1991 MITSUBISHI 3000GT service

27-22REAR AXLE - ‘Drive Shaft
SERVICE POINTS OF DISASSEMBLYM27JEADI4. REMOVAL OF SNAP RING
/ 5. SPIDER ASSEMBLY
(1) Remove the snap ring from the drive shaft with the d i
snap ring pliers.
(2) Take out the spider assembly from the drive shaft.
(3) Clean the spider assembly.
Caution1. Do not disassemble the spider assembly.
2..If the T.J. of the drive shaft assembly is bent, the
joint may be damaged. Use care in handling the
drive shaft.3. The drive shaft joint use special grease. Do not
add another type of grease.
6. REMOVAL OF T.J. BOOT
/ 9. B.J. BOOT
(I) Wrap vinyl tape around the spline part on the T.J. side ofthe drive shaft so that the T.J. and B.J. boots are not
damaged when they are removed.
(2) Withdraw the T.J. and B.J. boots from the drive shaft.
10. REMOVAL OF GREASE FROM B.J.
Wipe out the grease from the B.J.
CautionDo not disassemble the B.J.h
llKOO7
INSPECTIONM27JFADl Check the drive shaft for damage, bending or corrosion.
l Check the drive shaft spline part for wear or damage.
lCheck for entry of water and/or foreign material into B.J.l Check the spider assembly for roller rotation, wear or
corrosion.
lCheck the groove inside T.J. case for wear or corrosion.l Check the boots for deterioration, damage or cracking.
SERVICE POINTS OF REASSEMBLYM27JGAE9. INSTALLATION OF B.J. BOOT
/ 8. B.J. BOOT BAND
(SMALL) / 7. B.J. BOOT BAND (LARGE) / 6. T.J. BOOT
(1) Wrap vinyl tape around the drive shaft spline.
(2) Insert the drive shaft in B.J. boot, boot bands, T.J. bootin that sequence.
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27-24REAR AXLE - Differential Carrier
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
M271A. -
Pre-removal and Post-installation Operationl Draining and Filling of Differential Gear Oil
(Refer to Group 00 - Maintenance Service.)l Removal and Installation of Main Muffler
(Refer to Group 15 - Exhaust Pipe and Muffler.)24Nm
17 ft.lbs.
90 Nm65 ft.lbs.4
/lIl8
c/
90 Nm65 ft.lbs.
63
i
i !f%
43 - 51ft.lbs.
90 Nm65 ftlbs.
,55-65Nm40 - 47 fklbs.
22 - 25 ft.lbs.
90 Nm65 ft.lbs.llFO034
Removal steps
a*1. Drive shaft
2. Circlipl * l a3. Propeller shaft connection
4. Differential support assembly
5. Differential support member assembly
6. Rear wheel oil pump installation bolt
l * l *7. Differential carrier
8. O-ring
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REAR AXLE - Differential Carrier
27-25
Mating marks
//
MB991 153
MBggo8477J=f 4
Differential support member
llNOOl1
DifferentialllN0053
SERVICE POINTS OF REMOVALm27wAm
1. REMOVAL OF DRIVE SHAFT
With a tire lever, etc., remove the drive shaft from the
differential carrier.
NOTE
Be cautious to ensure that the differential carrier oil seal isnot damaged by the drive shaft spline.
3. DISCONNECTION OF PROPELLER SHAFT
(1) Make mating marks on the differential companion
flange and the propeller shaft flange yoke for reference
during reassembly.
(2) Remove the differential carrier and propeller shaft
connection.
(3) Support the propeller shaft with wire.
7. REMOVAL OF DIFFERENTIAL CARRIER
Holding the bottom of the differential carrier and removing
the rear wheel oil pump through the mounting hole, removethe differential carrier.
Caution1. Use care not to damage the rear wheel oil pump
gears.
2.Use care not to allow dirt or foreign matter to fall
into the differential carrier.
DIFFERENTIAL SUPPORT BUSHING AND DIF-
FERENTIAL SUPPORT MEMBER BUSHING RE-
PLACEMENTM271YAB
Install or remove the bushing using the special tool. Install the
bushing with its hollow portion facing in the direction shown.
CautionInstall the bushing with the differential support and
differential support member chamfered end first and
install until the bushing outer case end face is flush withthe support and support member.

