MITSUBISHI MONTERO 1991 Service Manual

INNER SHAFT SPECIFICATIONS








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Application In. (mm)
Shaft O.D.
Bearing Area ................ 1.38 (35.0)
Center Area ................. 1.24 (31.4)









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INSTALLATION
1) If oil seal replacement is necessary, install new oil seal
in differential carrier using Oil Seal Installer (MB990934-01) and
Handle (MB990938-01). Coat seal lips with grease. Install housing
tube. Using Seal Installer (MB990955) and Handle (C-4171), install n\
ew
dust seal in housing tube. Dust seal must be even with housing tube.
Coat seal lip with grease.
2) Using a pipe with O.D. of 2.95" (74.3 mm), wall thickness\
of .16" (4.0 mm) and with overall length of 1.97" (50.0 mm), install\
dust cover on shaft. Coat inside of dust cover with grease. Press
bearing on shaft. Install new circlip on inner shaft. Drive inner
shaft into differential. Use care not to damage oil seal.
DRIVE AXLES & BEARINGS OVERHAUL
NOTE: References to BJ refer to Birfield Joint and DOJ to Double
Offset Joint.
DISASSEMBLY
1) Remove boot bands. Remove circlip from DOJ outer race.
Separate drive axle from DOJ outer race. Remove balls from DOJ cage.
Remove DOJ cage from DOJ inner race in direction of BJ. See Fig. 2.
Fig. 2: Exploded View of Drive Axles
Courtesy of Chrysler Motors.
2) Remove snap ring from drive axle shaft. Remove DOJ inner
race from shaft. Remove circlip from shaft. Wrap tape around splines

of shaft to prevent boot damage during removal.
3) Remove DOJ boot. Note size of boot. Remove dust cover from
shaft. Straighten BJ boot protector and remove protector band. Move
boot protector toward BJ side of shaft and remove. Remove BJ boot.
CAUTION: Drive axle and BJ are serviced as a unit. DO NOT
disassemble BJ and drive axle.
REASSEMBLY
1) Coat shaft with light coat of grease. Wrap splines with
tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Boot bands must be installed so lever is pulled toward
rear of vehicle when band is tightened. Pack proper amount of grease
in BJ and BJ boot. See GREASE APPLICATION table.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race, and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage.
4) Apply proper amount of grease to outer DOJ race. Install
shaft into DOJ outer race. Apply proper amount of grease to DOJ outer
race and install circlip. See GREASE APPLICATION table.
5) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between centerline of boot
bands. See BOOT BAND SPECIFICATIONS table. This distance is necessary
to control air in DOJ boot. Tighten boot bands.
6) Install boot protector and band. Install dust cover on
shaft. Use a pipe with O.D. of 2.68" (68.0 mm), wall thickness of .09"\
(2.3 mm) and with overall length of 6.70" (170.1 mm) to install dust\
cover.
GREASE APPLICATION









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Application Ozs. (g)
BJ Boot
Montero
3.0L Engine .................. 4.6 (130)
All Others .................... 3.9 (110)
DOJ Outer Race
Montero
3.0L Engine ................... 2.3 (60)
All Others ..................... 1.9 (55)









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BOOT BAND SPECIFICATIONS








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Application In. (mm)
All Models .......... 3.03-3.27 (76.9-83.0)









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DIFFERENTIAL DISASSEMBLY
1) Remove differential carrier from vehicle. See DIFFERENTIAL
CARRIER R & I in this article. Remove cover. Mark bearing caps for
reassembly reference. Remove bearing caps. Remove differential case
assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components

must be installed in original location.
2) Using bearing puller, remove differential case side
bearings. Loosen ring gear retaining bolts in diagonal sequence.
Remove ring gear.
3) Remove drive pinion shaft lock pin from ring gear side.
Remove pinion shaft and pinion gears. Remove side gears and thrust
spacers.
DRIVE PINION
1) Remove pinion flange nut. Scribe alignment mark on pinion
flange and pinion. Remove flange. Using soft-faced hammer, drive out
pinion. Remove rear bearing and oil seal from carrier. Remove rear
adjusting shim from pinion.
2) Press front bearing from pinion. Remove front adjusting
shim and spacer from pinion. Inspect all components for unusual wear
or damage. Replace as necessary.
DIFFERENTIAL REASSEMBLY & ADJUSTMENTS
CASE REASSEMBLY
1) Place side gear thrust spacers behind side gears in
original position. Assemble side gears in differential case. Install
pinion gears and washers. Rotate pinion gears to mesh with side gears.
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. 3.
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.
4) Install pinion shaft lock pin. Securely stake in 2 places.
Ensure adhesive is removed from ring gear mounting bolts and gear
mounting surface. Clean internal threads with tap.
5) Install ring gear on differential case. Ensure alignment
marks on differential case and ring gear are aligned. Apply Loctite
271 to bolts and install. Tighten bolts alternately in diagonal
sequence to specification. See TORQUE SPECIFICATIONS table at the end
of this article.
PINION & SIDE GEAR BACKLASH SPECIFICATIONS









