MITSUBISHI ECLIPSE 1991 Service Manual

REAR AXLE - Differential Carrier
DIFFERENTIAL CARRIER
3-19
lEMOVAL AND INSTALLATIONN03lA--Pre-removal Operation
@Drainage of Differential Gear Oil (Refer toP.3-8.)*Removal of Center Exhaust Pipe (Refer
to GROUP 1 l-Exhaust Pipe and Main
Muffler.)
loo-120 Nm
72-87 ft.lbs.
\9-14 Nm7-10 ft.lbs.
80-100 Nm
58-72 ft.lbs.
loo-120 Nm
72-87 ftlbs.\/*
91hl A-55-65 Nm-/40-47 ftilis.22-25
ft.lbs.
Removal steps
4*I. Drive shaft
2. Circlip~~ ++ 3. Propeller shaft connection
4. Differential support member installation
nut
5. Stopper (lower)
6. Differential support member installation
llA0358
I Ibolts
7. Differential support member
8. Differential support member installation
bolts
9. Differential carrier
NOTE(I) Reverse the removal procedures to reinstall(2) +I) : Refer to “Service Points of Removal”.(2) W : Refer to “Service Points of Installation”.
(3) m : Non-reusable parts.

3-20REAR AXLE - Differential CarrierMating marks
’
lODSO5
Beveled place
1 lA0274
SERVICE POINTS OF REMOVALN031BAL1. REMOVAL OF DRIVE SHAFT
With a tyre lever, etc.,remove the drive shaft from the
differential carrier.
NOTEBe cautious to ensure that the differential carrier oil seal is
not damaged by the drive shaft spline.
3. DISCONNECTION OF PROPELLER SHAFT
(1) Place mating marks on the differential companion
flange and flange yoke for reference during reassembly.(2) Remove the differential carrier and propeller shaft
connection.(3) Support the propeller shaft with wire.
DIFFERENTIAL SUPPORT MEMBER BUSHING RE-
PLACEMENT
NOBIYAAUse the special tool to pull out and press in the differential
support member bushing.
NOTEPress in the bushing from the beveled part of the differential
support member; press in until the end surface of the bushing
outer cylinder is flush with the support member.
SERVICE POINTS OF INSTALLATIONN03lDAK3. CONNECTION OF PROPELLER SHAFT
Align the mating marks on the flange yoke and the
companion flange to install the propeller shaft.
INSPECTION BEFORE DISASSEMBLYNOJIEAIHold the working base in a vice, and attach the differential
carrier to the working base.
FINAL DRIVE GEAR BACKLASH
With the drive pinion locked in place, measure the final drive
gear backlash with a dial indicator on the drive gear.
NOTEMeasure at four points or more on the circumference of the
drive gear.
Standard value:
0.11-0.16 mm (.004-.006 in.)

REAR AXLE -Differential Carrier3-21
.-11GOO73
-
llG0076DRIVE GEAR RUNOUT
Measure the drive gear
runout at the shoulder on the reverse
side of the drive gear.
Limit: 0.05 mm
(.002 in.)
DIFFERENTIAL GEAR BACKLASH
While locking the side gear with the wedge, measure the
differential gear backlash with a dial indicator on the pinion
gear.Standard value:O-0.076 mm (O-.003 in.)
’ Limit:0.2 mm (.008 in.)
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps
below.
(1) Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.
(2) Insert a brass rod between the differential carrier and the
differential case, and then rotate the companion flange by
hand (once in the normal direction, and then
on& in the
reverse direction) while applying a load to the drive gear, sothat the revolution torque [approximately
2.5-3.0 Nm
(28-33
in.lbs.)] is applied to the drive pinion.
CautionIf the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
(3) Check the tooth contact condition of the drive gear and
drive pinion.

