wheel MITSUBISHI MONTERO 1998 Repair Manual
Page 361 of 1501
AXLE RATIO SPECIFICATIONS \
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Application Ratio
Montero ..................................................... 4.27:1
Montero Sport .................................................. (1)
( 1) - On vehicles equipped with wide fender, ratio is 4.64:1. On
vehicles with narrow fender, ratio is 4.27:1.
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LUBRICATION
CAPACITY
DIFFERENTIAL FLUID CAPACITY \
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Application Specification
Montero & Montero Sport ............................ 2.4 Pts. (1.1L)\
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FLUID TYPE
All models use fluid type SAE 80W-90/API GL-5.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
AXLE SHAFTS R & I
Removal
1) Raise and support vehicle. Remove wheels and undercover.
Ensure hub is in free-wheeling position. Place transfer case in 2H
position. Remove drive hub cover, snap ring and shim from axle shaft.
See Fig. 3 . Remove brake calipers and support aside.
2) Disconnect tie rod assembly. Support lower control arm
with jack. Separate ball joints from knuckle. Remove knuckle and front
hub assembly. Using flat-blade pry bar, carefully remove left axle
shaft from differential carrier. DO NOT damage oil seal. On right axle
shaft, remove axle shaft-to-inner shaft flange retaining bolts. Remove
right axle shaft.
CAUTION: Replace circlips on BJ/DOJ splined shaft end.
Installation
1) Install right axle shaft on inner shaft flange. Install
new circlip on DOJ side of left axle shaft. Carefully install left
axle shaft into differential. DO NOT damage oil seal.
2) Reinstall knuckle with front hub assembly. To complete
installation, reverse removal procedure. Install shim and snap ring.
Check axle end play. See Fig. 4. End play should be .016-.028" (.4-.7
mm). If end play is not within specification, install correct shim.
Page 368 of 1501
Brake Caliper Bolt ......................................... 65 (88)\
Carrier-To-Housing Tube Bolt
Montero ...................................................... (1)
Montero Sport ...................................... 58-72 (79-98)\
Differential
Cover Bolt ............................................... 14 (19)\
Drain Plug
Montero .......................................... 43-51 (58-69)\
Montero Sport .............................................. ( 1)
Fill Plug
Montero ................................................ 39 (53)\
Montero Sport .......................................... 36 (49)\
Drive Shaft Flange Bolt .............................. 36-43 (49-58)\
Front Crossmember Bolt .............................. 72-87 (98-118)\
Hub Cover Bolt ....................................... 13-25 (18-34)\
Knuckle-To-Ball Joint Nut
Upper
Montero ................................................ 54 (73)\
Montero Sport .................................... 44-65 (60-88)\
Lower
Montero .............................................. 108 (146)\
Montero Sport ............. .................. 87-130 (118-176)\
Mounting Bracket-To-Frame Bolt ...................... 58-80 (79-108)\
Mounting Bracket-To-Housing Tube Bolt ................ 58-72 (79-98)\
Pinion Flange Nut
Montero
A/T .................................................. 137 (186)\
M/T .................................................. 159 (216)\
Montero Sport .......................................... 159 (216)\
Right Drive Axle-To-Inner Shaft Bolt ................. 36-43 (49-58)\
Ring Gear-To-Case Bolt ............................... 58-65 (79-88)\
Side Bearing Cap Bolt ................................ 40-47 (54-64)\
Tie Rod-To-Knuckle Nut
Montero .................................................. 33 (45)\
Montero Sport ............................................ 32 (43)\
Wheel Lug Nuts
Montero ........................................... 72-87 (98-118)\
Montero Sport
Aluminum Wheel .................................. 73-86 (99-117)\
Steel Wheel ................................... 87-101 (118-137)\
INCH Lbs. (N.m)
Undercover-To-Frame Bolts (Montero) .............. 84-108 (9.5-12.2\
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( 1) - Information is not available from manufacturer.
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Page 370 of 1501
TESTING & INSPECTION
AXLE SHAFT END PLAY
Montero & Montero Sport
Using dial indicator, check axle shaft end play. End play
should be .010" (.25 mm). If end play is not within specification,
replace axle bearing. See AXLE SHAFT OVERHAUL under OVERHAUL.
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 mm). See RING GEAR BACK-LASH
procedure under DIFFERENTIAL ASSEMBLY (LIMITED SLIP) under OVERHAUL.
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel off ground and remove wheel. Release parking brake.
2) Using torque wrench and axle puller adapter, measure
starting torque while rotating wheel in forward direction. See Fig. 1.
Differential must be repaired if torque is less than 18 ft. lbs. (25
N.m).
Fig. 1: Testing Limited Slip Differential Preload
Courtesy of Mitsubishi Motor Sales of America.
LOCKING DIFFERENTIAL (MONTERO)
Air Pump
Page 371 of 1501
Connect air pressure gauge in-line to air hose from air pump.
Air pump is located in right storage area, under rear seat. Connect
battery voltage to air pump (positive lead to Red wire). The air pump
is operating correctly when the following sequences occur;
* Pump should operate for no more than 5 seconds.
* Pressure should be 4-6 psi (.28-.41 kg/cm
) within 10-20
seconds after pump has stopped.
* After air pump has stopped operating, it should not restart
operating for 5 minutes.
Center Differential Lock Operation Switch
See ANTI-LOCK BRAKE SYSTEM article in BRAKES.