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Application In. (mm)
Standard ....................... .003 (.08)
Wear Limit ..................... .008 (.20)









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Fig. 3: Checking Pinion & Side Gear Backlash
Courtesy of Chrysler Motors.
DRIVE PINION DEPTH

1) Install pinion bearing races in carrier. For front race
use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L a\
nd
2.6L models and Race Installer (MB990935-01) for 3.0L models. For rear\
race, use Handle and Race Installer (MB990936-01). Ensure races are
fully seated.
2) Install Pinion Height Gauge (MB990901-01) and pinion
bearings. See Fig. 4. DO NOT install oil seal. Using INCH lb. torque
wrench, measure pinion rotating torque. Gradually tighten pinion
height gauge to increase rotating torque to proper specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
3) Install Cylinder Gauge (MB990903-01) in side bearing
seats. Ensure flat areas are aligned and gauge contacts side bearing
seat firmly. See Fig. 4.
4) Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge. Use minimum amount of
adjusting shims. Install selected adjusting shims between drive pinion
gear and rear pinion bearing. Using Bearing Installer (MB990802-01),
install rear pinion bearing.
PINION ROTATING TORQUE SPECIFICATIONS









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Application INCH Lbs. (N.m)
With Oil Seal
2.4L & 2.6L Engines . 3.04-3.91 (.35-.45)
3.0L Engine ........... 5.21-6.08 (.6-.7)
Without Oil Seal
2.4L & 2.6L Engines . 1.30-2.17 (.15-.25)
3.0L Engine ........... 3.47-4.34 (.4-.5)









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Fig. 4: Setting Pinion Depth
Courtesy of Chrysler Motors.
DRIVE PINION PRELOAD

1) Install drive pinion in differential carrier. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion flange, washer and retaining
nut. Check pinion rotating torque without pinion oil seal.
2) Recheck rotating torque. Rotating torque must be within
specification. See PINION ROTATING TORQUE SPECIFICATIONS table. Adjust
rotating torque by replacing drive pinion front shims or spacer. Once
correct rotating torque is obtained, install oil seal. Coat seal lip
with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install new
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See PINION
ROTATING TORQUE SPECIFICATIONS table.
SIDE BEARING
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges, measure clearance between carrier and side bearing shim
at opposite sides of bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add removed shim
thickness and 1/2 of feeler gauge clearance measurement plus .002" (.
05 mm). This is thickness of shim that should be installed on each
side of case. Select proper shims. Install equal shims on each side of
case assembly.
NOTE: Ensure no clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Check ring gear
backlash.
RING GEAR BACKLASH
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash must be within .004-.006" (.10-.15 mm).
2) If not within specification, change side bearing adjusting
shims and recheck backlash. If backlash is too small, install thinner
shim behind ring gear and thicker shim opposite ring gear.
3) If backlash is excessive, install thicker shim behind ring
gear and thinner shim opposite ring gear. Check gear tooth contact
using paint impression method.
CAUTION: When changing shims, total thickness of all shims must
remain constant.
RING GEAR RUNOUT
Using dial indicator, measure runout at back side of ring
gear. Runout must be within .002" (.05 mm). If runout is excessive,
change ring gear-to-differential case mounting position. Recheck
runout. Install cover and gasket.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Bearing Cap Bolt ...................... 40-47 (54-64)
Brake Caliper Bolt .................... 58-72 (79-98)
Carrier-to-Housing Tube Bolt .......... 58-72 (79-98)
Cover Bolt ............................ 11-16 (15-22)
Drain Plug ............................ 43-51 (58-69)
Fill Plug ............................. 29-43 (39-58)
Front Crossmember Bolt ............... 72-87 (98-118)
Hub Cover ............................. 13-25 (18-34)
Knuckle-to-Ball Joint Nut
Upper ............................... 43-65 (58-88)
Lower ............................ 87-130 (118-176)
Mount Bracket-to-Frame Bolt .......... 58-80 (79-108)
Mount Bracket-to-Housing Tube Bolt ... 58-72 (79-98)
Pinion Flange Nut
2.4L & 2.6L ..................... 116-159 (157-216)
3.0L ............................ 137-181 (186-245)
Drive Shaft Flange Bolt ............... 36-43 (49-58)
Right Drive Axle-to-Inner Shaft Bolt .. 36-43 (49-58)
Ring Gear-to-Case Bolt ................ 58-65 (79-88)
Tie Rod-to-Knuckle Nut ...................... 33 (45)
Wheel Lug Nuts
Montero ............................ 72-87 (98-188)
Pick-Up .......................... 87-101 (118-137)
INCH Lbs. (N.m)
Undercover-to-Frame
Bolts (Montero) ................. 84-108 (9.5-12.2)









