MITSUBISHI MONTERO 1998 Service Manual

Fig. 12: Exploded View Of Locking Differential
Courtesy of Mitsubishi Motor Sales of America.
Reassembly
1) Arrange friction plates and discs of each side of
differential. Measure each assembly thickness. Assembled discs and
plates should not exceed a difference of .002" (.05 mm). Replace discs\
or plates as needed.
2) Assemble one spring plate and one spring disc on each
side. Measure assembly thickness. Assemble disc and plates to obtain
minimum difference in thickness between each assembly.
3) Assemble clutch assemblies, pressure rings, pinion gears,
side gears and pinion shaft. Measure overall width of assembly plus
spring plates and spring discs (dimension "C"). See Fig. 13.
4) Determine depth of differential case (dimension "D"). On
2.4L, dimension "D" = "E" + "F" - "G"; on 3.0L, dimension "D" = "E" +
"H"
See Fig. 14. Subtract "C" from "D" to determine spring plate-
to-case clearance. Adjust spring disc thickness to obtain proper
spring plate-to-case clearance. Correct clearance is .0024-.0079" (.
060-.200 mm).

Fig. 13: Measuring Clutch Assembly Width
Courtesy of Mitsubishi Motor Sales of America.
Fig. 14: Measuring Limited Slip Case Depth
Courtesy of Mitsubishi Motor Sales of America.
5) Remove spring plates, spring discs, friction plates and
friction disc from pressure rings. Mark components for location.

Install thrust washers on each end of pressure rings. See Fig. 15.
6) Measure clearance from end of thrust washer to rear face
of pressure ring. Clearance should be .002" (.05 mm) or less. If
clearance is not as specified, select proper thickness thrust washers
to obtain correct clearance.
7) Once correct thrust washers are determined, install thrust
washers on pressure rings. Squeeze pressure rings together, and
measure width (dimension "H") from end of thrust washer to remaining
thrust washer.
8) Determine distance between thrust washer surfaces when
differential case is assembled (dimension "I"). Dimension "I" = "J" +
"K" + "L". Dimension "J" is the same as dimension "D" in step 4).
Fig. 15: Measuring Thrust Washer Clearance
Courtesy of Mitsubishi Motor Sales of America.
9) Subtract "H" from "I". This is the clearance between
thrust washer and differential case. Correct clearance is .002-.008"

(.05-.20 mm). If clearance is not within specification, change thrust
washer to obtain correct clearance.
10) Apply gear oil and friction modifier to all components.
Install components in differential case. Ensure assembly order and
direction of clutch components are correct. See Fig. 16.
Fig. 16: Limited Slip Differential Assembly
Courtesy of Mitsubishi Motor Sales of America.
11) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See
TORQUE SPECIFICATIONS . Ensure cases contact each other completely when
fully assembled. Check for incorrect clutch assembly if gap exists.
12) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. See Fig. 17.
Rotate unit slightly before measuring starting torque.

Fig. 17: Checking Differential Starting Torque
Courtesy of Mitsubishi Motor Sales of America.
13) Ensure starting torque is within specification. See
STARTING TORQUE table. Ensure adhesive is removed from ring gear
mounting bolts and gear mounting surface. Clean internal threads with
tap.
14) Ensure alignment marks on differential case and ring gear
align. Apply Loctite 271 to bolts, and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS .
STARTING TORQUE









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Application Ft. Lbs. (N.m)\
Used Clutch Plates ................................... 29-54 (40-75)\
New Clutch Plates .................................... 18-54 (25-75)\









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Carrier Assembly & Drive Pinion Installation
1) Install pinion bearing races in differential housing.
Ensure races are fully seated. Install Pinion Height Gauge (MB990901)
and pinion bearings. See Fig. 18. DO NOT install oil seal.

Fig. 18: Setting Pinion Height
Courtesy of Mitsubishi Motor Sales of America.
2) Using torque wrench, measure pinion rotating torque.
Gradually tighten pinion height gauge to increase rotating torque. See

PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS









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Application INCH Lbs. (N.m)\
Oil Seal Not Installed
With Lubrication ................................. 3.5-4.3 (.4-.5)\
Without Lubrication .............................. 5.2-7.8 (.6-.9)\
Oil Seal Installed
With Lubrication ............................... 5.6-6.5 (.65-.75)\
Without Lubrication .......................... 7.4-10.0 (.85-1.15)\









