1991 MITSUBISHI MONTERO oil

Fig. 4: Exploded View of Typical Limited Slip Differential
Courtesy of Chrysler Motors.
Drive Pinion
1) Remove pinion flange retaining nut. Scribe alignment marks
on drive pinion and pinion flange for reassembly. Using soft-faced
hammer, drive out pinion. Remove front adjusting shim and spacer from
pinion.
2) Using bearing puller, remove rear bearing from pinion.
Remove rear adjusting shim from pinion. Remove oil seal and bearing
races from differential carrier.
Inspection
1) Inspect all gears for cracked or flaking teeth. Inspect
pinion shaft for wear. Inspect pinion flange and drive pinion for
damaged splines.
2) Inspect bearings and races for roughness or flaking.
Replace worn components. On limited slip axles, inspect clutch
components and contact areas for wear or overheating. Inspect friction
plates, friction discs, spring plates and pressure rings for signs of
seizure, excessive heat, severe friction or nicks.
NOTE: Outer areas of friction surfaces will wear heavier due to
clutch plate and preload spring.
3) Using dial indicator, check friction plate and friction
disc for warpage. Replace components if beyond specification. See
FRICTION PLATE & DISC SPECIFICATIONS table.
4) Measure friction plates and disc thickness at projection
areas not within wear area. Measure plate and disc thickness in
friction surface. Difference between thickness of projections and
friction surface indicates amount of wear. Replace components if not

Thrust washer must be changed to obtain correct specification. Correct
clearance is .002-.008" (.05-.20 mm).
10) Select thrust washers to obtain correct clearance from
pressure ring face and end of thrust washer surface. Thrust washers
are available in 3 sizes.
11) Apply gear oil and friction modifier to all components.
Install components in differential case. Ensure assembly order and
direction of clutch components are correct. See Fig. 9.
Fig. 9: Limited Slip Differential Assembly
Courtesy of Chrysler Motors.
12) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See TORQUE
SPECIFICATIONS table at end of article. Ensure cases contact each
other completely when fully assembled. Check for incorrect clutch
assembly if gap exists.
13) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. Slightly rotate\
unit before measuring starting torque. See Fig. 10.

Fig. 10: Checking Differential Starting Torque
Courtesy of Chrysler Motors.
14) Starting torque must be within specification. See
STARTING TORQUE SPECIFICATIONS table. Ensure adhesive is removed from
ring gear mounting bolts and gear mounting surface. Clean internal
threads with tap.
15) Ensure alignment marks on differential case and ring gear
are aligned. Apply Loctite 271 to bolts and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS table.
STARTING TORQUE SPECIFICATIONS









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Application Ft. Lbs. (N.m)
Used Clutch Plates .................. 25-72 (34-98)
New Clutch Plates ................... 47-72 (64-98)









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DRIVE PINION HEIGHT
1) Install pinion bearing races in carrier. Ensure races are
fully seated. Install pinion height gauge and pinion bearings. Use
Pinion Height Gauge (MB990901) for all others. See Fig. 10. DO NOT
install oil seal.
2) Using torque wrench, measure pinion rotating torque.
Gradually tighten pinion height gauge to increase rotating torque to
3.5-4.3 INCH lbs. (.40-.48 N.m).
3) Install cylinder gauge in side bearing seats. Ensure flat
areas are aligned and gauge contacts side bearing seat firmly. See
Fig. 11 . Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected

1) Install drive pinion in differential carrier. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal. Install pinion flange, washer and retaining nut. Tighten nut
to specification. See TORQUE SPECIFICATIONS table.
2) Check pinion rotating torque. Rotating torque must be
within specification. Correct specification is 3.5-4.3 INCH lbs. (.40-
.48 N.m) without oil seal. Adjust rotating torque by replacing drive
pinion front shims or spacer.
3) Once correct rotating torque is obtained, install oil
seal. Coat seal lip with grease. Install pinion flange so alignment
marks are correct. Apply light coat of grease to contact area of
pinion flange washer.
4) Install new retaining nut. Recheck pinion rotating torque.
Rotating torque must be within specification.
SIDE BEARING
1) Press side bearings onto differential case. Install outer
races. Install differential case into differential carrier. Align
bearing cap index marks, and snug carrier cap bolts. Ensure outer
races and bearing caps are installed in original location. Tighten
bearing cap bolts finger tight.
2) Install side bearing nuts. Tighten bearing cap bolts. See
TORQUE SPECIFICATIONS table. Rotate bearing nuts in and out until
rotation is smooth. Temporarily tighten side bearing nuts to preload
side bearings. See TORQUE SPECIFICATIONS table. Adjust ring gear
backlash.
RING GEAR BACKLASH
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash must be within specification. See RING
GEAR BACKLASH SPECIFICATIONS table.
RING GEAR BACKLASH SPECIFICATIONS









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Application In. (mm)
2.4L ....................... .0043-.0063 (.109-.160)
3.0L ....................... .0051-.0071 (.130-.180)









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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 is beyond 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 center of 2 neighboring holes on side
bearing nut. Recheck backlash. Ensure bearing cap bolts are tightened
to specification. See TORQUE SPECIFICATIONS table.
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 table. Check gear tooth
contact using paint impression method. See GEAR TOOTH CONTACT PATTERNS
in this article.
RING GEAR RUNOUT
Using dial indicator, measure runout at back side of ring
gear. Runout must be within .002" (.05 mm). If runout is excessive,
change ring gear-to-differential case mounting position. Recheck

FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES

CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION








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Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.









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CLUTCH FORKS
CLUTCH FORK INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Broken .................. A ............ Require replacement.
Leaking (hydraulic
mount) ................. A ............ Require replacement.
Mounting hole worn,
affecting performance .. A ............ Require replacement.
Mounting hole worn, not
affecting performance .. .. ........ No service suggested or
required.
Rubber deteriorated,
affecting performance .. A ............ Require replacement.
Rubber deteriorated, not
affecting performance .. .. ........ No service suggested or
required.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.









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ODOMETER DRIVES (MECHANICAL)
See SPEEDOMETER/ODOMETER DRIVES (MECHANICAL) .
ODOMETER HEADS (MECHANICAL)
See SPEEDOMETER/ODOMETER HEADS (MECHANICAL) .
OIL PANS
See TRANSMISSION PANS .
PANS
See TRANSMISSION PANS .
PILOT HOLES
See DOWEL PINS, GUIDES AND PILOT HOLES .
PRESSURE PLATES
PRESSURE PLATE INSPECTION








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Condition Code Procedure
Balance weight missing .. C ............ Require replacement.
Broken .................. A ............ Require replacement.
Contact surface
distorted .............. B ............ Require replacement.
Cracks .................. B ............ Require replacement.
Fingers bent ............ A ............ Require replacement.
Hard spots .............. B ............ Require replacement.

Idle Speed Control Sensor On throttle body assembly.
Intake Air Temperature Sensor Inside airflow sensor
assembly.
Oil Pressure Sending Unit On right side of engine, near
oil filter.
Temp. Gauge Sending Unit On thermostat housing.