3-22REAR AXLE - Differential CarrierStandard tooth contact pattern
1 Narrow tooth side
2 Drive-side tooth surface (the side applying power
during forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the side applying pow-
er during reverse movement)
ProblemTooth contact pattern resulting from exces-
sive pinion heightSolution
3
The drive pinion is positioned too far from the:enter of the drive gear.
3
Increase the thickness of the pinion height adjustingshim, and position the drive pinion closer to the
center of the drive gear.
Also, for backlash adjustment, position the drive
gear farther from the drive pinion.
rooth contact pattern resulting from insuffi-
:ient pinion height
3
The drive pinion is positioned too close to the centerIf the drive gear.
3Decrease the thickness of the pinion height
adjust-ing shim, and position the drive pinion farther from
ihe center of the drive gear.
Also, for backlash adjustment, position the drive
gear closer to the drive pinion.
115642
NOTE(1) Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear
backlash. The adjustment of drive pinion hight and final drive gear backlash should be repeated until tooth contact
patterns bear a similarity to the standard tooth contact pattern.
(2)When adjustment is not able to obtain a correct pattern, it may be judged that the drive gear and drive pinion have
exceed their usage limits and both gears should be replaced as a set.

REAR AXLE - Differential Carrier3-23
DISASSEMBLYInspection Before Disassembly
@Final Drive Gear Backlash (Refer to P.3-20.)*Differential Gear Backlash(Refer to P.3-21.)
/ ;3-21.)’1
@Drive Gear Runout (Refer to P.3-21.)aFInal Drove Gear Tooth Contact (Refer to

\ \\Oi6 27i0
q l7 18 20llA0260

Disassembly steps
1. Differential cover
2. Vent plug
3. Bearing caps
*I)4. Differential case assembly5. Side bearing spacers
6. Side bearing outer race
:z
7. Side bearing inner race8. Drive gear
l * l *9. Lock pin 9. Lock pin10. Pinion shaft11. Pinion gears12. Pinion washers
13. Side gears
14. Side gear spacers15. Differential case
16. Limited slip differential case assembly
*I)17. Self-locking nut18. Washer
4*19. Drive pinion assembly
20. Companion flangellvlI , ,,,igellA0290llA0290
21. Drive pinion front shim-:-- ‘--nt shim
(for preload adjustment)Jstment)22. Drive pinion spacer3cerl *23. Drive pinion rear bearing inner racerr bearing inner race
24. Drive pinion rear shimrr shim,Ivl PJ” llUl I I IcIyIit adjustment)(for pinion height adjustment)?Cl3.r;. I,-. ..:..;A-25. Drive pinion
::
26. Oil seal“II >twI27. Drive pinion front bearingDrive pinion front bearing
4*28. Drive pinion rear bearing outer racen-‘..- -‘-‘-- --lr bearing outer race
29. Oil seal
30. Gear carrier
NOTE(1) +I) : Refer to “Service Points of Disassembly”.(2) m : Non-reusable parts.

3-24REAR AXLE- Differential Carrier
SERVICE POINTS OF DISASSEMBLYN03lGSC4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
kPrize out the differential case assembly using hammer
‘-
shafts.
NOTEWhen removing the differential case assembly, the
re’mov-
al should be accomplished slowly and carefully and cautionpaid to ensure that the side bearing outer race is not
dropped.
Keep the right and left side bearings separate, so that theydo 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 the
drive gear.
(2) Loosen the drive gear attaching bolts in diagonal
fisequence 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.
17. REMOVAL OF SELF-LOCKING NUT
Use the special tools to hold the companion flange and
remove the companion flange self-locking nut.

REAR AXLE -Differential Carrier3-25
Mating marks
llD237
llY175
llY17619. REMOVAL OF DRIVE PINION
) Make the mating marks to the drive pinion and
companion flange.
NOTEMating 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.
23. REMOVAL OF DRIVE PINION REAR BEARING INNER
RACE
Pull out the drive pinion rear bearing inner race by using thespecial tools.
26. REMOVAL OF OIL SEAL/27. DRIVE PINION FRONT
BEARINGDrive out the drive pinion front bearing from the gear
carrier.28. REMOVAL OF DRIVE PINION REAR BEARING OUTER
RACEDrive out the drive pinion rear bearing outer race from the
gear carrier.
INSPECTIONN03lHADl 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 wearor damage.
l Check the side gear spline for wear or damage.