27-26
REAR AXLE - Differential Carrier
SERVICE POINTS OF INSTALLATION
7. INSTALLATION OF DIFFERENTIAL CARRIERm27lDAL
Install the rear wheel oil pump by inserting it through the
mounting hole and install the differential carrier securely.\yiIlYl61
Caution
Use care not to damage the rear wheel oil pump gears.
3. CONNECTION OF PROPELLER SHAFTAlign the mating marks on the flange yoke and the
companion flange to install the propeller shaft.
INSPECTION BEFORE DISASSEMBLYM27lEAJHold 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 drivegear backlash with a dial indicator on the drive gear.
NOTEMeasure at four points or more on the circumference of the
drive gear.d’Standard value: 0.11
- 0.16 mm (.004 - .006 in.)IDRIVE GEAR
RUNOUTI
Measure the drive gear runout at the shoulder on the reverseside of the drive gear.
Limit: 0.05 mm
(.002 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.
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DISASSEMBLYREAR AXLE
- Differential Carrier27-29
M27lF- -
inspection Before Disassemblyl Final Drive Gear Backlash(Refer to P.27-26.)l Drive Gear Runout(Refer to P.27-26.)l Final Drive Gear Tooth Contact(Refer to P.27-26.)Disassembly steps
1. Differential cover assembly2.Vent plug
3.Oil seal
4.Snap ring4*5. Side bearing nut4*6. Side bearing outer race7. Differential case assembly4*8. Side bearing inner race4*9. Drive gear (for 4WS)4*10. Drive gear
11. Spring pin (for 4WS)4*12. LSD case (refer to P.2759.)4*13. Self-locking nut14:Washer
4*
4*
4*4*4*
64 111 FO032
15. Drive pinion assembly
16. Companion flange
17. Drive pinion front shim
(for preload adjustment)18. Drive pinion spacer19. Drive pinion rear bearing inner race20. Drive pinion rear shim
(for pinion height adjustment)
21. Drive pinion
22. Oil seal
23. Drive pinion front bearing
24. Drive pinion rear bearing outer race
25. Differential carrier’
SERVICE POINTS OF DISASSEMBLYM27lGBD5. REMOVAL OF SIDE BEARING NUT
Using the special tool, remove the side bearing nut.
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REAR AXLE - Differential Carrier
27-33
Lubrication, Sealing and Adhesion Points
L
11lwO.llFOO11
Sealant: 3M AID Part No. 8663 or equivalentllFO032
Adhesive: 3M Stud Locking Part
No. 4170 or equivalent
Spring pinDjive gear
View A
ilA0262llA0261
SERVICE POINTS OF REASSEMBLYM27UBG
1. INSTALLATION OF SPRING PIN (FOR
4WS)
Tap the spring pin into the differential case to the position
shown in the illustration before
press fitting the rear wheel
oil pump drive gear. The notch on the spring pin should bein the position shown in the illustration.
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27-40REAR AXLE - LSD Case Assembly
r
Differential side
Differential
Differential
pinion mate
Thrust washer
llPO128
Pinion matewasherllPO12’
1 lFOO35(3) Insert the special tool at the spline part of differential
case B (right) and check to be sure the side gear (right)
rotates.
(4) Then insert a 0.09 mm t.0035 in.) feeler gauge to \Ljreplace a 0.03 mm
(.0012 in.) gauge.
(5) Insert the special tool at the spline part of the
differential side gear (right) and check to be sure the
side gear (right) does not rotate.
Differential gear backlash
Standard value (clearance in thiust direction ofside gear): 0.03
- 0.09 mm (.0012 - .0035 in.)
NOTE
If the clearance in the thrust direction of the side gear iswithin the standard value range, the backlash of the
differential gear is normal.
(6) If the clearance in the thrust direction of the side gear is
not within the standard value range, remove differentialcase A and make the adjustment by adjusting the
thickness of the thrust washer (left).
SERVICE POINTS OF DISASSEMBLYM27NGAA
3. REMOVAL OF THE THRUST WASHER (LEFT)
/ 9.
THRUST WASHER (RIGHT)The thrust washers (left and right) are of different thick-
ness, and so should be discriminated in some way for
reference during installation.
INSPECTIONM27NHAA
(1) Check the gears and differential pinion shaft for unusual
wear or damage.
(2) Check the spline part of the differential side gear (right) forstepped wear or damage.
(3) Check the thrust washer and pinion mate washer for
unusual wear of contact surfaces, heat damage or other
damage.(4) Check differential cases A and B for unusual wear of
contact surfaces, heat damage or other damage.
0: Contact surface with the viscous unit
0: Contact sur acef
with the pinion mate washer
@ and 0: Contact surfaces with thrust washer
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1

iREAR AXLE
- LSD Case Assembly27-41
viscous unit
bSpline part
(5) Check the spline part of the viscous unit for stepped wear
or damage, and check the contact surface with differentialcase
B.(6) Check the side gear (left) of the viscous unit for unusual
wear or damage.
Pinion mate
llPO134
Feeler qauqe
/11 FO03Feeler
Differential g;ar (right)Th‘rust kasher (righl
11 FOO3i
SERVICE POINTS OF REASSEMBLYM27NlhA
10. INSTALLATION OF THE DIFFERENTIAL CASE B
/ 2.
DIFFERENTIAL CASE A
Align the mating marks of differential cases B and A, and
assemble the cases.
6.INSTALLATION OF THE DIFFERENTIAL PINION MATE /5. PINION MATE WASHER
With the washer in the position shown in the illustration,
install to the differential pinion shaft, and then install to
differential case B.3. SELECTION OF THE THRUST WASHER (LEFT)
If the differential side gear and pinion mate gear have beenreplaced, select the thrust washer (left) by following the
steps below.
(1) Wash the differential side gear and pinion mate gear inunleaded gasoline to remove all oil, grease, etc.
(2) Install the previously used thrust washers (being carefulthe left and right ones are used at the correct side),
together with the gears, viscous unit, pinion mate
washer and pinion shaft, to differential cases A and B,and then, using screws, secure them temporarily.
(3) Secure the differential case assembly in a vise so thatthe differential side gear (right) is facing upward.
Caution
When securing in the vise, be sure not to hold thedifferential case assembly too tightly.
(4) Insert a 0.03 mm j.0012 in.) feeler gauge at two places
(diagonally) between differential case B and the thrust
washer (right).
CautionDo not insert a feeler gauge in the oil groove of
differential case B.
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