1991 MITSUBISHI ECLIPSE differential

REAR AXLE - Differential Carrier
I\I I!llGOO73I
11 S564(3) Adjust the differential gear backlash by the following
procedures:
@ While locking the side gear with the wedge,
measure the differential gear backlash with a dial
indicator on the pinion gear.
NOTEThe measurement should be made for both pinion
gears individually.
Standard value:
O-0.076 mm (O-.003 in.)
Limit:0.2 mm
(.008 in.)
@ If the differential gear backlash exceeds the limit,
adjust the backlash by installing thicker side gear
spacers.
@ Measure the differential gear backlash once again,
and confirm that it is within the limit.
NOTE(1) After adjustment, check that the backlash is the
less than the limit and differential gear rotates
smoothly.
(2) When adjustment is impossible, replace the side
gear and the pinion gear as a set.
23. INSTALLATION OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
w24. INSTALLATION OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Use an
Ml0 X 1.25 tap to remove the adhesive
adhering to the threaded holes of the drive gear, and
then clean the threaded holes by applying compressed
air.(3) Apply multipurpose adhesive to the threaded holes of
the drive gear.
Specified adhesive:MOPAR
Part No.4318031 or
4318032 or equivalent
(4) Install the drive gear onto the differential case with the
Amating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.

REAR AXLE -Differential Carrier3-31
= Thicknessof the
spacer on one side
llV241I25. PRESS-FITTING OF SIDE BEARING INNER RACE
Press-fit the side bearing inner races to the differential caseby using the special tool.
. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH
Adjust the final drive gear backlash by the following
procedures:(1) Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and
then mount the differential case assembly into the gear
carrier.
NOTE
Select side bearing spacers with the same thickness forboth the drive pinion side and the drive gear side.
(2) Push the differential case to one side, and measure theclearance between the gear carrier and the side
bearing.(3) Measure the thickness of the side bearing spacers on
one side, select two pairs of spacers which correspondto that thickness plus one half of the clearance plus
0.05 mm (.002 in.), and then install one pair each to thedrive pinion side and the drive gear side.
(4) Install the side bearing spacers and differential case
assembly, as shown in the illustration, to the gear
carrier.

3-32REAR AXLE - Differential Carrier
llY167If backlash is too small
If backlash is too large
llY168
(5) Tap the side bearing spacers with a brass bar to fit themto the side bearing outer race.
4(6) Align the mating marks on the gear carrier and the
bearing cap, and then tighten the bearing cap.
(7) With the drive pinion locked in place, measure the final
drive gear backlash with a dial indicator on the drive
gear.
NOTE
-cc
Measure at four points or more on the circumference ofthe drive gear.
Standard value:
0.11-0.16 mm (.004-.006 in.)
(8) Change the side bearing spacers as illustrated, and thenadjust the final drive gear backlash between the drive
gear and the drive pinion.
NOTEWhen increasing the number of side bearing spacers,
use the same number for each, and as few as possible.(9) Check the drive gear and drive pinion for tooth contact.
If poor contact is evident, make adjustment. (Refer to
P.3-22.)(lO)Measure the drive gear
runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
(.002 in.)
(ll)lf the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential
,+case, and remeasure.

REAR AXLE - Differential Carrier3-3311
K60411K625
30. INSTALLATION OF VENT PLUG/31. DIFFERENTIAL
COVERApply specified sealant to the installation surface of
vent plug and differential cover.
Specified sealant: 3M ATD Part No.8661, 8663 or
equivalent

3-34REAR AXLE - Differential Carrier (Limited Slip Differential)
DIFFERENTIAL CARRIER (LIMITED SLIP DIFFERENTIAL)
DISASSEMBLY AND REASSEMBLYNO31K--
Disassembly steps
1. Screwl + 2. Differential case A+e I)+ 3. Thrust washer (L.H.)4. Viscous unit
llP0127
I)+ 5. Pinion mate washer
M 6. Differential pinion mate
7. Differential pinion shaft
8. Differential side gear
(R.H.)
4+9. Thrust washer (R.H.)
l +
10. Differential case 6Feeler gauge-eeler gauge
\Feeler gauge/
’ IL4l\’IIDifferential sideThrkt washer
aear (riaht)(right)\llPO139
INSPECTION BEFORE DISASSEMBLYNO3IEBA1. CHECKING THE DIFFERENTIAL GEAR BACKLASH
(1) Secure the differential case assembly in a vise so that
the differential side gear (right) is facing upward.
Caution
When securing the vise, be sure not to hold the
differential case assembly too tightly.
(2) Insert a 0.03 mm (.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.

REAR AXLE - Differential Carrier (Limited Slip Differential)3-35ferential side gear
(right)Differential
Differential
pinion mate
llPO12BThrust washer
Pinion mate
Pinion mate
washerThrust washer
,,po,29Differential case
BerentiieA11
PO1311(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
(.0035 in.) feeler gauge to
replace 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 thrust direction of side
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 DISASSEMBLYNO3lLBB3. 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.
INSPECTIONN03lMBB(1) Check the gears and differential pinion shaft for unusual
wear or damage.
(2) Check the spline part of the differential side gear (right) for
stepped 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 surface with the pinion mate washer
@ and @I: Contact surfaces with thrust washer

3-36REAR AXLE - Differential Carrier (Limited Slip Differential)Contact surface
with differential
viscous unit
llPO142
Mamaifferential case
BPinion mate
washer
bDifierential7-pinion matellPO134Feeler gauge
Feeler
gaugeFeeler gauge
lifferential gear (right)Thrust washer (right),\llPO130
1(5) Check the
spline part of the viscous unit for stepped
wear or damage, and check the contact surface with
differential case B.
45
(6)Check the side gear (left) of the viscous unit for unusualwear or damage.
SERVICE POINTS OF REASSEMBLYNOOINBE
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 figure, install
to the differential pinion shaft, and then install to differentialM.case
B.3. SELECTION OF THE THRUST WASHER (LEFT)
(1) If the differential side gear and pinion mate gear have
been replaced, select the thrust washer (left) by
following the steps below.
@ Wash the differential side gear and pinion mate gear
in unleaded gasoline to remove all oil, grease, etc.
@ Install the previously used thrust washers (being
careful the 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.
@ Secure the differential case assembly in a vise so
that the differential side gear (right) is facing
upward.Caution
When securing in the vise, be sure not to hold the
differential case assembly too tightly.
@I Insert a 0.03 mm LOO12 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
rsrdifferential case B.

REAR AXLE - Differential Carrier (Limited Slip Differential)3-370
,.,:*,> ..’~ .;;s, ,~ ,$.’ j0
h
MB990990Feeler gauge ”
/
Feeler
gauge
@ Insert the special tool at the spline part of differen-
tial side gear (right) and check to be sure the side
gear (right) rotates.
@I Then insert a 0.09 mm (0035 in.) feeler gauge to
replace a 0.03 mm
(.0012 in.) gauge.
@ Insert the special tool at the spline part of the
differential side gear (right) and check to be sure theside gear (right) does not rotate.
Differential gear backlash
Standard value (clearance in thrust direction of side
gear):
0.03-0.09 mm (.OOlZ-.0035 in.)
NOTE
If the clearance in the thrust direction of the side gear iswithin the standard value range, the backlash of the
differential side gear is normal.
@I If the clearance in the thrust direction of the side
gear is not within the standard value range, removedifferential case A and make the adjustment by
adjusting the thickness of the thrust washer (left).
Thrust washer (left)
Part No.Thickness mm (in.)
0.8
t.031)0.9
f.035)1
.o i.039)1 .I
($043)1
.15 (.045)MB5692431.2
LO4711.25
(.049)1.3
i.051)1.35
(.053)1.4
l.055)1.5
i.059)Thrust washer (right) (reference)
NOTESelect one thrust washer (left) from the eleven types in the kit.