the
companion flange to install the propeller shaft.
INSPECTION BEFORE DISASSEMBLYNOJIEAIHold the working base in a vice, and attach the differential
carrier to the working base.
FINAL DRIVE GEAR BACKLASH
With the drive pinion locked in place, measure the final drive
gear backlash with a dial indicator on the drive gear.
NOTEMeasure at four points or more on the circumference of the
drive gear.
Standard value:
0.11-0.16 mm (.004-.006 in.)

REAR AXLE -Differential Carrier3-21
.-11GOO73
-
llG0076DRIVE GEAR RUNOUT
Measure the drive gear
runout at the shoulder on the reverse
side of the drive gear.
Limit: 0.05 mm
(.002 in.)
DIFFERENTIAL GEAR BACKLASH
While locking the side gear with the wedge, measure the
differential gear backlash with a dial indicator on the pinion
gear.Standard value:O-0.076 mm (O-.003 in.)
’ Limit:0.2 mm (.008 in.)
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps
below.
(1) Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.
(2) Insert a brass rod between the differential carrier and the
differential case, and then rotate the companion flange by
hand (once in the normal direction, and then
on& in the
reverse direction) while applying a load to the drive gear, sothat the revolution torque [approximately
2.5-3.0 Nm
(28-33
in.lbs.)] is applied to the drive pinion.
CautionIf the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
(3) Check the tooth contact condition of the drive gear and
drive pinion.

3-22REAR AXLE - Differential CarrierStandard tooth contact pattern
1 Narrow tooth side
2 Drive-side tooth surface (the side applying power
during forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the side applying pow-
er during reverse movement)
ProblemTooth contact pattern resulting from exces-
sive pinion heightSolution
3
The drive pinion is positioned too far from the:enter of the drive gear.
3
Increase the thickness of the pinion height adjustingshim, and position the drive pinion closer to the
center of the drive gear.
Also, for backlash adjustment, position the drive
gear farther from the drive pinion.
rooth contact pattern resulting from insuffi-
:ient pinion height
3
The drive pinion is positioned too close to the centerIf the drive gear.
3Decrease the thickness of the pinion height
adjust-ing shim, and position the drive pinion farther from
ihe center of the drive gear.
Also, for backlash adjustment, position the drive
gear closer to the drive pinion.
115642
NOTE(1) Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear
backlash. The adjustment of drive pinion hight and final drive gear backlash should be repeated until tooth contact
patterns bear a similarity to the standard tooth contact pattern.
(2)When adjustment is not able to obtain a correct pattern, it may be judged that the drive gear and drive pinion have
exceed their usage limits and both gears should be replaced as a set.

REAR AXLE - Differential Carrier3-23
DISASSEMBLYInspection Before Disassembly
@Final Drive Gear Backlash (Refer to P.3-20.)*Differential Gear Backlash<Conventional type>(Refer to P.3-21.)
/ ;3-21.)’1
@Drive Gear Runout (Refer to P.3-21.)aFInal Drove Gear Tooth Contact (Refer to
<Conventional differential>
\ \\Oi6 27i0
q l7 18 20llA0260
<Limited slip differential>
Disassembly steps
1. Differential cover
2. Vent plug
3. Bearing caps
*I)4. Differential case assembly5. Side bearing spacers
6. Side bearing outer race
:z
7. Side bearing inner race8. Drive gear
l * l *9. Lock pin 9. Lock pin10. Pinion shaft11. Pinion gears12. Pinion washers
13. Side gears
14. Side gear spacers15. Differential case
16. Limited slip differential case assembly
*I)17. Self-locking nut18. Washer
4*19. Drive pinion assembly
20. Companion flangellvlI , ,,,igellA0290llA0290
21. Drive pinion front shim-:-- ‘--nt shim
(for preload adjustment)Jstment)22. Drive pinion spacer3cerl *23. Drive pinion rear bearing inner racerr bearing inner race
24. Drive pinion rear shimrr shim,Ivl PJ” llUl I I IcIyIit adjustment)(for pinion height adjustment)?Cl3.r;. I,-. ..:..;A-25. Drive pinion
::
26. Oil seal“II >twI27. Drive pinion front bearingDrive pinion front bearing
4*28. Drive pinion rear bearing outer racen-‘..- -‘-‘-- --lr bearing outer race
29. Oil seal
30. Gear carrier
NOTE(1) +I) : Refer to “Service Points of Disassembly”.(2) m : Non-reusable parts.

3-24REAR AXLE- Differential Carrier
SERVICE POINTS OF DISASSEMBLYN03lGSC4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
kPrize out the differential case assembly using hammer
‘-
shafts.
NOTEWhen removing the differential case assembly, the
re’mov-
al should be accomplished slowly and carefully and cautionpaid to ensure that the side bearing outer race is not
dropped.
Keep the right and left side bearings separate, so that theydo not become mixed at the time of reassembly.
7. REMOVAL OF SIDE BEARING INNER RACES
Pull out the side bearing inner races by using the special
tools.8. REMOVAL OF DRIVE GEAR
(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching bolts in diagonal
fisequence to remove the drive gear.
9. REMOVAL OF LOCK PIN
Drive out the lock pin with a punch and remove the pinion
gears, pinion washers, side gears and side gear spacers.
17. REMOVAL OF SELF-LOCKING NUT
Use the special tools to hold the companion flange and
remove the companion flange self-locking nut.

REAR AXLE -Differential Carrier3-25
Mating marks
llD237
llY175
llY17619. REMOVAL OF DRIVE PINION
) Make the mating marks to the drive pinion and
companion flange.
NOTEMating marks should not be made to the contact
surfaces of companion flange and propeller shaft.
!) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims.
23. REMOVAL OF DRIVE PINION REAR BEARING INNER
RACE
Pull out the drive pinion rear bearing inner race by using thespecial tools.
26. REMOVAL OF OIL SEAL/27. DRIVE PINION FRONT
BEARINGDrive out the drive pinion front bearing from the gear
carrier.28. REMOVAL OF DRIVE PINION REAR BEARING OUTER
RACEDrive out the drive pinion rear bearing outer race from the
gear carrier.
INSPECTIONN03lHADl Check the companion flange for wear or damage.
l Check the oil seal for wear or deterioration.
l Check the bearings for wear or discoloration.
l Check the gear carrier for cracks.
lCheck the drive pinion and drive gear for wear or cracks.
lCheck the side gears, pinion gears and pinion shaft for wearor damage.
l Check the side gear spline for wear or damage.