MITSUBISHI GALANT 1989 Service Repair Manual

REAR AXLE <AWD> - Differential Carrier27-31
‘71
I
I
SERVICE POINTS OF DISASSEMBLYM27lGBC
4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
Prize out the differential case assembly using hammer
shafts.
NOTE
When removing the differential case assembly, the remov-
al should be accomplished slowly and carefully and caution
paid to ensure that the side bearing outer race is not
dropped. Keep the right and left side bearings separate, so that they
do 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 thedrive gear.
(2) Loosen the drive gear attaching bolts in diagonal
sequence 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.
18. REMOVAL OF SELF-LOCKING NUT
Use the special tools to hold the companion flange and
remove the companion flange self-locking nut.
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27-32REAR AXLE <AWD> - Differential Carrier
Mating marks
n
0161
llY175
llY176
20. REMOVAL OF DRIVE PINION
) Make the mating marks to the drive pinion and
companion flange.
NOTE
Mating 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.
24. REMOVAL OF DRIVE PINION REAR BEARING INNER
RACE
Pull out the drive pinion rear bearing inner race by using the
special tools.
27. REMOVAL OF OIL
SEAL/28. DRIVE PINION FRONT
BEARING
Drive out the drive pinion front bearing from the gear
carrier.
29. REMOVAL OF DRIVE PINION REAR BEARING OUTER
RACE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
INSPECTIONM27lHAD
l 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 wear
or damage.
l Check the side gear spline
for wear or damage.
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REASSEMBLY
REAR AXLE <AWD> - Differential Carrier27-33
M27n-
160-220
Nm
116-159
ft.lbs.
Differential gear set
11BOO66
Final drive gear set
Reassembly steps
1. Gear carrier*a 2. Oil seal++ 3. Drive pinion rear bearing outer racel +4. Drive pinion front bearing outer race*aAdjustment of pinion height
5. Drive pinion
6. Drive pinion rear shim (for pinion height adjustment)
7. Drive pinion rear bearing inner race
8. Drive pinion spacer
*aAdjustment of drive pinion preload
9. Drive pinion front shim (for preload adjustment)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer 15. Self-locking nut
16. Differential case so-9d
Nm*
5845
ft.lbs.*
llA0260
~~ 17. Drive gear (Vehicles with 4WS)e+ 18, Spring pin (Vehicles with 4WS)l *Adjustment of differential gear backlash
19. Side gear spacer
20. Side gear
21. Pinion washer
22. Pinion gear
23. Pinion shaft
l a 24. Lock pinl a 25.Drive gearl * 26.Side bearing inner race
27. Side bearing outer race
l *Adjustment of final drive gear backlash
28. Side bearing spacer 29. Differential case assembly
30. Bearing cap
31. Vent plug
32. Differential cover
NOTEl : Tightening torque with oil applied
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27-34REAR AXLE <AWD> - Differential Carrier
\
Lubrication, sealing and adhesion points
r
1 MO326
r
‘, 29c.
,’ :
~
;I::a e-**,i ,,,,3;;,*; :i
L
Adhesive: 3M Stud locking
No. 4170 or equivalentPart
llK60411K626
Sealant:3M ATD Part No.6661, 6663or equivalent
llA0260
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REAR AXLE <AWD> - Differential Carrier27-35
IllK610
90938-o 1
llY181
llY182
MB990905-4-C
MIT216335
MIT216336
MB990905-2-01
u-
MB990905l-01
llW616
SERVICE POINTS OF REASSEMBLYM27lJ6c6
2. PRESS FITTING OF OIL SEAL
(1) With the special tool, press fit the oil seal until it iswith the end of the gear carrier.
(2) Apply multipurpose grease to the oil seal lip. flush
3. INSTALLATION OF DRIVE PINION REAR BEARING OUTER RACE/A DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion rear and front bearing outer races
into the gear carrier by using the special tool.
Caution
Be careful not to press in the outer race at an angle.
. ADJUSTMENT OF PINION HEIGHT
Adjust the drive pinion height by the following procedures: (I)
Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequence
shown in the illustration.
(2) Tighten the handle of the special tool until the standard value of drive pinion turning torque is obtained.
(3)
Ea;sure the drive pinion turning torque (without the oil
Standard value:
I I
Bearing BearingRotation torque
classification lubrication (starting friction torque)
Nm (in.lbs.)
I,;,r,used 1 EJi!x%;; 1/;;;;y;-;
NOTE(1) Gradually tighten the handle ?f the special tool while
checking the drive pinion turning torque.(2)Because the special tool cannot be turqed one tur?,
turn
it several times within the range that It
can be turned;
then, after fitting to the bearing, measure the rotation
torque.
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27-36REAR AXLE <AWD> - Differential Carrier
lllllllll
1
7
(4) Position the special tool in the side bearing seat of thegear carrier, and then select a drive pinion rear shim of a
thickness which corresponds to the gap between the
special tools.
NOTE
Clean the side bearing seat thoroughly. Confirm that the
special tool is in close contact with the side bearing
sf?at---_.
