MITSUBISHI GALANT 1989 Service Repair Manual

REAR AXLE <AWD> - Drive Shaft27-21
REMOVAL AND INSTALLATION
Removal steps
1.Bolt4,l +2.Drive shaft3.
Circlip
l 44.Oil seal
llAO32f
llAO324
SERVICE POINTS OF REMOVALM27JBAo
2. REMOVAL OF DRIVE SHAFT
Using a tire lever, etc. remove the drive shaft from the
differential carrier.
INSPECTIONM27JHAA
l Check the drive shaft boots for damage or deterioration.
lCheck the ball joints (B.J. and D.O.J.) for excessive play or
check operation. 0 Check the drive shaft spline for wear or damage.
SERVICE POINTS OF INSTALLATIONM27JCAF
4. INSTALLATlON OF OIL SEAL
If the oil seal is to be replaced because of damage, drive it
in by using the special tool.
2. INSTALLATION OF DRIVE SHAFT
Caution
Be cautious to ensure that the differential carrier oil seal is not damaged by the drive shaft spline.
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27-22REAR AXLE <AWD> - Drive Shaft
DISASSEMBLY AND REASSEMBLYM27JD-
c
I -“&” -
YllA0075
5
1 lAOO69llAOO571 lAoo66
II
D.O.J. kitB.J. boot repair kit
D.O.J. boot repair kit
Disassembly steps 1. Circlip
2. Boot band
(B)3. Boot band (C)an.4. Lrrcnp
5. D.O.J. outer race
**6. Snap ring
**7. D.O.J. inner race, cage and ball assembly
8. Balls
::9.D.O.J. inner race
l *10. D.O.J. cage11.D.O.J. boot
12. Boot band (A)13. Boot band (C)*I)14. B.J. boot15.Dust cover
16. Drive shaft and B.J.
l 4 12. Boot band (A)
Reassembly steps
~~ 13. Boot band (C)l + 3. Boot band(C)l a 2. Boot band (B)*4’ 11. D.O.J. boot 16. Drive shaft and B.J.l +
15. Dust cover
7. D.O.J. inner race, cage and ball assembly
10. D.O.J. cage
9. D.O.J. inner race
l 4 14. B.J. boot
8. Balls
6. Snap ring
I)+ 5. D.O.J. outer race
4. Circlip
1.
Circlip
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REAR AXLE <AWD> - Drive Shaft27-23
LUBRICATION POINTS
llWI6#
Grease: Repair kit grease
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Grease: Repair kit grease 90 g (3.20 oz.)
CautionThe orease in the repair kit should be
divided in half for use, respectively, at
the joint andinA soecial tvoe ofide the boot.orease is used on thejoint. Be caitious ti ensure that no other
grease is allowd to come in contact with
the joint.
\ -
\llVlO6llvlos
Grease: Repair kit grease 90 g (3.20 oz.)
CautionThe grease in the repair kit should be
divided in half for use, respectively, at
the joint and inside the boot.
A special type of grease is used on thejoint. Be cautious to ensure that no othergrease is allowed to come in contact
with the joint.

27-24REAR AXLE <AWD> - Drive Shaft
WE507llYG97
7___-- -- --

-
-.I
AC
~~~~~
B
”/
B.J: boot
Boot bands
D.O.J. bootVW592
SERVICE POINTS OF DISASSEMBLYMZ7JEAC
8. REMOVAL OF SNAP RING/8. BALLS/S. D.O.J. INNER RACE/lo.
D.O.J. CAGE (I

)Remove the snap ring with the snap ring pliers and then
remove the D.O.J. inner race, the D.O.J. cage, and the
balls as a unit.
(2) Clean the D.O.J. inner race, the D.O.J. cage, and the balls, without dismantling them.
Caution
1.Be careful that balls do not drop out of the cage.
2. If the balls drop out, press them back into the D.O.J. cage with the D.O.J. inner race.
11. REMOVAL OF D.O.J. BOOT/14. B. J. BOOT
(1) Wipe the grease off of the spline portion.
