1989 MITSUBISHI GALANT Service Repair Manual

REAR AXLE - Differential Carrier
Standard tooth contact pattern
1 Narrow tooth side
2 Drive-side tooth surface (the side applying powerduring forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the side applying pow- er during reverse movement)
Problem
Tooth contact pattern resulting from exces-
sive pinion height
Solution
3
The drive pinion is positioned too far from the
center of the drive gear. 3Increase
the thickness of the pinion height adjusting
shim, 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. 3
Decrease the thickness of the pinion height adjust-
ing shim, and position the drive pinion farther from
the center of the drive gear.
Also, for backlash adjustment, position the drive gear closer to the drive pinion.
lls642
NOTE
(1)Tooth contact pattern is a method for judging the result of the adjustme\
nt of drive pinion height and final drive gear
backlash. The adjustment of drive pinion hight and final drive gear back\
lash 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 judg\
ed that the drive gear and drive pinion have exceed their usage limits and both gears should be replaced as a set.
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27-30
DISASSEMBLY
REAR AXLE - Differential Carrier
Inspection Before Disassembly*Final Drive Gear Backlash (Refer to P.27-27.)*Differential Gear Backlash
(Refer to
P.27-27.)@Drive Gear Runout
(Refer to P.27-27.)
*Final Drive Gear Tooth Contact (Refer to
P.27-28.)
llA0260
Disassembly steps
1. Differential cover
2. Vent plug
**l *
l *
3. Bearing cap
4. Differential case assembly
5. Side bearing
spacer
n n.* I0. slae oeanng outer race
7. Side bearing inner race
8.Drive
9. gear
10.Lock pin
Pinion shaft
11.Pinion12.gear
Pinion washer
13.
Sidegears
14. Side gear spacer
15. Spring pin (Vehicles with
4WS)16. Drive gear (Vehicles with 4WS)17. Differential case
18.
19.
Self-loclhg nut
Washer
l *20. Drive pinion assembly
21. Companion flange
22. Drive pinion front shim
(for preload adjustment)
23. Drive pinion spacer
24. Drive pinion rear bearing inner race
25. Drive pinion rear shim
(for pinion height adjustment)
26. Drive pinion
27. Oil seal
28. Drive pinion front bearing
29. Drive pinion rear bearing outer race 30. Oil seal
31. Gear carrier
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REAR AXLE - Differential Carrier27-31
‘71
I
I
SERVICE POINTS OF DISASSEMBLYM27lGBC
4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
Prize out the differential case assembly using hammer
shafts.
NOTE
When removing the differential case assembly, the remov-
al should be accomplished slowly and carefully and caution
paid to ensure that the side bearing outer race is not
dropped. Keep the right and left side bearings separate, so that they
do 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 thedrive gear.
(2) Loosen the drive gear attaching bolts in diagonal
sequence 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.
18. REMOVAL OF SELF-LOCKING NUT
Use the special tools to hold the companion flange and
remove the companion flange self-locking nut.
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27-32REAR AXLE - Differential Carrier
Mating marks
n
0161
llY175
llY176
20. REMOVAL OF DRIVE PINION
) Make the mating marks to the drive pinion and
companion flange.
NOTE
Mating 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.
24. REMOVAL OF DRIVE PINION REAR BEARING INNER
RACE
Pull out the drive pinion rear bearing inner race by using the
special tools.
27. REMOVAL OF OIL
SEAL/28. DRIVE PINION FRONT
BEARING
Drive out the drive pinion front bearing from the gear
carrier.
29. REMOVAL OF DRIVE PINION REAR BEARING OUTER
RACE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
INSPECTIONM27lHAD
l 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 wear
or damage.
l Check the side gear spline
for wear or damage.
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REASSEMBLY
REAR AXLE - Differential Carrier27-33
M27n-
160-220
Nm
116-159
ft.lbs.
Differential gear set
11BOO66
Final drive gear set
Reassembly steps
1. Gear carrier*a 2. Oil seal++ 3. Drive pinion rear bearing outer racel +4. Drive pinion front bearing outer race*aAdjustment of pinion height
5. Drive pinion
6. Drive pinion rear shim (for pinion height adjustment)
7. Drive pinion rear bearing inner race
8. Drive pinion spacer
*aAdjustment of drive pinion preload
9. Drive pinion front shim (for preload adjustment)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer 15. Self-locking nut
16. Differential case so-9d
Nm*
5845
ft.lbs.*
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~~ 17. Drive gear (Vehicles with 4WS)e+ 18, Spring pin (Vehicles with 4WS)l *Adjustment of differential gear backlash
19. Side gear spacer
20. Side gear
21. Pinion washer
22. Pinion gear
23. Pinion shaft
l a 24. Lock pinl a 25.Drive gearl * 26.Side bearing inner race
27. Side bearing outer race
l *Adjustment of final drive gear backlash
28. Side bearing spacer 29. Differential case assembly
30. Bearing cap
31. Vent plug
32. Differential cover
NOTEl : Tightening torque with oil applied
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27-34REAR AXLE - Differential Carrier
\
Lubrication, sealing and adhesion points
r
1 MO326
r
‘, 29c.
,’ :
~
;I::a e-**,i ,,,,3;;,*; :i
L
Adhesive: 3M Stud locking
No. 4170 or equivalentPart
llK60411K626
Sealant:3M ATD Part No.6661, 6663or equivalent
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REAR AXLE - Differential Carrier27-35
IllK610
90938-o 1
llY181
llY182
MB990905-4-C
MIT216335
MIT216336
MB990905-2-01
u-
MB990905l-01
llW616
SERVICE POINTS OF REASSEMBLYM27lJ6c6
2. PRESS FITTING OF OIL SEAL
(1) With the special tool, press fit the oil seal until it iswith the end of the gear carrier.
(2) Apply multipurpose grease to the oil seal lip. flush
3. INSTALLATION OF DRIVE PINION REAR BEARING OUTER RACE/A DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion rear and front bearing outer races
into the gear carrier by using the special tool.
Caution
Be careful not to press in the outer race at an angle.
. ADJUSTMENT OF PINION HEIGHT
Adjust the drive pinion height by the following procedures: (I)
Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequence
shown in the illustration.
(2) Tighten the handle of the special tool until the standard value of drive pinion turning torque is obtained.
(3)
Ea;sure the drive pinion turning torque (without the oil
Standard value:
I I
Bearing BearingRotation torque
classification lubrication (starting friction torque)
Nm (in.lbs.)
I,;,r,used 1 EJi!x%;; 1/;;;;y;-;
NOTE(1) Gradually tighten the handle ?f the special tool while
checking the drive pinion turning torque.(2)Because the special tool cannot be turqed one tur?,
turn
it several times within the range that It
can be turned;
then, after fitting to the bearing, measure the rotation
torque.
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27-36REAR AXLE - Differential Carrier
lllllllll
1
7
(4) Position the special tool in the side bearing seat of thegear carrier, and then select a drive pinion rear shim of a
thickness which corresponds to the gap between the
special tools.
NOTE
Clean the side bearing seat thoroughly. Confirm that the
special tool is in close contact with the side bearing
sf?at---_.
When selectina
the drive oinion rear shims. keen 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 followingprocedures
:
(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 by using the special tools.
NOTE
Do not install the oil seal.
(3) Measure the drive pinion turning torque (without the oilseal) by using the special tools.
Standard value:
Bearing Bearingclassification lubrication
Rotation torque
(starting friction torque)
Nm (in.lbs.)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque byreplacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When 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.
(5) Remove the companion flange and drive pinion once
again.
Drive the oil seal into the gear carrier front lip by using
the special tool.
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