bolts MITSUBISHI MONTERO 1998 Owner's Guide
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
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
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into left side axle housing. Install left axle shaft assembly into
axle housing, and tighten nuts to specification. See
TORQUE SPECIFICATIONS.
2) Install right axle shaft assembly into axle housing
without shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case of right axle and rear axle housing end with
feeler gauge.
3) Select shims equal to sum of measured clearance plus .002-
.008" (.05-.20 mm). Remove right axle shaft, and install selected
shim(s) and "O" ring into right axle housing end. Install right axle
shaft assembly into rear axle housing. Tighten nuts in diagonal
sequence to specification. See TORQUE SPECIFICATIONS.
4) Using dial indicator, check end play of axle shaft. End
play should be .002-.008" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake, and bleed brake system.
CARRIER ASSEMBLY
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFT R & I . Support differential carrier with jack.
Remove differential carrier retaining nuts. Remove differential
carrier.
Inspection
Check for leaks at vent plug, differential carrier companion
flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts and drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
OVERHAUL
AXLE SHAFT OVERHAUL
Removal
1) Secure axle shaft assembly in a vise, and remove one
retainer bolt from backing plate. Push bearing case completely to side
of dust cover. Place adhesive tape around edge of bearing case at
retainer bolt hole to prevent damage.
CAUTION: DO NOT damage bearing case or axle shaft when grinding or
chiseling retainer ring.
2) Secure axle shaft, and grind retainer ring until retainer
ring wall thickness is .04-.06" (1.0-1.5 mm) on axle shaft side and .
08" (2.0 mm) on bearing side. See Fig. 4.
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assembly and drive pinion installation.
Carrier Assembly & Drive Pinion Removal
1) Remove differential carrier from axle housing. Remove lock
plates. Mark location of side bearing nuts for reassembly. Remove side
bearing nuts. See Fig. 9. Mark location of bearing caps for
reassembly. Remove bearing caps. Remove differential carrier assembly
from differential housing.
Fig. 9: Exploded View Of Conventional Rear Differential (Typical)
Courtesy of Mitsubishi Motor Sales of America.
2) Secure drive pinion companion flange from turning. Remove
companion flange retaining nut. Scribe alignment marks on drive pinion
and companion flange for reassembly. Using soft-face hammer, drive
pinion out of housing. Remove front adjusting shim and spacer from
pinion.
3) Using bearing splitter and press, remove rear bearing from
pinion. Remove rear adjusting shim from drive pinion. Remove oil seal
and bearing races from differential housing.
Disassembly (Carrier Assembly)
1) Using bearing splitter and press, remove differential case
side bearings. Place alignment marks on ring gear and differential
case for reassembly. Loosen ring gear bolts in diagonal sequence.
Remove ring gear.
2) Remove pinion shaft lock pin from differential carrier.
Remove differential pinion shaft and thrust block (if equipped).
Remove pinion gears and washers. Remove side gears and thrust spacers.
Mark components for reassembly reference.
Inspection
Wash parts in clean solvent and dry with compressed air.
Inspect bearings for discoloration and/or flaking. Check all gears for
irregular wear or damage. Ring gear and drive pinion must be replaced
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as matched set. Side gears and pinion gears must be replaced as
matched set.
Reassembly & Adjustment
1) Install thrust spacers, side gears, pinion washers and
pinion gears in differential case. DO NOT install thrust block (if
equipped) at this time.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. See
Fig. 8 . Using dial indicator, measure gear backlash. Backlash should
be .0004-.0030" (.010-.080 mm). Service limit is .008" (.20 mm).
3) Adjust backlash by using different side gear spacers.
Ensure both sides are equally shimmed. Install thrust block (if
equipped) once correct backlash is obtained. Install pinion shaft lock
pin from ring gear side of carrier housing. Securely stake pin in 2
places. Ensure adhesive is removed from ring gear mounting bolts and
gear mounting surface. Clean internal threads with tap.
4) 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 . Using appropriate adapter,
press on carrier side bearings.
DIFFERENTIAL ASSEMBLY (LIMITED SLIP)
NOTE: Manufacturer does not provide disassembly or reassembly
procedures for locking type differential. Use illustrations
for exploded views of assembly. See Figs. 11 and 12.
NOTE: See PRE-DISASSEMBLY INSPECTION under
DIFFERENTIAL ASSEMBLY (CONVENTIONAL) before disassembling
carrier assembly. For carrier assembly and drive pinion
removal, see DIFFERENTIAL ASSEMBLY (CONVENTIONAL) .
Disassembly
1) Once ring gear is removed, loosen carrier housing screws
in diagonal pattern. Separate cases and remove components. See Fig. 10
. Maintain parts in order of disassembly. Clean all parts in new
solvent.
2) Inspect condition of friction and spring plates and
friction discs. Replace disc and/or plates if worn or heat damaged.
Distortion of discs will cause incorrect clutch pressure. Scratches,
nicks or burrs on components can be repaired with an oil stone.
3) Discs must be flat and free of distortion. Check discs on
surface plate with dial indicator. Maximum warpage of friction plate
or disc is .003" (.08 mm). Inspect thickness of discs and plates.
Thickness limit between discs and plates is .004" (.10 mm).