(2) Remove the D.O.J. boot and B.J. boot.
NOTE
If the boots are reused, wrap vinyl tape around the drive
shaft spline so that the boots are not damaged when
they are removed.
Caution
Do not disassemble the B.J.
INSPECTIONMZ7JFAC
l Check the drive shaft for damage, bending or corrosion.
l Check the drive shaft spline for wear or damage.
l Check the B.J. for entry of water and/or
foreign material.
l Check the D.O.J. outer race for damage or corrosion.
l Check the D.O.J. cage, balls and D.O.J. inner race for damage, corrosion or wear.
SERVICE POINTS OF REASSEMBLYMnJoAD
14. INSTALLATION OF B.J. BOOTI12. BOOT BAND (A)/13.
BOOT BAND (C)/3. BOOT BAND (C)/2. BOOT BAND
(B)/ll. D.O.J. BOOT
(I) Wrap vinyl tape around the drive shaft spline.
(2) Insert the drive shaft in B.J. boot, boot band (A), (C), (C),
(B), D.O.J. boot in that sequence.
(3) Fill the inside of the B.J. and B.J. boot with the specified grease.
Specified grease: Repair kit grease
Caution90 g (3.2 oz.)
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the
boot.
A special type of grease is used on the joint. Be
cautious to ensure that not other grease is allowed
to come in contact with the joint.
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REAR AXLE <AWD> - Drive Shaft27-25
t
Snap
inner race
1180116
(4) Secure the B.J. boot with boot bands (A) and (C) to the
drive shaft and B.J.
Caution
Ensure that the B.J. is at a zero angle with the drive
shaft to ensure the boot contains the specified
amount of air.
7. INSTALLATION OF D.O.J. INNER RACE, CAGE AND
BALL ASSEMBLY
(1) Apply the specified grease to the D.O.J. cage, the balls and the D.O.J. inner race.
Specified grease: Repair kit grease (As required)
(2) Install the cage, balls and inner race to the drive shaft, then, using snap ring pliers, fit the snap ring securelyinto the groove in the shaft.
5. APPLICATION OF GREASE TO D.O.J. OUTER RACE (1) Fill the specified grease to the D.O.J. outer race, fit thedrive shaft into the D.O.J. outer race, and then fill more
grease to the D.O.J. outer race.
Specified grease: Repair kit grease90 g (3.2 OZ.)
Caution
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the
boot.
A special type of grease is used on the joint. Be
cautious to ensure that no other grease is allowed
to come in contact with the joint.
(2) Install the circlip
to the D.O.J. outer race.
(3) Assemble the D.O.J. boot to the D.O.J. outer race, then secure the boot to the drive shaft with boot band
(C).
(4) Place boot band (B) on the D.O.J. boot.
NOTE
Do not secure boot band (B).
(5) Set the D.O.J. boot bands at the specified distance in order to adjust the amount of air inside the D.O.J. boot,
and then tighten the D.O.J. boot band (C) securely.
Standard value:
76f3 mm @JO+ 23 in.)
(6) Release a part of the D.O.J. boot from the D.O.J. outer race to allow pressure to escape from the boot.
(7) Tighten boot band
(B) and secure the D.O.J. boot.

1 Pre-removal and Post-installationIOperationl Draining and Refilling of DifferentialOil (Refer to P.27-15.)
l Removai and installation of Centfhaust Pipe (Refer to GROUP
Exhaust PiDe and Main Muffler.) Gear
:r Ex-15-
19-28 Nm14-20 ft.lbs.
27-26REAR AXLE <AWD> - Differential Carrier
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATIONM27w 100-120

Nm72-87 ft.lbs.
\ “\//
5a
/
i //14-21 NmIO-15 ft.lbs.
/9-14 Nm7-10 ft.lbs.
loo-120 Nm72-87 ft.lbs.
/
I
-
-
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1I
I-
M-85 Nm/40-47 ft.lbs.
