1998 MITSUBISHI MONTERO lock

Check ring gear, pinion and side gears for wear or damage. Replace
components as necessary.
Reassembly & Adjustments
1) Place side gear thrust spacers behind side gears, in
original position. Assemble side gears in differential case. Install
pinion gears and washers. Rotate pinion gears to mesh with side gears.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. Using
dial indicator, measure gear backlash. See Fig. 5.
3) Backlash must be within specification. See
PINION & SIDE GEAR BACKLASH SPECIFICATIONS table. Adjust backlash by
using different side gear spacers. Ensure both sides are equally
shimmed. If backlash cannot be adjusted within specifications, replace
side and pinion gears as matched set.
4) Install pinion shaft lock pin. Using a punch, securely
stake lock pin in 2 places. Ensure adhesive is removed from ring gear
mounting bolts and gear mounting surface. Clean internal threads with
tap.
5) Install ring gear on differential case. Ensure alignment
marks on differential case and ring gear are aligned. Apply Loctite
271 to bolts and install bolts. Tighten bolts alternately in diagonal
sequence to specification. See TORQUE SPECIFICATIONS.
PINION & SIDE GEAR BACKLASH SPECIFICATIONS









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Application In. (mm)\
Standard ................................................ .003 (.08)\
Wear Limit .............................................. .008 (.20)\









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Fig. 5: Checking Pinion & Side Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.
Drive Pinion Depth
1) Install pinion bearing races in carrier housing. Ensure

spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion companion flange, washer and
retaining nut. Tighten nut to 137 ft. lbs. (190 N.m).
2) Using INCH-lb. torque wrench, check pinion rotating torque
without pinion oil seal. See PINION ROTATING TORQUE SPECIFICATIONS
table. Adjust rotating torque by replacing drive pinion front shims or
spacer. Once correct rotating torque is obtained, install oil seal.
Coat seal lip with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install NEW
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
Side Bearing Installation
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal in thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier housing.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges (feeler gauges 180 degrees opposed), measure clearance
between carrier and side bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add .002" (.05 mm) to\
50% of measured clearance and then add thickness measurement of
removed shim. This is thickness of new shim that should be installed
on each side of case. Install equal thickness shims on each side of
case assembly.
NOTE: Ensure zero clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Check 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 should be .004-.006" (.10-.15 mm).
2) If backlash is not within specification, change side
bearing adjusting shims and recheck backlash. See
GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Check gear
tooth contact using Prussian Blue.
CAUTION: When changing shims, total thickness of all shims must
remain constant to ensure correct bearing preload.
Ring Gear Runout
Using dial indicator, measure runout at back side of ring
gear. Runout should not exceed .002" (.05 mm). If runout is excessive,\
change ring gear-to-differential case mounting position. Ensure ring
gear mounting bolts are tightened to correct specification. Recheck
runout. Install cover and gasket.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\

DIFFERENTIAL & AXLE SHAFTS REAR
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Differentials & Axle Shafts - Rear Non-Integral
Montero, Montero Sport
DESCRIPTION
Rear axle features a rigid banjo-type housing with semi-
floating axle shafts. Differential consists of hypoid reduction gears
and straight bevel differential gears. Limited Slip Differential (LSD)\
is available on some models. Locking rear differential is available on
1997-98 Montero and 1998 Montero Sport. See DIFFERENTIAL LOCK - REAR
article.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS









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Application Ratio
Montero ..................................................... 4.27:1
Montero Sport
With Wide Fender
2WD ..................................................... 4.22:1
4WD ..................................................... 4.27:1
Without Wide Fender ....................................... 4.64:1









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LUBRICATION
CAPACITY
REAR AXLE GEAR OIL CAPACITY








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Application Pts. (L)\
Montero .................................................. 6.8 (3.2)\
Montero Sport
Conventional & Locking ................................. 3.2 (1.5)\
Limited Slip ........................................... 5.5 (2.6)\









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FLUID TYPE
Conventional differentials use SAE 80W or SAE 90W API GL-5.
Limited slip differentials use Mitsubishi Gear Oil (8149630 EX), or
Mopar Gear Oil (4318058) and Mopar Friction Modifier (4318060).
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.

TESTING & INSPECTION
AXLE SHAFT END PLAY
Montero & Montero Sport
Using dial indicator, check axle shaft end play. End play
should be .010" (.25 mm). If end play is not within specification,
replace axle bearing. See AXLE SHAFT OVERHAUL under OVERHAUL.
AXLE TOTAL BACKLASH
1) Raise and support rear axle. Place transmission in
Neutral. Apply parking brake. Rotate drive shaft clockwise. Place
reference marks on pinion dust cover and differential housing.
2) Rotate drive shaft counterclockwise, and measure distance
between reference marks. Differential must be removed and backlash
adjusted if distance exceeds 0.2" (5 mm). See RING GEAR BACK-LASH
procedure under DIFFERENTIAL ASSEMBLY (LIMITED SLIP) under OVERHAUL.
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel off ground and remove wheel. Release parking brake.
2) Using torque wrench and axle puller adapter, measure
starting torque while rotating wheel in forward direction. See Fig. 1.
Differential must be repaired if torque is less than 18 ft. lbs. (25
N.m).
Fig. 1: Testing Limited Slip Differential Preload
Courtesy of Mitsubishi Motor Sales of America.
LOCKING DIFFERENTIAL (MONTERO)
Air Pump