3-26REAR AXLE - Differential Carrier
REASSEMBLYN0311-40-60
Nm*B-43 ft.lbs.*
80-90 Nm*58-65 ft.lbs.*

11 BOO86Differential gear setFinal drive gear set
Reassembly steps
1. Gear carrierl * 2. Oil seale+3. Drive pinion rear bearing outer racel +4. Drive pinion front bearing outer race
l *Adjustment of pinion height
5. Drive pinion
6. Drive pinion rear shim
(for pinion height adjustment)
7. Drive pinion rear bearing inner race8. Drive pinion spacer
l 4Adjustment of drive pinion preload9. Drive pinion front shim
(for preload adjustment)10. Drive pinion assembly11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut
16. Differential casellA0260llA0290
17. Limited slip (viscous coupling) differential
case
l *Adjustment of differential gear backlash
18. Side gear spacers
19. Side gears20. Pinion washers
21. Pinion gears22. Pinion shaft
l * 23. Lock pin
l + 24. Drive gear
+4 25. Side bearing inner race
26. Side bearing outer race
l 4Adjustment of final drive gear backlash
27. Side bearing spacers28. Differential case assembly
29. Bearing capsl 30. Vent plug
l
31. Differential cover
NOTE(I) I)+ : Refer to “Service Points of Reassembly”.[Z!/ m : Non-reusable parts.*: Tightening torque with oil applied.

REAR AXLE - Differential Carrier3-27
llK010
71
llY181llY182
.MB990836(MB990835)
llrm3
V223
SERVICE POINTS OF REASSEMBLYNOJUBD2. PRESS FITTING OF OIL SEAL
(1) With the special tool, press fit the oil seal until it is flushwith the end of the gear carrier.
(2) Apply multipurpose grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
3. lNSTALLATlON OF DRIVE PINION REAR BEARING
OUTER RACE/4. DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion rear and front bearing outer racesinto the gear carrier by using the special tools.
CautionBe careful not to press in the outer race at an angle.
l ADJUSTMENT OF PINION HEIGHT
Adjust the drive pinion height by the following procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequenceshown in the illustration.
NOTEApply a thin coat of multipurpose grease to the mating
face of the washer of the special tool.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
(2) Tighten the handle of the special tool until the standardvalue of drive pinion turning torque is obtained.
(3) Measure the drive pinion turning torque (without the oil
seal).Standard value:
Rotation torque
(starting friction torque)Nm
(in.lbs.)
I
NoneNew(with rust-I0.9-1.2 (8-10)prevention oil)New/reused Oil application
NOTE
0.4-0.5 (3-4)(I) Gradually tighten the nut of the special tool while
checking the drive pinion turning torque.
(2) Because the special tool cannot be turned one turn, turnit several times within the range that it can be turned;then, after fitting to the bearing, measure the rotation
torque.

3-28REAR AXLE - Differential Carrier
Y223
MB990031(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion rear shim of athickness which corresponds to the gap between the
special tools.
NOTE
Clean the side bearing seat thoroughly. When position-
ing the special tool, be sure that the cut-out sections ofthe special tool are in the position shown in the
illustration, and also confirm that the special tool is in
close contact with the side bearing seat.
When selecting the drive pinion rear shims, keep 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 following
procedures:
(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 byusing the special tools.
NOTEDo not install the oil seal.
(3) Measure the drive pinion turning torque (without the oil
seal) by using the special tools.
Standard value:
21
.;c
1 New
New/reused Oil application
0.4-0.5 (3-4)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTEWhen 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.