I
\--
90-70/Nm43-51ft.lbs.
30-35Nm
22-25ft.lbs./1
y I’ .c..,/-
W?c\. fQ(-01
R3
&I
0
Removal steps
llAo373
1. Drive shaft (Refer to P.27-21.)2.Circlip
3. Propeller shaft connection
(Refer to GROUP 25-Propeller Shaft)
4. Feed tube (Vehicles with 4WS)
5. O-ring (Vehicles with
4WS)6. Rear oil pump (Vehicles with 4WS)7. O-ring (Vehicles with 4WS)8. f$erential support member installation
9.Stopper (lower)
10. D$erentral support member installation
11. Dynamic damper
(I 990 models)
12. Differential support member
13.
F;fprentral support member installation
14. Differential carrier

REAR AXLE <AWD> - Differential Carrier27-27
Beveled placeDIFFERENTIAL SUPPORT MEMBER BUSHING RE-
PLACEMENT
M27lKAA
Use the special tool to pull out and press in the differential
support member bushing.
NOTE
Press 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.
llGO073 \
INSPECTION BEFORE DISASSEMBLYMmEAl
Hold 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.
NOTE
Measure at four points or more on the circumference of the,
drive gear.
Standard value: 0.11-0.16
mm (.004-.006
in.)
DRIVE 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.)

27-28REAR AXLE <AWD> - Differential Carrier
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps
~l”~~ply 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 once in the
reverse direction) while applying a load to the drive gear, so
that the revolution torque [approximately
2.5-3.0 Nm
(28-33 in.lbs.)l
is applied to the drive pinion.
Caution
If 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.
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REAR AXLE <AWD> - Differential Carrier
Standard tooth contact pattern
1 Narrow tooth side
2 Drive-side tooth surface (the side applying powerduring forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the side applying pow- er during reverse movement)
Problem
Tooth contact pattern resulting from exces-
sive pinion height
Solution
3
The drive pinion is positioned too far from the
center of the drive gear. 3Increase
the thickness of the pinion height adjusting
shim, 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. 3
Decrease the thickness of the pinion height adjust-
ing shim, and position the drive pinion farther from
the center of the drive gear.
Also, for backlash adjustment, position the drive gear closer to the drive pinion.
lls642
NOTE
(1)Tooth contact pattern is a method for judging the result of the adjustme\
nt of drive pinion height and final drive gear
backlash. The adjustment of drive pinion hight and final drive gear back\
lash 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 judg\
ed that the drive gear and drive pinion have exceed their usage limits and both gears should be replaced as a set.
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27-30
DISASSEMBLY
REAR AXLE <AWD> - Differential Carrier
Inspection Before Disassembly*Final Drive Gear Backlash (Refer to P.27-27.)*Differential Gear Backlash<Conventional type>
(Refer to
P.27-27.)@Drive Gear Runout
(Refer to P.27-27.)
*Final Drive Gear Tooth Contact (Refer to
P.27-28.)
llA0260
Disassembly steps
1. Differential cover
2. Vent plug
**l *
l *
3. Bearing cap
4. Differential case assembly
5. Side bearing
spacer
n n.* I0. slae oeanng outer race
7. Side bearing inner race
8.Drive
9. gear
10.Lock pin
Pinion shaft
11.Pinion12.gear
Pinion washer
13.
Sidegears
14. Side gear spacer
15. Spring pin (Vehicles with
4WS)16. Drive gear (Vehicles with 4WS)17. Differential case
18.
19.
Self-loclhg nut
Washer
l *20. Drive pinion assembly
21. Companion flange
22. Drive pinion front shim
(for preload adjustment)
23. Drive pinion spacer
24. Drive pinion rear bearing inner race
25. Drive pinion rear shim
(for pinion height adjustment)
26. Drive pinion
27. Oil seal
28. Drive pinion front bearing
29. Drive pinion rear bearing outer race 30. Oil seal
31. Gear carrier
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