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3) Install cylinder gauge in side bearing seats. Ensure flat
areas align, and gauge contacts side bearing seat firmly. Select
adjusting shim with same thickness as gap between cylinder gauge and
pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected
adjusting shims between drive pinion gear and rear pinion bearing.
Using bearing installer and press, install rear pinion bearing.
5) Install drive pinion in differential housing. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal. Install pinion companion flange, washer and retaining nut.
Tighten nut to specification. See TORQUE SPECIFICATIONS.
6) Check pinion rotating torque. 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.
Install pinion companion flange so alignment marks are correct. Apply
light coat of grease to contact area of pinion flange washer.
7) Install NEW retaining nut. Recheck pinion rotating torque.
Ensure rotating torque is within specification. Press side bearings
onto differential case. Install outer races. Install differential
carrier into differential housing. Align bearing cap index marks, and
snug carrier cap bolts. Ensure outer races and bearing caps are
installed in original location.
8) Install side bearing nuts. Tighten bearing cap bolts to
specification. See TORQUE SPECIFICATIONS . Tighten bearing nuts until
bearing outer races are seated against bearings. Adjust ring gear
backlash.
Ring Gear Backlash
1) Secure drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. See Fig. 6. Measure at
4 locations of ring gear. Gear backlash must be within specification.
Backlash should be .005-.007" (.13-.18 mm).
2) If backlash is less than specification, loosen side
bearing nut at back of ring gear, and tighten side bearing nut on
tooth side of ring gear by same amount. If backlash exceeds
specification, loosen side bearing nut at tooth side of ring gear, and
tighten side bearing nut at back of ring gear by same amount.
3) After adjusting backlash, tighten both side bearing nuts
half the distance between 2 adjacent holes on side bearing nut.
Recheck backlash. Ensure bearing cap bolts are tightened to
specification. See TORQUE SPECIFICATIONS .
4) Lock plates are of 2 designs for hole location of side
bearing nuts. Install proper type lock plate. Tighten lock plate bolt
to specification. See TORQUE SPECIFICATIONS. Check gear tooth contact
pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL
INFORMATION.
Ring Gear Runout

Using dial indicator, measure runout at back side of ring
gear. See Fig. 7. Runout must be within .002" (.05 mm). If runout is
excessive, change ring gear-to-differential case mounting position.
Recheck runout.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Bearing Cap Bolt
Montero ............................................ 40-47 (54-64)\
Montero Sport ...................................... 37-48 (51-65)\
Bearing Case-To-Axle Housing Bolt
Montero .................................................. 35 (47)\
Montero Sport ...................................... 40-47 (54-64)\
Brake Tube Flare Nut ....................................... 11 (15)\
Differential Carrier-To-Axle Housing Nut
Montero .................................................. 35 (47)\
Montero Sport
2.4L ............................................. 18-21 (24-28)\
3.0L ................................................... 35 (47)\
Drain Plug (Montero Sport) ................................. 44 (60\
)
Drive Shaft-To-Flange Bolt ........................... 36-43 (49-58)\
Lock Plate Bolt ...................................... 11-16 (15-22)\
Pinion Flange Nut ........................................ 159 (216)\
Ring Gear Bolt ....................................... 58-65 (79-88)\
Side Bearing Lock Plate Bolts ........................ 11-16 (15-22)\
Wheel Lug Nut
Montero ........................................... 72-87 (98-118)\
Montero Sport
Aluminum Wheel .................................. 73-86 (99-117)\
Steel Wheel ................................... 87-101 (118-137)\









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DIFFERENTIAL LOCK - REAR
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Rear Differential Lock
Montero, Montero Sport
DESCRIPTION & OPERATION
The rear differential lock system is designed to be used only
when low-speed wheel spin occurs in a ditch, or on a slippery or
uneven surface. The indicator light will blink when switch is turned
on as system completes locking operation. After the differential is
locked, the light will stop blinking and remain on.
The rear differential lock system will not lock with vehicle
in 4H or 2H position, and if vehicle speed is greater than 7 MPH.
Vehicle speed should be maintained at less than 12 MPH during rear
differential lock operation.
NOTE: The Anti-lock Brake System (ABS) does not operate when the
rear differential is locked. It is normal for the ABS
warning light to be on at this time.
COMPONENT LOCATIONS
Rear Differential Lock Air Pump
Air pump is located under left side of rear seat.
Rear Differential Lock Control Unit
Control unit is located under left side lower quarter trim
panel in rear compartment.
Rear Differential Lock Switch
Lock switch is located on lower center of instrument panel,
below radio.
Rear Differential Lock Detection Switch
Lock detection switch is located on rear differential
carrier.
TROUBLE SHOOTING
INDICATOR LIGHT FLASHES WHEN LOCK SWITCH IS TURNED ON
If vehicle speed is greater than 7 MPH, reduce speed to less
than 3 MPH. If vehicle speed is less than 7 MPH, rotate steering wheel
to right and left to reset light.
INDICATOR LIGHT FLASHES WHEN LOCK SWITCH IS TURNED OFF
If indicator flashes after lock switch is turned off, depress
and release accelerator several times while driving straight ahead to
reset light.
TESTING
REAR DIFFERENTIAL LOCK AIR PUMP

1) Connect pressure gauge with "T" joint to air pump
discharge outlet nozzle. See Fig. 1. Install air hose to differential.
Apply battery voltage to air pump connector. Note amount of time
between when air pump starts operating to when air pump stops
operating. If air pump stops within 5 seconds, internal pressure
switch is operating properly.
2) Measure pressure 10-20 seconds after air pump has stopped.
Pressure should be 4-6 psi (.28-.42 kg/cm
). If pressure is as
specified, internal release valve is operating properly. Ensure air
pump does not begin operating for 5 minutes after it has stopped.
Fig. 1: Testing Rear Differential Lock Air Pump
Courtesy of Mitsubishi Motor Sales of America.
REAR DIFFERENTIAL LOCK CONTROL UNIT