Connect air pressure gauge in-line to air hose from air pump.
Air pump is located in right storage area, under rear seat. Connect
battery voltage to air pump (positive lead to Red wire). The air pump
is operating correctly when the following sequences occur;
* Pump should operate for no more than 5 seconds.
* Pressure should be 4-6 psi (.28-.41 kg/cm
) within 10-20
seconds after pump has stopped.
* After air pump has stopped operating, it should not restart
operating for 5 minutes.
Center Differential Lock Operation Switch
See ANTI-LOCK BRAKE SYSTEM article in BRAKES.
Differential Lock Switch
Remove switch from center console. To test switch operation,
see Fig. 2 . Replace switch as needed.
Differential Lock Control Unit
See ANTI-LOCK BRAKE SYSTEM article in BRAKES.
Lock Detection Switch
1) Raise and support vehicle. Disconnect air hose connection
near rear differential. Connect air source with pressure regulator and
pressure gauge. Apply 4 psi (.28 kg/cm
) pressure. Disconnect lock
detection switch harness connector.
2) Using ohmmeter, check if continuity exists with air
pressure applied. Continuity should exist with air pressure applied.
If continuity exists, ensure axle is locked by attempting to turn rear
wheels separately of each other.
3) If continuity does not exist, go to step 4). If continuity\
does exist but axles are not locked, see CARRIER ASSEMBLY under
REMOVAL & INSTALLATION and inspect locking assembly.
4) Remove detection switch from housing. Using ohmmeter,
check continuity of switch. Continuity should exist with switch
plunger extended. With plunger in neutral position, continuity should
not exist. Replace switch as needed.
Fig. 2: Checking Differential Lock Switch Continuity
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION

AXLE SHAFT R & I
Removal (Montero & Montero Sport)
Block front wheels. Raise and support rear axle housing.
Remove brake caliper and rotor. See Fig. 3. Remove parking brake cable
attaching bolts. Remove connection for parking brake cable end from
rear brake assembly. Remove ABS speed sensor (if equipped). Unbolt
backing plate with bearing housing from rear axle housing. Using
Puller (MB990241) and Slide Hammer (MB990211), remove axle assembly.\
DO NOT damage oil seal. Remove "O" ring. Replace if necessary.
Installation
Install NEW oil seal in axle housing as needed. To install
axle assembly, reverse removal procedure.
Fig. 3: Exploded View Of Typical Axle Shaft
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Insert new "O" ring and shim of .04" (1.0 mm) thickness

.060 (1.52) .................................................... Red\
.067 (1.70) ................................................. Purple\
.073 (1.85) ................................................... Blue\
.079 (2.01) ................................................. Yellow\
.085 (2.16) ................................................ Neutral\









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DIFFERENTIAL ASSEMBLY (CONVENTIONAL)
Pre-Disassembly Inspection
1) Secure differential assembly in appropriate holder. Secure
drive pinion from turning. Mount dial indicator on case and check ring
gear backlash at 4 positions. See Fig. 6. Backlash should be .005-.
007" (.13-.18 mm).
2) Remount dial indicator and measure ring gear runout. See
Fig. 7 . On all models, runout should not exceed .002" (.05 mm).
Remount dial indicator and measure pinion gear backlash on models
without limited slip differential. See Fig. 8. Secure side gear from
turning with wedge. Backlash should be 0-.003" (0-.08 mm). Pinion gear\
backlash service limit is .008" (.20 mm).
3) Check gear tooth contact pattern between ring gear and
drive pinion gear. Apply Prussian Blue to both surfaces of ring gear
teeth. Insert brass rod between differential housing and carrier
assembly to provide resistance while turning drive pinion.
4) Turning resistance of drive pinion should be 28-33 INCH
lbs. (2.5-3.0 N.m). Rotate drive pinion until ring gear completes one
revolution. Reverse direction of rotation and return to original
starting point. Check wear pattern. See GEAR TOOTH CONTACT PATTERNS
article in GENERAL INFORMATION.
5) On Montero models with differential lock, connect air
supply hose with pressure gauge and regulator to actuator air pipe.
Apply 4 psi (.28 kg/cm
) of pressure. Using Adapter Shaft (MB990992),
turn side gear on one side of carrier assembly only. Locking mechanism
should engage. To disengage, release air pressure and turn side gear
1/4-1/2 turn.
6) With lock mechanism engaged, measure turning torque of
drive pinion. Turning torque should not be less than 36 ft. lbs. (50
N.m). With lock mechanism disengaged, turning torque should not be
more than 36 ft. lbs. (50 N.m).
Fig. 6: Measuring Ring Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.

assembly and drive pinion installation.
Carrier Assembly & Drive Pinion Removal
1) Remove differential carrier from axle housing. Remove lock
plates. Mark location of side bearing nuts for reassembly. Remove side
bearing nuts. See Fig. 9. Mark location of bearing caps for
reassembly. Remove bearing caps. Remove differential carrier assembly
from differential housing.
Fig. 9: Exploded View Of Conventional Rear Differential (Typical)
Courtesy of Mitsubishi Motor Sales of America.
2) Secure drive pinion companion flange from turning. Remove
companion flange retaining nut. Scribe alignment marks on drive pinion
and companion flange for reassembly. Using soft-face hammer, drive
pinion out of housing. Remove front adjusting shim and spacer from
pinion.
3) Using bearing splitter and press, remove rear bearing from
pinion. Remove rear adjusting shim from drive pinion. Remove oil seal
and bearing races from differential housing.
Disassembly (Carrier Assembly)
1) Using bearing splitter and press, remove differential case
side bearings. Place alignment marks on ring gear and differential
case for reassembly. Loosen ring gear bolts in diagonal sequence.
Remove ring gear.
2) Remove pinion shaft lock pin from differential carrier.
Remove differential pinion shaft and thrust block (if equipped).
Remove pinion gears and washers. Remove side gears and thrust spacers.
Mark components for reassembly reference.
Inspection
Wash parts in clean solvent and dry with compressed air.
Inspect bearings for discoloration and/or flaking. Check all gears for
irregular wear or damage. Ring gear and drive pinion must be replaced