Fig. 10: Exploded View Of Limited Slip Differential
Courtesy of Mitsubishi Motor Sales of America.
Page 385 of 1501
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.
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![MITSUBISHI MONTERO 1998 Owners Guide PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS
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PINION ROTATING TORQUE SPECIFICATIONS
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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
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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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Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Distorted ............... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Positioned incorrectly .. B .. Require repair or replacement.
Stepped ................. A .. Require repair or replacement.
Worn to the extent that it
no longer performs its
intended function ...... A .. Require repair or replacement.
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DRIVE SHAFT FLANGES
See COMPANION FLANGES .
DRIVE SHAFTS AND HALF SHAFTS
DRIVE SHAFT AND HALF SHAFT INSPECTION \
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Condition Code Procedure
Balance weight missing .. C .. Require repair or replacement.
Bearing cap bore
distorted .............. A .. Require repair or replacement.
Bent .................... A ............ Require replacement.
Bolt holes elongated .... A .. Require repair or replacement.
Bushing or seal surface
worn, affecting
performance ............ A .. Require repair or replacement.
Leaking through soft yoke
plug ................... A ... Require repair or replacement
of soft yoke plug.
Out of balance .......... A .. Require repair or replacement.
Retainer strap bent ..... A .......... Require replacement of
retainer strap.
Slip yoke broken ........ A ............ Require replacement.
Splines worn, affecting
performance ............ A ............ Require replacement.
Splines worn close to
the end of their
useful life ............ 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
U-bolt damaged, affecting
performance ............ A . Require replacement of U-bolts.
Yoke damaged, affecting
performance ............ A .. Require repair or replacement.
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DUST BOOTS
NOTE: Does not include CV boots.
DUST BOOT INSPECTION
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Condition Code Procedure
Cracked, not leaking .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
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![MITSUBISHI MONTERO 1998 Owners Guide \
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YOKE AND SLIP YOKE INSPECT](/img/19/57333/w960_57333-453.png "MITSUBISHI MONTERO 1998 Owners Guide \
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YOKES AND SLIP YOKES
YOKE AND SLIP YOKE INSPECT")
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YOKES AND SLIP YOKES
YOKE AND SLIP YOKE INSPECTION \
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Condition Code Procedure
Bearing cap bore
distorted .............. A .. Require repair or replacement.
Bent .................... A ............ Require replacement.
Bolt holes elongated .... A .. Require repair or replacement.
Bushing or seal surface
worn, affecting
performance ............ A .. Require repair or replacement.
Leaking through soft yoke
plug ................... A ... Require repair or replacement
of soft yoke plug.
Retainer strap bent ..... A .......... Require replacement of
retainer strap.
Slip yoke broken ........ A ............ Require replacement.
Splines worn, affecting
performance ............ A ............ Require replacement.
Splines worn close
to the end of their
useful life ............ 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
U-bolt damaged, affecting
performance ............ A ............. Require replacement
of U-bolts.
Yoke damaged, affecting
performance ............ A .. Require repair or replacement.
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rust may be removed using bead blasting method. Components must be
free of oil and grease prior to bead blasting. Beads will stick to
grease or oil soaked areas causing area not to be cleaned.
Use air pressure to remove all trapped residual beads from
components after cleaning. After cleaning internal engine parts made
of aluminum, wash thoroughly with hot soapy water. Component must be
thoroughly cleaned as glass beads will enter engine oil resulting in
bearing damage.
CHEMICAL CLEANING
Solvent tank is used for cleaning oily residue from
components. Solvent blasting sprays solvent through a siphon gun using
compressed air.
The hot tank, using heated caustic solvents, is used for
cleaning ferrous materials only. DO NOT clean aluminum parts such as
cylinder heads, bearings or other soft metals using the hot tank.
After cleaning, flush parts with hot water.
A non-ferrous part will be ruined and caustic solution will
be diluted if placed in the hot tank. Always use eye protection and
gloves when using the hot tank.
Use of a cold tank is for cleaning of aluminum cylinder
heads, carburetors and other soft metals. A less caustic and unheated
solution is used. Parts may be lift in the tank for several hours
without damage. After cleaning, flush parts with hot water.
Steam cleaning, with boiling hot water sprayed at high
pressure, is recommended as the final cleaning process when using
either hot or cold tank cleaning.
COMPONENT CLEANING
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
SHEET METAL PARTS
Examples of sheet metal parts are the rocker covers, front
and side covers, oil pan and bellhousing dust cover. Glass bead
blasting or hot tank may be used for cleaning.
Ensure all mating surfaces are flat. Deformed surfaces should
be straightened. Check all sheet metal parts for cracks and dents.
INTAKE & EXHAUST MANIFOLDS
Using solvent cleaning or bead blasting, clean manifolds for
inspection. If the intake manifold has an exhaust crossover, all
carbon deposits must be removed. Inspect manifolds for cracks, burned
or eroded areas, corrosion and damage to fasteners.
Exhaust heat and products of combustion cause threads of
fasteners to corrode. Replace studs and bolts as necessary. On "V"
type intake manifolds, the sheet metal oil shield must be removed for
proper cleaning and inspection. Ensure that all manifold parting
surfaces are flat and free of burrs.
CYLINDER HEAD REPLACEMENT
* PLEASE READ THIS FIRST *