1991 MITSUBISHI ECLIPSE lock

REAR AXLE - Troubleshooting3-7
Symptom
NOTE
1 Probable cause1 Remedy
In addition to a malfunction of the differential carrier components, abnormal noise can also be caused by the universal
joint of the propeller shaft, the axle shafts, the wheel bearings, etc. Before disassembling any parts, take all
possibilities into consideration and confirm the source of the noise.
Abnormal noise when
Damaged differential gears
ReplacecorneringDamaged pinion shaftInsufficient gear oil quantity
Replenish
Gear noiseImproper final drive gear tooth contact adjustmentAdjust or replace
Incorrect final drive gear backlashAdjust
Improper drive pinion preload adjustment
Damaged, broken, and/or seized tooth surfaces of
Replacethe drive gear and drive pinion
Damaged, broken, and/or seized drive pinion bear-
ings
NOTE
Damaged, broken, and/or seized side bearings
Damaged differential case
Inferior gear oilInsufficient gear oil quantity
Replenish
Noise from the engine, muffler vibration, transaxle, propeller shaft, wheel bearings, tires, body, etc., is easily mistaken
as being caused by malfunctions in the differential carrier components. Be extremely careful and attentive whenperforming the driving test, etc.
Test methods to confirm the source of the abnormal noise include:coasting acceleration, constant speed driving,
raising the rear wheels on a jack, etc. Use the method most appropriate to the circumstances.
Gear oil leakageWorn or damaged front oil seal, or an improperlyReplace
installed oil seal
Damaged gasket
Seizure
VOTE
Loose companion flange self-locking nut
Loose filler or drain plug
Clogged or damaged vent plug
Insufficient final drive gear backlash
Excessive drive pinion preload
Excessive side bearing preload
Insufficient differential gear backlash
Excessive clutch plate preload
Inferior gear oilInsufficient gear oil quantityRetighten or replace
Retighten or apply adhesive
Clean or replaceAdjust
Replace
Replenish
n the event of seizure, disassemble and replace the parts involved, and also be sure to check all components for any
rregularities and repair or replace as necessary.
3reak downIncorrect final drive gear backlashAdjustInsufficient drive pinion preload
Insufficient side bearing preload
Excessive differential gear backlash
Loose drive gear clamping boltsRetighten
VOTEn addition to disassembling and replacing the failed parts, be sure to check all components for irregularities and repairIr
replace as necessary.
The limited slip differentialThe limited slip device is damagedDisassemble, check the func-
lees not function (ontioning, and replace the dam-
;now, mud, ice, etc.)aged parts

3-8REAR AXLE - Service Adjustment Procedures
09D031
llA0065SERVICE ADJUSTMENT PROCEDURES
REAR AXLE TOTAL BACKLASH CHECK
N03FAAF
If the vehicle vibrates and produces a booming sound due to animbalance of the driving system, measure the rear axle total
backlash by the following procedures to see if the differential
carrier assembly required removal.
(1) Place the gearshift lever in the neutral position, apply the
parking brake and jack up the vehicle.
(2) Manually turn the propeller shaft clockwise as far as it will
go and make mating marks on the companion flange dust
cover and the differential carrier.
(3) Manually turn the propeller shaft counterclockwise as far as
it will go and measure the movement of the mating marks.Limit: 5 mm
(.2 in.)
(4) If the backlash exceeds the limit, remove the differential
carrier assembly and adjust the backlash. (Refer to P.3-20.)
GEAR OIL LEVEL CHECKN03FCAA1. Remove the filler plug, and check the oil level.
2. The oil level is sufficient if it reaches the filler plug hole.
Specified gear oil:
MOPAR Hypoid Gear Oil API classification
GL-5 or
higher
[0.7 liter (0.74 qts.)]
NOTEAbove
-23°C (-10°F): SAE 90, 85W-90, 8OW-90
From
-34°C (-30°F) to -23°C (-10°F): SAE 8OW,
8OW-90Below
-34°C (-30°F): SAE 75WREAR WHEEL BEARING END PLAY
CHECKN03FEAE
(1) Support the vehicle on axle stands positioned at the
specified locations and remove the rear wheel.
(2) Separate the parking brake cable from the rear brake.
(3) Remove the caliper assembly and brake disc.
(4) Place a dial gauge as shown in the figure, and then
measure the play when the axle shaft is moved in the axial
direction.Limit: 0.8 mm
(.031 in.)
(5) If the play exceeds the limit, check the tightening torque of
the companion flange of the axle shaft; if it is correct,
replace the wheel bearing.

REAR AXLE - Service Adjustment Procedures3-9
14A0521
IncorrectREAR WHEEL BEARING ROTATION SLIDING
RESISTANCE CHECKNOOFJAA
(1) Remove the drive shaft from the companion flange.
(2) Remove the brake pad or caliper assembly.
(3) Attach a spring balance to the hub bolt, then, pulling the
balance at a right angle to the hub bolt, measure the
rotation sliding resistance (rotation starting torque) to see
whether it is within the standard value.
Standard value: 12
N (2.6 Ibs.) [rotation starting tor-
que 0.7 Nm (6 in
Ibs.)] or less
(4) If the rotation starting torque exceeds the standard value,
check the tightening torque of the axle shaft companion
flange. If it is normal, replace the bearing.
LIMITED-SLIP DIFFERENTIAL CHECKNOJFIAA(1) Block the front wheels and move the shift lever to neutral.
(2) Completely release the parking brake.
(3) Jack up the rear wheels and place a rigid rack at the
specified part of the side sill.
(4) Disconnect the coupling of the differential and propeller
shaft.(5) When one wheel is slowly rotated, check whether or not
the wheel on the other side turns in the same direction.
(6) If it turns in the opposite direction, replace the viscous unit.
_--

3-10REAR AXLE - Axle Shaft
AXLE SHAFT
REMOVAL AND INSTALLATION
Pre-removal Operation
*Disconnecting of Parking Brake Cable
End9-14 Nm
7-W ft.lbs.55-65Nm
40-47ft.lbs.160-220Nm
!116- 159 Ift.lbs.50-60 36-43ft.lbs. Nm
Removal steps
4*1. Rear speed sensor 2. O-ring
c*3. Brake caliper assembly4. Brake disc
/llA03604
5. Drive shaft mounting nut
+e l +6. Self-locking nut
7. Washer
8. Companion flange
c+9. Axle shaft assembly4I) +4 10. Rear rotor +e ++ 11. Outer bearing*e ++ 12. Dust cover++ 13. Dust cover
14. Axle shaft
4* +4 15. Oil seal+e l + 16. Inner bearing
NOTE(1) Reverse the removal procedures to reinstall.
(2)
*I) : Refer to “Service Points of Removal”.
(3) l + : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts
ALNOBHA-Post-installation Operation
Konnecting of Parking Brake Cable EndaAdjusting Parking Brake Lever
Stroke (Refer to GROUP
5-ServiceAdjustment Procedures.)
SERVICE POINTS OF REMOVAL
NOBHBAP
1.REMOVAL OF REAR SPEED SENSOR ABS>NOTE
Be cautious to ensure that the tip of the pole piece does not
Acome in contact with other parts when removing the speed
csensor.
3. REMOVAL OF BRAKE CALIPER ASSEMBLY
Remove the brake caliper assembly and suspend it with a
piece of wire.

12A0611
REAR AXLE - Axle Shaft3-116. REMOVAL OF SELF-LOCKING NUT
With the special tool, secure the axle shaft and remove thecompanion flange self-locking nut.
9. REMOVAL OF AXLE SHAFT ASSEMBLY
With the special tool, remove the axle shaft from the
trailing arm.
10. REMOVAL OF REAR ROTOR Remove the rear rotor from the axle shaft.
111. REMOVAL OF OUTER BEARING/lZ. DUST COVER
With the special tool, remove the outer bearing and dust
cover concurrently from the axle shaft.
115. REMOVAL OF OIL SEAL/lG. INNER BEARING
MB990560
/Trailing arm
/
/MB99092811
A0038
With the special tool, remove the inner bearing and oil sealfrom the trailing arm.
INSPECTIONNOBHCAFl Check the companion flange for wear or damage.
l Check the dust cover for deformation or damage.
l Check the wheel bearings for burning or discoloration.
l Check the wheel bearing for unsmooth rotation.
l Check the axle shaft for cracking, wear or damage.
l Check oil seal for cracking or damage.

REAR AXLE - Axle Shaft/Drive Shaft3-13
DRIVE SHAFTN03JA--
PARTS DISTINCTION--
Boots and boot bands can be distinguished by the
indicated part number as below.
10. INSTALLATION OF REAR ROTOR ABS>Press fit the rear rotor to the axle shaft with the rear rotor
groove surface toward the axle shaft flange.
6. INSTALLATION OF SELF LOCKING NUT
With the special tool, secure the axle shaft and tighten the
companion flange self locking nut.
F
I
IIidentification number
location
1 D.O.J. boot 1 nB.J. boot band

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.