1998 MITSUBISHI MONTERO torque

into left side axle housing. Install left axle shaft assembly into
axle housing, and tighten nuts to specification. See
TORQUE SPECIFICATIONS.
2) Install right axle shaft assembly into axle housing
without shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case of right axle and rear axle housing end with
feeler gauge.
3) Select shims equal to sum of measured clearance plus .002-
.008" (.05-.20 mm). Remove right axle shaft, and install selected
shim(s) and "O" ring into right axle housing end. Install right axle
shaft assembly into rear axle housing. Tighten nuts in diagonal
sequence to specification. See TORQUE SPECIFICATIONS.
4) Using dial indicator, check end play of axle shaft. End
play should be .002-.008" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake, and bleed brake system.
CARRIER ASSEMBLY
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFT R & I . Support differential carrier with jack.
Remove differential carrier retaining nuts. Remove differential
carrier.
Inspection
Check for leaks at vent plug, differential carrier companion
flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts and drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
OVERHAUL
AXLE SHAFT OVERHAUL
Removal
1) Secure axle shaft assembly in a vise, and remove one
retainer bolt from backing plate. Push bearing case completely to side
of dust cover. Place adhesive tape around edge of bearing case at
retainer bolt hole to prevent damage.
CAUTION: DO NOT damage bearing case or axle shaft when grinding or
chiseling retainer ring.
2) Secure axle shaft, and grind retainer ring until retainer
ring wall thickness is .04-.06" (1.0-1.5 mm) on axle shaft side and .
08" (2.0 mm) on bearing side. See Fig. 4.

.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.

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.

(.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.

Fig. 17: Checking Differential Starting Torque
Courtesy of Mitsubishi Motor Sales of America.
13) Ensure starting torque is within specification. See
STARTING TORQUE table. Ensure adhesive is removed from ring gear
mounting bolts and gear mounting surface. Clean internal threads with
tap.
14) 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 .
STARTING TORQUE









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Application Ft. Lbs. (N.m)\
Used Clutch Plates ................................... 29-54 (40-75)\
New Clutch Plates .................................... 18-54 (25-75)\









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Carrier Assembly & Drive Pinion Installation
1) Install pinion bearing races in differential housing.
Ensure races are fully seated. Install Pinion Height Gauge (MB990901)
and pinion bearings. See Fig. 18. DO NOT install oil seal.

Fig. 18: Setting Pinion Height
Courtesy of Mitsubishi Motor Sales of America.
2) Using torque wrench, measure pinion rotating torque.
Gradually tighten pinion height gauge to increase rotating torque. See

PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS









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Application INCH Lbs. (N.m)\
Oil Seal Not Installed
With Lubrication ................................. 3.5-4.3 (.4-.5)\
Without Lubrication .............................. 5.2-7.8 (.6-.9)\
Oil Seal Installed
With Lubrication ............................... 5.6-6.5 (.65-.75)\
Without Lubrication .......................... 7.4-10.0 (.85-1.15)\









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3) Install cylinder gauge in side bearing seats. Ensure flat
areas align, and gauge contacts side bearing seat firmly. Select
adjusting shim with same thickness as gap between cylinder gauge and
pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected
adjusting shims between drive pinion gear and rear pinion bearing.
Using bearing installer and press, install rear pinion bearing.
5) Install drive pinion in differential housing. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal. Install pinion companion flange, washer and retaining nut.
Tighten nut to specification. See TORQUE SPECIFICATIONS.
6) Check pinion rotating torque. 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.
Install pinion companion flange so alignment marks are correct. Apply
light coat of grease to contact area of pinion flange washer.
7) Install NEW retaining nut. Recheck pinion rotating torque.
Ensure rotating torque is within specification. Press side bearings
onto differential case. Install outer races. Install differential
carrier into differential housing. Align bearing cap index marks, and
snug carrier cap bolts. Ensure outer races and bearing caps are
installed in original location.
8) Install side bearing nuts. Tighten bearing cap bolts to
specification. See TORQUE SPECIFICATIONS . Tighten bearing nuts until
bearing outer races are seated against bearings. Adjust ring gear
backlash.
Ring Gear Backlash
1) Secure drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. See Fig. 6. Measure at
4 locations of ring gear. Gear backlash must be within specification.
Backlash should be .005-.007" (.13-.18 mm).
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 exceeds
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 2 adjacent holes on side bearing nut.
Recheck backlash. Ensure bearing cap bolts are tightened to
specification. See TORQUE SPECIFICATIONS .
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. Check gear tooth contact
pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL
INFORMATION.
Ring Gear Runout

Using dial indicator, measure runout at back side of ring
gear. See Fig. 7. Runout must be within .002" (.05 mm). If runout is
excessive, change ring gear-to-differential case mounting position.
Recheck runout.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Bearing Cap Bolt
Montero ............................................ 40-47 (54-64)\
Montero Sport ...................................... 37-48 (51-65)\
Bearing Case-To-Axle Housing Bolt
Montero .................................................. 35 (47)\
Montero Sport ...................................... 40-47 (54-64)\
Brake Tube Flare Nut ....................................... 11 (15)\
Differential Carrier-To-Axle Housing Nut
Montero .................................................. 35 (47)\
Montero Sport
2.4L ............................................. 18-21 (24-28)\
3.0L ................................................... 35 (47)\
Drain Plug (Montero Sport) ................................. 44 (60\
)
Drive Shaft-To-Flange Bolt ........................... 36-43 (49-58)\
Lock Plate Bolt ...................................... 11-16 (15-22)\
Pinion Flange Nut ........................................ 159 (216)\
Ring Gear Bolt ....................................... 58-65 (79-88)\
Side Bearing Lock Plate Bolts ........................ 11-16 (15-22)\
Wheel Lug Nut
Montero ........................................... 72-87 (98-118)\
Montero Sport
Aluminum Wheel .................................. 73-86 (99-117)\
Steel Wheel ................................... 87-101 (118-137)\









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