Differential Lock Switch
Remove switch from center console. To test switch operation,
see Fig. 2 . Replace switch as needed.
Differential Lock Control Unit
See ANTI-LOCK BRAKE SYSTEM article in BRAKES.
Lock Detection Switch
1) Raise and support vehicle. Disconnect air hose connection
near rear differential. Connect air source with pressure regulator and
pressure gauge. Apply 4 psi (.28 kg/cm
) pressure. Disconnect lock
detection switch harness connector.
2) Using ohmmeter, check if continuity exists with air
pressure applied. Continuity should exist with air pressure applied.
If continuity exists, ensure axle is locked by attempting to turn rear
wheels separately of each other.
3) If continuity does not exist, go to step 4). If continuity\
does exist but axles are not locked, see CARRIER ASSEMBLY under
REMOVAL & INSTALLATION and inspect locking assembly.
4) Remove detection switch from housing. Using ohmmeter,
check continuity of switch. Continuity should exist with switch
plunger extended. With plunger in neutral position, continuity should
not exist. Replace switch as needed.
Fig. 2: Checking Differential Lock Switch Continuity
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
Page 372 of 1501
AXLE SHAFT R & I
Removal (Montero & Montero Sport)
Block front wheels. Raise and support rear axle housing.
Remove brake caliper and rotor. See Fig. 3. Remove parking brake cable
attaching bolts. Remove connection for parking brake cable end from
rear brake assembly. Remove ABS speed sensor (if equipped). Unbolt
backing plate with bearing housing from rear axle housing. Using
Puller (MB990241) and Slide Hammer (MB990211), remove axle assembly.\
DO NOT damage oil seal. Remove "O" ring. Replace if necessary.
Installation
Install NEW oil seal in axle housing as needed. To install
axle assembly, reverse removal procedure.
Fig. 3: Exploded View Of Typical Axle Shaft
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Insert new "O" ring and shim of .04" (1.0 mm) thickness
Page 374 of 1501
3) Change angle of grind, and remove remaining .08" (2.0 mm)\
of retainer ring wall on bearing side. Using a chisel, cut retainer
ring. Remove ring. DO NOT damage axle shaft.
4) Install Puller (MB990787-01) to remove bearing case from
axle shaft. See Fig. 5. Rotate nuts with equal force to remove wheel
bearing. Remove bearing outer race using a hammer and drift. Remove
oil seal from axle housing using a slide hammer and hook.
Fig. 4: Grinding Bearing Retainer Ring
Courtesy of Mitsubishi Motor Sales of America.
Page 388 of 1501
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\
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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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Page 389 of 1501
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
Page 391 of 1501
Using voltmeter, backprobe rear differential lock control
unit connector between terminal No. 6 (ground) and specified terminal
under specified conditions. See WIRING DIAGRAMS. See
REAR DIFFERENTIAL LOCK CONTROL UNIT VOLTAGE table. If voltage is not
as specified, replace control unit.
REAR DIFFERENTIAL LOCK CONTROL UNIT VOLTAGE
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Terminal No. Circuit Voltage
3 .................... Ignition Switch (IG1) ............ ( 1) Zero
3 .................... Ignition Switch (IG1) ......... ( 2) Battery
9 (ON side) ............. Rear Lock Switch .......... ( 2)( 3) Zero
1 (OFF side) ............ Rear Lock Switch ....... ( 2)( 4) Battery
10 ...................... Indicator Light ........... ( 2)( 5) Zero
10 ...................... Indicator Light ........ ( 2)( 6) Battery
2 .................. Vehicle Speed Reed Switch ............. ( 7) 5
8 ................. Rear Lock Detection Switch ...... ( 2)( 5) Zero
8 ................. Rear Lock Detection Switch ... ( 2)( 6) Battery
4 ..................... Rear Lock Air Pump ....... ( 2)( 8) Battery
4 ..................... Rear Lock Air Pump .......... ( 2)( 9) Zero
5 ................... Center Lock Operation ..... ( 2)( 10) Battery
5 ...................... Detection Switch ....... ( 2)( 10) Battery
5 ...................... Detection Switch .......... ( 2)( 11) Zero
( 1) - Ignition off.
( 2) - Ignition on.
( 3) - ON side or OFF side.
( 4) - In Neutral.
( 5) - Rear differential locked.
( 6) - Rear differential free.
( 7) - Select Drive or 1st gear and drive forward slowly.
( 8) - When filing or holding.
( 9) - When releasing.
( 10 ) - Center differential free.
( 11 ) - Center differential locked.
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REAR DIFFERENTIAL LOCK DETECTION SWITCH
NOTE: DO NOT apply more pressure than required to bring pressure
gauge reading to about 4 psi (.28 kg/cm ).
1) Raise and support vehicle. Remove air pipe and air hose
connections. Connect a pressure gauge and air regulator (for adjusting
compressed air pressure) to air hose. See Fig. 2. Using air regulator,
adjust compressed air pressure until pressure gauge indicates about 4
psi (.28 kg/cm
).
2) While an assistant holds one wheel on one side of vehicle
stationary, slowly turn wheel on other side of vehicle. Using
ohmmeter, check for continuity between rear differential lock
detection switch connector terminals.
3) With air supplied, continuity should exist. With air
released, continuity should not exist. If continuity is not as
specified, replace lock detection switch.
Page 415 of 1501
FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES