1998 MITSUBISHI MONTERO Service Manual

Fig. 7: Measuring Ring Gear Runout
Courtesy of Mitsubishi Motor Sales of America.
Fig. 8: Checking Pinion & Side Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.
NOTE: See DIFFERENTIAL ASSEMBLY (LIMITED SLIP) for carrier

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

as matched set. Side gears and pinion gears must be replaced as
matched set.
Reassembly & Adjustment
1) Install thrust spacers, side gears, pinion washers and
pinion gears in differential case. DO NOT install thrust block (if
equipped) at this time.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. See
Fig. 8 . Using dial indicator, measure gear backlash. Backlash should
be .0004-.0030" (.010-.080 mm). Service limit is .008" (.20 mm).
3) Adjust backlash by using different side gear spacers.
Ensure both sides are equally shimmed. Install thrust block (if
equipped) once correct backlash is obtained. Install pinion shaft lock
pin from ring gear side of carrier housing. Securely stake pin in 2
places. Ensure adhesive is removed from ring gear mounting bolts and
gear mounting surface. Clean internal threads with tap.
4) Ensure alignment marks on differential case and ring gear
align. Apply Loctite 271 to bolts, and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS . Using appropriate adapter,
press on carrier side bearings.
DIFFERENTIAL ASSEMBLY (LIMITED SLIP)
NOTE: Manufacturer does not provide disassembly or reassembly
procedures for locking type differential. Use illustrations
for exploded views of assembly. See Figs. 11 and 12.
NOTE: See PRE-DISASSEMBLY INSPECTION under
DIFFERENTIAL ASSEMBLY (CONVENTIONAL) before disassembling
carrier assembly. For carrier assembly and drive pinion
removal, see DIFFERENTIAL ASSEMBLY (CONVENTIONAL) .
Disassembly
1) Once ring gear is removed, loosen carrier housing screws
in diagonal pattern. Separate cases and remove components. See Fig. 10
. Maintain parts in order of disassembly. Clean all parts in new
solvent.
2) Inspect condition of friction and spring plates and
friction discs. Replace disc and/or plates if worn or heat damaged.
Distortion of discs will cause incorrect clutch pressure. Scratches,
nicks or burrs on components can be repaired with an oil stone.
3) Discs must be flat and free of distortion. Check discs on
surface plate with dial indicator. Maximum warpage of friction plate
or disc is .003" (.08 mm). Inspect thickness of discs and plates.
Thickness limit between discs and plates is .004" (.10 mm).
Fig. 10: Exploded View Of Limited Slip Differential
Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Exploded View Of Locking Differential Actuator Assembly
Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Exploded View Of Locking Differential
Courtesy of Mitsubishi Motor Sales of America.
Reassembly
1) Arrange friction plates and discs of each side of
differential. Measure each assembly thickness. Assembled discs and
plates should not exceed a difference of .002" (.05 mm). Replace discs\
or plates as needed.
2) Assemble one spring plate and one spring disc on each
side. Measure assembly thickness. Assemble disc and plates to obtain
minimum difference in thickness between each assembly.
3) Assemble clutch assemblies, pressure rings, pinion gears,
side gears and pinion shaft. Measure overall width of assembly plus
spring plates and spring discs (dimension "C"). See Fig. 13.
4) Determine depth of differential case (dimension "D"). On
2.4L, dimension "D" = "E" + "F" - "G"; on 3.0L, dimension "D" = "E" +
"H"
See Fig. 14. Subtract "C" from "D" to determine spring plate-
to-case clearance. Adjust spring disc thickness to obtain proper
spring plate-to-case clearance. Correct clearance is .0024-.0079" (.
060-.200 mm).

Fig. 13: Measuring Clutch Assembly Width
Courtesy of Mitsubishi Motor Sales of America.
Fig. 14: Measuring Limited Slip Case Depth
Courtesy of Mitsubishi Motor Sales of America.
5) Remove spring plates, spring discs, friction plates and
friction disc from pressure rings. Mark components for location.

Install thrust washers on each end of pressure rings. See Fig. 15.
6) Measure clearance from end of thrust washer to rear face
of pressure ring. Clearance should be .002" (.05 mm) or less. If
clearance is not as specified, select proper thickness thrust washers
to obtain correct clearance.
7) Once correct thrust washers are determined, install thrust
washers on pressure rings. Squeeze pressure rings together, and
measure width (dimension "H") from end of thrust washer to remaining
thrust washer.
8) Determine distance between thrust washer surfaces when
differential case is assembled (dimension "I"). Dimension "I" = "J" +
"K" + "L". Dimension "J" is the same as dimension "D" in step 4).
Fig. 15: Measuring Thrust Washer Clearance
Courtesy of Mitsubishi Motor Sales of America.
9) Subtract "H" from "I". This is the clearance between
thrust washer and differential case. Correct clearance is .002-.008"

(.05-.20 mm). If clearance is not within specification, change thrust
washer to obtain correct clearance.
10) 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. 16.
Fig. 16: Limited Slip Differential Assembly
Courtesy of Mitsubishi Motor Sales of America.
11) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See
TORQUE SPECIFICATIONS . Ensure cases contact each other completely when
fully assembled. Check for incorrect clutch assembly if gap exists.
12) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. See Fig. 17.
Rotate unit slightly before measuring starting torque.