MITSUBISHI SPYDER 1990 Service Repair Manual

REAR AXLE Drive Shaft
Lever section.
BOOT BAND BOOT
(LARGE) INSTALLATION
Be careful that the drive shaft should be. straight when
tightening the B.J. boot bands.
Caution
Always check the identification numbers
boot band levers. Never the ‘bands;
section
I
T.J. BOOT/SPIDER CASE
I N S T A L L A T I O N
the drive shaft in T.J. boot.
(2) Install the spider assembly to the shaft from t he direction
, of the section.
(3) After applying specified grease to the T.J. cas e, insert
the drive shaft and apply grease one more time.
Specified grease:
Repair kit grease
<Conventional differential> 95
(3.35
<Limited slip differential> 105 (3.70 oz.)
NOTE
The grease in the repair kit should be divided in h alf
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint use special grease. Do not
old and new or different types of grease.
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REAR AXLE Drive __
B O O T BA N D
( L A R G E )
INSTALLATION
Set the T.J. boot bands at the specified distance i n order
to adjust the amount of air inside the T.J.
and then
tighten the, T.J. boot bands securely.
Standard value (A): <Conventional differential> 79
3
<Limited slip differential> 84 3 mm in.)
Caution
Always check the identification numbers on the
band levers. Never confuse the bands.
Items Identification numberI
T.J. boot band (large)I
T.J. boot band (small)
INSPECTION
lCheck the drive Shaft for corrosion.
l drive shaft part for wear or damage.
lCheck for entry of water and/or foreign
l Check the spider assembly
corrosion.
lCheck the groove inside T.J. case for
lCheck the boots for deterioration, or
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REAR AXLE Differential Carrier
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal OperationlBrake Fluid Draining with drum brakes>l Differential Gear Oil Draining
98 Nm
Post-installation OperationlDifferential Gear Oil Filling (Refer to lBrake Line Bleeding with drum (Refer to GROUP Service.)l Parking Brake Adjustment (Refer to GROUP Service.)
98
2 2 - 2 5
118-13785-99
11
<Vehicles with drum

5
11
Removal steps
1. Rear wheel speed sensor
with 2. Caliper assembly (Refer to
3. Brake disc
4. Brake drum
5. Shoe and lining assembly (Refer to
GROUP 36
Parking Brake<Drum-in-disc brakes>.)6. Shoe and lever assembly7. Clip8. Parking brake cable9. Brake pipe connection
10. Shock absorber connection
11. Trailing arm connection 12. Lower arm connection
13. Toe control arm ball joint and
connection (Refer to
14. Differential mount support 15. Propeller shaft connection 16. shaft 17. Differential mount
bracket assembly
parts which should be tightened,and then fully tightened wlth the vehicle on the gr oundin the unladen condition.
Revision

R E A R A X L E D i f f e r e n t i a l
Mating marksR E M O V A L S E R V I C E P O I N T S . --
PROPELLER SHAFT
(1) Make mating marks on the differential
and flange yoke, and then separate the differential carrier
assembly and the propeller shaft;
(2) Suspend the propeller shaft the body wire,
so that there are no-sharp bends.
Caution
Be careful that there are no sharp bends in the pro pel-
ler shaft, as they may damage the joint.
DRIVE SHAFT DISCONNECTION
(1) Push the lower part of the knuckle to the of the
vehicle, and then separate the drive shaft from the differen-
tial carrier. At this time, use a tire lever similar to
separate the drive shaft connection,
(2) Support the separated drive shaft
wire or similar
so as not to
the joint.
(3) Use the special tool as a
not to let objects
get into the
carrier.
DIFFERENTIAL REMOVAL
Support the differential carrier with a jack. Then remove the
connecting bolt between it and the rear crossmember and
remove the differential carrier.
INSTALLATION SERVICE
DRIVE SHAFT CONNECTION
Caution
Do not damage the differential carrier ‘oil seal.
PROPELLER SHAFT
Connect the propeller shaft so‘ that the marks on the
differential companion flange and the
are aligned.
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REAR AXLE Differential Carrier
INSPECTION BEFORE
I
Hold the special tool in a vice, and attach the differential
carrier to the special tool.
DRIVE GEAR BACKLASH CHECK
(1) With the drive pinion locked in place, measure the drive
gear backlash with a dial indicator on the drive ge ar.
NOTE
Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11
0.16 mm in.)
(2) If the backlash is outside the standard value, adjust using
the side bearing spacer.
NOTE
After adjustment, inspect the contact of the drive gear.
DRIVE GEAR
CHECK
(1) Measure the drive gear
at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
in.)
(2) If the
exceeds the limit value, check that there
is no foreign material between the reverse side of the
drive gear and the differential case, or that there is no
looseness in the drive gear mounting bolt.
(3) If step (2) is normal, change the assembly posi tion of
the drive gear and differential case, and then take another
measurement.
NOTE
If adjustment is impossible, replace case
or the drive gear and drive pinion as a set.
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27-32REAR AXLE Differential Carrier .
DIFFERENTIAL GEAR BACKLASH
differential> ,
(1) While locking the side gear with measure
the differential gear
a on the
pinion gear.
NOTE
(1) The measurement should be
g e a r s i n d i v i d u a l l y .
(2) Refer to for of the limited
differential gear backlash.
Standard value: 0.076 mm In.)
Limit: 0.2 mm
in.)
(2) If the differential gear backlash
limit, adjust
the backlash by installing thicker side
NOTE
If adjustment is impossible, gear and
pinion gear as a set.
DRIVE GEAR TOOTH CONTACT CHECK
Check the drive gear tooth contact by following the steps
below.
(1) Apply a thin, uniform coat of machine blue to bo th surfaces
of the drive gear teeth.
(2) Insert a special tool between the
carrier
the differential case, and then rotate companion flange
by hand (once in the normal direction, and then onc e
in the reverse direction) while a the drive
gear, so that the revolution 2.5
3.0 Nm (22-27 is pinion.
Caution
If the drive gear is rotated contact
pattern will become unclear to check.
(3) Check the tooth
condition of, the drive gear
drive pinion.

REAR AXLE Differential
Standard tooth contact patternProblemSolution
.
1Narrow tooth sideTooth contact pattern resulting from. .
2Drive-side tooth surface (the side
applying power during forward
movement)3 Wide tooth side
4 Coast-side tooth surface (the side applying power during
reverse movement)Increase the thickness of the pinion
height adjusting shim, and position
the drive pinion closer to the center of
4
The drive pinion is positioned too far the drive gear.
from the center of the drive gear. for backlash
tion the drive gear farther from the
drive pinion.
Tooth contact resulting from
insufficient pinion height
Decrease the thickness of pinion
height adjusting Shim, position
the drive pinion farther from the
The drive
positioned center of the drive gear.
close to the center of the drive gear. for backlash
tion the drive gear closer to the drive pinion.
NOTE
(1) Tooth contact pattern is a method for judging t he result of the adjustment of drive pinion height and drive gear
backlash. The adjustment of drive pinion height and drive gear backlash should be repeated until tooth contact
patterns bear a similarity to the standard tooth co ntact
(2) When adjustment is not able to obtain a correct pattern, it may be judged that the drive gear and pinion
have exceed their usage limits and both gears shoul d be replaced as a set.
Revision

27-34REAR AXLE. Differential
DISASSEMBLY
Drive Gear Tooth Contact Check (Refer to
1820 27 2831<Limited slip differential>
Disassembly steps
l Inspection before disassembly
(Refer to
Differential cover assembly2. Vent plug3. Bearing cap
4. Differential case assembly
5. Side bearing spacer
6. Side bearing outer race
7. Side bearing inner race
Drive gear
9. Lock pin
<Conventional differential>10. Pinion shaft<Conventional differential>
11. Pinion gear <Conventional differential>
12. Pinion washer <Conventional differential>
13. Side gear differentials
14. Side gear spacer
<Conventional differential>
Differential case<Conventional differential>16. Limited slip differential case assem-
bly (Refer to
17. Self-locking nut
18. Washer
19. Drive pinion assembly20. Companion flange21. Drive pinion front shim (for preload
adjustment)22. Drive pinion spacer
23. Drive pinion rear bearing inner race
24. Drive pinion rear shim (for pinion
height adjustment)25. Drive pinion
26. Oil seal
27. Drive pinion front bearing inner race
28. Drive pinion front bearing outer race
29. Drive pinion rear bearing outer race
30. Oil seal 31. Gear carrier
.

REAR AXLE Differential ‘Carrier
DISASSEMBLY SERVICE POINTS
DIFFERENTIAL CASE ASSEMBLY
Caution
the differential case slowly
fully so that the side bearing race is not
NOTE
Keep the right and left side bearings separate, so that they
do not become mixed at the time of reassembly.
BEARING INNER RACE REMOVAL
Place the nut on top of the differential case, and then use
the special tool to remove the side bearing inner r ace.
NOTE
Attach the prongs of the special tool to the inner ‘race of
the side bearing through the openings in the differential case.
DRIVE GEAR REMOVAL
(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching bolts in diagon al se-
quence to remove the drive gear.
LOCK PIN REMOVAL differential>
NUT REMOVAL
Revision

REAR AXLE Differential Carrier
Mating marks
I
(1) Make the mating marks to the drive pinion and companion
.
Caution
Mating marks should not be sur-
faces of companion shaft.“‘
(2) Drive out the drive pinion
spacer and drive pinion ,
. .
PINION REAR BEARING
REMOVAL
O I L
RACE/DRIVE PINION FRONT
OUTER RACE REMOVAL
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REAR BEARING
REMOVAL
INSPECTION
lCheck the companion flange for wear or damage.
lCheck the bearings for wear discoloration.
lCheck the gear carrier for cracks.
lCheck the drive pinion and drive gear or
lCheck the side gears, pinion gears and shaft for
wear or damage.
l Check the side gear
for damage