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\003
DRIV E A XLE - R EA R N O N-IN TE G RAL
1991 M it s u bis h i M onte ro
199192 DRIVE AXLES
Differentials & Axle Shafts - Rear Non-Integral
Mitsubishi: Montero, Pickup
DESCRIPTION
Rear axle features a rigid banjo-type housing with semi-
floating axle shafts. Differential consists of hypoid reduction gears
and straight bevel differential gears. Limited Slip Differential (LSD)\
is available on all models.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS









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Application Ratio
Montero .................................................. 4.63
Pickup
2WD w/Light Suspension ................................. 3.91
2WD w/Heavy Suspension ................................. 4.22
4WD .................................................... 4.22









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LUBRICATION
CAPACITY
REAR AXLE GEAR OIL CAPACITY








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Application Pts. (L)
Montero .................................. 5.4 (2.5)
Pickup
Conventional
2WD ................................... 3.2 (1.5)
4WD ................................... 5.5 (2.6)
LSD .................................... 5.5 (2.6)









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FLUID TYPE
Conventional differentials use API classification GL-5 SAE
80W or 90W. Limited slip differentials use Mitsubishi Gear Oil
(8149630 EX) or Mopar Gear Oil (4318058) and Mopar Friction Modifier\
(4318060).
TROUBLE SHOOTING
DRIVE AXLE (RWD) TROUBLE SHOOTING








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PROBLEM
Possible Cause Action

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KNOCKING OR CLUNKING
Differential Side Gear Clearance .............. Check Clearance
Worn Pinion Shaft ........................ Replace Pinion Shaft
Axle Shaft End Play ............................ Check End Play
Missing Gear Teeth ................... Check Diff./Replace Gear
Wrong Axle Backlash ............................ Check Backlash
Misaligned Driveline ........................ Realign Driveline
CLUNKING DURING ENGAGEMENT
Side Gear Clearance ................. Check Side Gear Clearance
Ring and Pinion Backlash ....................... Check Backlash
Worn/Loose Pinion Shaft ................. Replace Shaft/Bearing
Bad "U" Joint ............................... Replace "U" Joint
Sticking Slip Yoke ............................. Lube Slip Yoke
Broken Rear Axle Mount .......................... Replace Mount
Loose Drive Shaft Flange ......................... Check Flange
CLICK/CHATTER ON TURNS
Differential Side Gear Clearance .............. Check Clearance
Worn Clutch Plates (1) .................. Replace Clutch Plates
Wrong Diff. Lubricant (1) .................... Change Lubricant
RHYTHMIC KNOCK OR CLICK
Flat Spot on Rear Wheel Bearing ......... Replace Wheel Bearing
HUM/LOW VIBRATION AT ALL SPEEDS
Faulty Wheel Bearings ........................ Replace Bearings
Faulty "U" Joint ............................ Replace "U" Joint
Faulty Drive Shaft ........................ Balance Drive Shaft
Faulty Companion Flange ........................ Replace Flange
Faulty Slip Yoke Flange ........................ Replace Flange
(1) - Limited slip differential only.









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DRIVE AXLE (FWD)
DRIVE AXLE (FWD) TROUBLE SHOOTING








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PROBLEM
Possible Cause Action









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GREASE LEAKING
Ripped CV Boot ................................... Replace Boot
CLICKING NOISE WHILE CORNERING
Dry/Worn CV Joints .................... Replace Outer CV Joints
CLUNK ON ACCELERATION
Dry/Worn CV Joints .................... Replace Inner CV Joints
Worn Trans. Gears/Bearings ..................... Inspect Trans.
VIBRATION/SHUDDER ON ACCELERATION
Dry/Worn CV Joints .......................... Replace CV Joints
Alignment Out ................................. Check Alignment
Incorrect Spring Height ................... Check Spring Height
SQUEALING OR HUMMING
Dry/Worn CV Joints ..................... Lube/Replace CV Joints
Faulty Wheel Bearing .................... Replace Wheel Bearing









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TESTING & INSPECTION
AXLE SHAFT END PLAY
Using dial indicator, check axle shaft end play. End play
must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shims to obtain correct end play. See AXLE
SHAFTS under REMOVAL & INSTALLATION.
AXLE TOTAL BACKLASH
1) Raise and support rear axle. Place transmission in
Neutral. Apply parking brake. Rotate drive shaft clockwise. Place
reference marks on pinion dust cover and differential housing.
2) Rotate drive shaft counterclockwise and measure distance
between reference marks. Differential must be removed and backlash
adjusted if distance exceeds 0.2" (5.0 mm).
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel free of ground and remove wheel. Use Axle Puller
Adapter (MB990241) for Montero and Pickup models. Install adapter on
wheel studs. Release parking brake.
2) Using torque wrench, measure starting torque on Pickup
models while rotating wheel in forward direction. On Montero models,
measure rotating torque. This measurement is read once axle is
turning. Differential must be repaired if torque is less than
specification. See TESTING SPECIFICATIONS table.