1991 MITSUBISHI MONTERO check oil

Fig. 2: Removing Bearing Case from Axle Shaft
Courtesy of Chrysler Motors.
Inspection
Inspect bearings for roughness, pitting or damage. Inspect
axle shaft for damaged splines or flange. Inspect bearing case for
cracks or damage. Measure axle shaft O.D. in bearing area. Correct O.
D. is 1.57" (39.8 mm). Axle shaft must be replaced if O.D. is not to
specification.
Reassembly
1) Apply grease to outer surface of bearing outer race and
oil seal.Install outer race in bearing case. Install oil seal in
bearing case until it is even with bearing case surface. Apply grease
to bearing rollers. Install brake assembly, bearing case and bearing
onto axle shaft.
2) Apply grease to bearing rollers. Press inner bearing onto
axle shaft. Pack bearing case with grease. Coat lock nut threads with
grease. Install washer, NEW lock washer and lock nut. Lock nut must be
installed with chamfered edge toward axle shaft flange. Tighten lock
nut to specification. See TORQUE SPECIFICATIONS table at end of
article. Bend tab on lock washer into groove on lock nut.
DIFFERENTIAL
NOTE: Check pinion and side gear backlash, ring gear backlash and
ring gear runout before disassembly.
Disassembly
1) Remove differential carrier from axle housing. Remove lock

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

CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VACUUM HOSE, TUBE AND RESERVOIR INSPECTION








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Condition Code Procedure
Leaking ................. A .. Require repair or replacement.
Melted .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Oil-soaked (spongy) ..... 1 ............ Suggest replacement.
Restricted .............. A .. Require repair or replacement.
Surface cracks (dry-
rotted) ................ 1 ............ Suggest replacement.









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CRUISE CONTROL VEHICLE SPEED SENSORS
CRUISE CONTROL VEHICLE SPEED SENSOR INSPECTION








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Condition Code Procedure
Air gap incorrect ....... B ....... ( 1) Require adjustment to
vehicle manufacturer's
specifications.
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.
Housing cracked ......... A ............ Require replacement.
Internal resistance
does not meet
specifications ......... B ........ ( 2) Require replacement.
Lead routing incorrect .. B .. Require rerouting according to
vehicle manufacturer's
specifications.
Loose ................... B ....... ( 3) Require adjustment to
vehicle manufacturer's
specifications.
Missing ................. C ............ Require replacement.
Output signal incorrect . B ........... ( 2) Require repair or
replacement.
Surface contaminated .... 2 .. Suggest cleaning; identify and
correct source.
Tip bent ................ B ............ Require replacement.
Tip broken .............. B ............ Require replacement.
Tip missing ............. B ............ Require replacement.
Wire lead burned ........ A ............ Require replacement.
Wire lead conductors
exposed ................ B ............ Require replacement.
Wire lead corroded ...... A ............ Require replacement.
Wire lead open .......... A ............ Require replacement.
Wire lead shorted ....... A ............ Require replacement.
( 1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Component failure may be caused by water intrusion into
the wiring harness. Always check insulation for damage

rust may be removed using bead blasting method. Components must be
free of oil and grease prior to bead blasting. Beads will stick to
grease or oil soaked areas causing area not to be cleaned.
Use air pressure to remove all trapped residual beads from
components after cleaning. After cleaning internal engine parts made
of aluminum, wash thoroughly with hot soapy water. Component must be
thoroughly cleaned as glass beads will enter engine oil resulting in
bearing damage.
CHEMICAL CLEANING
Solvent tank is used for cleaning oily residue from
components. Solvent blasting sprays solvent through a siphon gun using
compressed air.
The hot tank, using heated caustic solvents, is used for
cleaning ferrous materials only. DO NOT clean aluminum parts such as
cylinder heads, bearings or other soft metals using the hot tank.
After cleaning, flush parts with hot water.
A non-ferrous part will be ruined and caustic solution will
be diluted if placed in the hot tank. Always use eye protection and
gloves when using the hot tank.
Use of a cold tank is for cleaning of aluminum cylinder
heads, carburetors and other soft metals. A less caustic and unheated
solution is used. Parts may be lift in the tank for several hours
without damage. After cleaning, flush parts with hot water.
Steam cleaning, with boiling hot water sprayed at high
pressure, is recommended as the final cleaning process when using
either hot or cold tank cleaning.
COMPONENT CLEANING
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
SHEET METAL PARTS
Examples of sheet metal parts are the rocker covers, front
and side covers, oil pan and bellhousing dust cover. Glass bead
blasting or hot tank may be used for cleaning.
Ensure all mating surfaces are flat. Deformed surfaces should
be straightened. Check all sheet metal parts for cracks and dents.
INTAKE & EXHAUST MANIFOLDS
Using solvent cleaning or bead blasting, clean manifolds for
inspection. If the intake manifold has an exhaust crossover, all
carbon deposits must be removed. Inspect manifolds for cracks, burned
or eroded areas, corrosion and damage to fasteners.
Exhaust heat and products of combustion cause threads of
fasteners to corrode. Replace studs and bolts as necessary. On "V"
type intake manifolds, the sheet metal oil shield must be removed for
proper cleaning and inspection. Ensure that all manifold parting
surfaces are flat and free of burrs.
CYLINDER HEAD REPLACEMENT
* PLEASE READ THIS FIRST *

NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.