When selectina
the drive oinion rear shims. keen the .--~ _.._
number of shims to a minimum.
(5) Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the drive pinion rear bearing inner
race by using the special tool.
. ADJUSTMENT OF DRIVE PINION PRELOAD Adjust the drive pinion turning torque by using the followingprocedures
:
(1) Fit the drive pinion front shim(s) between the drive pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion flange to the specified torque by using the special tools.
NOTE
Do not install the oil seal.
(3) Measure the drive pinion turning torque (without the oilseal) by using the special tools.
Standard value:
Bearing Bearingclassification lubrication
Rotation torque
(starting friction torque)
Nm (in.lbs.)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque byreplacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum by selecting the drive pinion spacers.
(5) Remove the companion flange and drive pinion once
again.
Drive the oil seal into the gear carrier front lip by using
the special tool.
I
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REAR AXLE <AWD> - Differential Carrier27-37
(6) Install the drive pinion assembly and companion flange
with mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified
torque by using the special tools.
(7) Measure the drive pinion turning torque (with oil seal) to verify that the drive pinion turning torque complies with
the standard value.
Standard value:
BearingBearingclassification lubrication Rotation torque
(starting friction torque)Nm (in.lbs.1
;;oy:;; (;5,,,,,, 1 ~%L; !
If there is a deviation from the standard value, check
whether or not there is incorrect tightening torque of
the companion flange tightening self-locking nut, or incorrect fitting of the oil seal.
. ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH Adjust the differential gear backlash by the followingprocedures:
(1) Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case.
(2) Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
(3) Adjust the differential gear backlash by the following procedures:
@ While locking the side gear with the wedge,
measure the differential gear backlash with a dial
indicator on the pinion gear.
NOTE
The measurement should be made for both pinion
gears individually.
Standard value:O-0.076 mm (O-.003 in.)
Limit:0.2 mm (.008 in.1

27-38REAR AXLE <AWD> - Differential Carrier
@ If the differential gear backlash exceeds the limit,
adjust the backlash by installing thicker side gear
spacers. @ Measure the differential gear backlash once again,
and confirm that it is within the limit.
NOTE
(1) After adjustment, check that the backlash is the
less than the limit and differential gear rotates
smoothly.
(2) When adjustment is impossible, replace the side
gear and the pinion gear as a set.
Spring pin
‘\ /
Drive gear TNyh fl
l~1/p(---\y-jj !5Lz+ /
17. INSTALLATION OF DRIVE GEAR/18. SPRING PIN
(1) Before installing the drive gear, drive the spring pin into the differential case.
At this time, face the notch in the spring pin in the
direction shown in the figure and have it stick out from
the differential case by the dimension shown in the
figure.
I I II II\ \\ II
llAO262llA026
1 / / MB990890-01
Chamfering
(large) llA0316
llA0101
(2)Use the special tool to press fit the drive gear until it hits
the end of the differential case.
At this time, the large chamfering of the inner cir-
cumference of the drive gear should be to the inside
(side touching the differential case).
(3)
ii,“;k that the drive gear and end of the spring pin are
24. INSTALLATION OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
25. INSTALLATION OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Use an
Ml0 X 1.25 tap to remove the adhesive
adhering to the threaded holes of the drive gear, and
then clean the threaded holes by applying compressed
air.
(3) Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
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REAR AXLE <AWD> - Differential Carrier27-39
26. PRESS-FITTING OF SIDE BEARING INNER RACE
Press-fit the side bearing inner races to the differential case
by using the special tool.
=Thickness of the
spacer on one side
llY241
l ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH
Adjust the final drive gear backlash by the followingprocedures:
(1) Install the side bearing spacers, which are thinner than those removed, to the side bearing outer races, and
then mount the differential case assembly into the gear
carrier.
NOTE
Select side bearing spacers with the same thickness for
both the drive pinion side and the drive gear side.
(2) Push the differential case to one side, and measure the clearance between the gear carrier and the side
bearing.
(3) Measure the thickness of the side bearing spacers on one side, select two pairs of spacers which correspond
to that thickness plus one half of the clearance plus0.05 mm I.002
in.), and then install one pair each to the
drive pinion side and the drive gear side.
(4) Install the side bearing spacers and differential case
, assembly, as shown in the illustration, to the gear
carrier.
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31-I
WHEEL
AND TIRE
CONTENTSMJlAA-
SERVICE ADJUSTMENT PROCEDURES . . . . . . .4
TROUBLESHOOTING. . . . . . . . . . . . . . ..*.....................3
Tire Inflation Pressure Check. . . . . . . . . . . . . . . . . . . . . .4 Bald Spots
TireWearCheck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . .4
Cracked Treads
Wheel Runout Check . . . . . . . . . . . . .._....................4
Feathered Edge
SPECIFICATIONS2 Rapid Wear at Center
.............................................
General Specifications
2Rapid Wear at Shoulders
..................................
Service Specifications
2Scalloped Wear
...................................
Torque Specifications
2Wear on One Side
...................................
WHEELANDTIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . .5