DRIVE AXLE - REAR NON-INTEGRAL

1991 Mitsubishi Montero

1991 92 DRIVE AXLES

Differentials & Axle Shafts - Rear Non-Integral

Mitsubishi: Montero, Pickup

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 all models.

AXLE RATIO & IDENTIFICATION

Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.

AXLE RATIO SPECIFICATIONS

Application Ratio

Montero .................................................. 4.63

Pickup
2WD w/Light Suspension ................................. 3.91
2WD w/Heavy Suspension ................................. 4.22
4WD .................................................... 4.22

LUBRICATION

CAPACITY
REAR AXLE GEAR OIL CAPACITY






















































Application Pts. (L)

Montero .................................. 5.4 (2.5)

Pickup
Conventional
2WD ................................... 3.2 (1.5)
4WD ................................... 5.5 (2.6)
LSD .................................... 5.5 (2.6)

FLUID TYPE
Conventional differentials use API classification GL-5 SAE
80W or 90W. Limited slip differentials use Mitsubishi Gear Oil
(8149630 EX) or Mopar Gear Oil (4318058) and Mopar Friction Modifier
(4318060).

TROUBLE SHOOTING
DRIVE AXLE (RWD) TROUBLE SHOOTING

































































PROBLEM
Possible Cause Action

































































KNOCKING OR CLUNKING

Differential Side Gear Clearance .............. Check Clearance

Worn Pinion Shaft ........................ Replace Pinion Shaft

Axle Shaft End Play ............................ Check End Play

Missing Gear Teeth ................... Check Diff./Replace Gear

Wrong Axle Backlash ............................ Check Backlash

Misaligned Driveline ........................ Realign Driveline

CLUNKING DURING ENGAGEMENT

Side Gear Clearance ................. Check Side Gear Clearance

Ring and Pinion Backlash ....................... Check Backlash

Worn/Loose Pinion Shaft ................. Replace Shaft/Bearing

Bad "U" Joint ............................... Replace "U" Joint

Sticking Slip Yoke ............................. Lube Slip Yoke

Broken Rear Axle Mount .......................... Replace Mount

Loose Drive Shaft Flange ......................... Check Flange

CLICK/CHATTER ON TURNS

Differential Side Gear Clearance .............. Check Clearance

Worn Clutch Plates (1) .................. Replace Clutch Plates

Wrong Diff. Lubricant (1) .................... Change Lubricant

RHYTHMIC KNOCK OR CLICK

Flat Spot on Rear Wheel Bearing ......... Replace Wheel Bearing

HUM/LOW VIBRATION AT ALL SPEEDS

Faulty Wheel Bearings ........................ Replace Bearings

Faulty "U" Joint ............................ Replace "U" Joint

Faulty Drive Shaft ........................ Balance Drive Shaft

Faulty Companion Flange ........................ Replace Flange

Faulty Slip Yoke Flange ........................ Replace Flange

(1) - Limited slip differential only.

DRIVE AXLE (FWD)

DRIVE AXLE (FWD) TROUBLE SHOOTING

































































PROBLEM
Possible Cause Action

































































GREASE LEAKING

Ripped CV Boot ................................... Replace Boot

CLICKING NOISE WHILE CORNERING

Dry/Worn CV Joints .................... Replace Outer CV Joints

CLUNK ON ACCELERATION

Dry/Worn CV Joints .................... Replace Inner CV Joints

Worn Trans. Gears/Bearings ..................... Inspect Trans.

VIBRATION/SHUDDER ON ACCELERATION

Dry/Worn CV Joints .......................... Replace CV Joints

Alignment Out ................................. Check Alignment

Incorrect Spring Height ................... Check Spring Height

SQUEALING OR HUMMING

Dry/Worn CV Joints ..................... Lube/Replace CV Joints

Faulty Wheel Bearing .................... Replace Wheel Bearing

TESTING & INSPECTION

AXLE SHAFT END PLAY

Using dial indicator, check axle shaft end play. End play
must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shims to obtain correct end play. See AXLE
SHAFTS under REMOVAL & INSTALLATION.

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" (5.0 mm).

LIMITED SLIP DIFFERENTIAL PRELOAD

1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel free of ground and remove wheel. Use Axle Puller
Adapter (MB990241) for Montero and Pickup models. Install adapter on
wheel studs. Release parking brake.
2) Using torque wrench, measure starting torque on Pickup
models while rotating wheel in forward direction. On Montero models,
measure rotating torque. This measurement is read once axle is
turning. Differential must be repaired if torque is less than
specification. See TESTING SPECIFICATIONS table.
TESTING SPECIFICATIONS























































Application Ft. Lbs. (N.m)

Montero & Pickup ............................ 25 (34)

REMOVAL & INSTALLATION

AXLE SHAFTS
Removal
1) Block front wheels. Raise and support rear axle housing.
Remove brake drum. See Fig. 1. Remove parking brake cable attaching
bolts. Remove connection for parking brake cable end and rear brake
assembly. Drain brake fluid from bleeder screw at left side of rear
brake and disconnect brake tubes.
2) On all models, remove flange nuts and rear axle shaft
assembly. Use Puller (MB990241) and Slide Hammer (MB990211) if
necessary. DO NOT damage oil seal. Remove shim(s) and "O" ring.
Replace if necessary.

Fig. 1: Exploded View of Axle Shaft

Courtesy of Chrysler Motors.

Installation
1) Insert a new "O" ring and a shim of .04" (1.0 mm)
thickness into left side axle housing. Install left axle shaft
assembly into axle housing and tighten nuts to specification. See
TORQUE SPECIFICATIONS table at the end of this article.
2) Install right axle shaft assembly into axle housing
WITHOUT a 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 and rear axle housing end with a feeler gauge.
3) Select shims equal to the sum of the thickness of the
measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle
shaft and install the 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 table.
4) Using dial indicator, check end play of axle shaft. End
play must be .0020-.0079" (.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.

DIFFERENTIAL CARRIER
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support
differential carrier with jack. Remove differential carrier retaining
nuts. Remove differential carrier.

Inspection
Inspect for leakage 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. Remove drive shaft from vehicle.

Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.

OVERHAUL

AXLE SHAFTS
Disassembly
1) Mount backing plate and axle shaft assembly in soft-jawed
vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench
(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall
lock nut on axle shaft approximately 3 turns.
2) Attach Bearing Puller (MB990787-01) to rear of backing
plate to remove bearing case from axle shaft. See Fig. 2. Using equal
pressure to avoid binding, tighten puller nuts diagonally to remove
bearing case. Using hammer and drift, remove bearing outer race from
bearing case. Remove oil seal from end of axle housing with Slide
Hammer and Adapter (MB990211).
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
plates and side bearing nuts. See Fig. 3. Mark bearing caps for
location. Remove bearing caps. Remove differential case assembly from
differential carrier.

CAUTION: Ensure side bearing nuts, bearing caps and side bearings
are marked for location. Components must be installed in
original location.

Fig. 3: Exploded View of Conventional Rear Differential

Courtesy of Chrysler Motors.

2) Using bearing puller, 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.
3) On conventional axles, remove drive pinion shaft lock pin
from differential case. 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.
4) On limited slip units, mark differential case and
differential case cover for reassembly reference. Remove differential
case retaining screws. Separate differential case and cover. Remove
components from case. See Fig. 4. Mark components for location.
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
within specification. See FRICTION PLATE & DISC SPECIFICATIONS table.

FRICTION PLATE & DISC SPECIFICATIONS

Application In. (mm)

Warpage Limit ......................... .003 (.08)

Wear Limit ............................ .004 (.10)

DIFFERENTIAL OVERHAUL

CASE ASSEMBLY (CONVENTIONAL)

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. 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.

PINION & SIDE GEAR BACKLASH SPECIFICATIONS

Application In. (mm)

4-Cylinder Engine
Standard .................. .0004-.0030 (.010-.076)
Wear Limit ............................. .008 (.20)
V6 Engine
Standard ......................... 0-.0030 (0-.076)
Wear Limit ............................. .008 (.20)

Fig. 5: Checking Pinion & Side Gear Backlash

Courtesy of Chrysler Motors.

4) Install thrust block (if equipped) once correct backlash

is obtained. Install pinion shaft lock pin from back side of ring
gear. Securely stake pin in 2 places. Ensure adhesive is removed from
ring gear mounting bolts and gear mounting surface. Clean internal
threads with tap.
5) 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 at the end of this
article.

CASE ASSEMBLY (LIMITED SLIP)

1) Assemble 2 friction discs and 2 friction plates; assemble
plate, disc, plate and disc. Measure assembly thickness. Assemble
discs and plates to give standard difference of .002" (.05 mm) between
the 2 sides.
2) Assemble spring plates and spring discs with one 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. This measurement is "C". See Fig. 6.

Fig. 6: Measuring Clutch Assembly Width

Courtesy of Chrysler Motors.

4) Determine depth "D" of differential case, using formula

"D"="E"+"F"-"G" or "D"="E"+"H"-"F"-"G" . See Fig. 7. Subtract
measurement "C" from measurement "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. 7: Measuring Limited Slip Case Depth (Montero 3.0L & Pickup)
Courtesy of Chrysler Motors.

CAUTION: DO NOT interchange clutch components for right and left

sides. Mark clutch components for location.

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. 8.
6) Measure distance from end of thrust washer to rear face of
pressure ring. Select proper thickness thrust washers to obtain a .
002" (.05 mm) or less difference between measurements.
7) Once correct thrust washers are determined, install thrust
washers on pressure rings. Squeeze pressure rings together and measure
width from end of thrust washer to remaining thrust washer. This is
dimension "H". See Fig. 8.
8) Determine distance between thrust washer surfaces when
differential case is assembled. This is dimension "I"
("I"="J"+"K"+"L"). See Fig. 8. Dimension "J" is the same as dimension
"D" in step 4).
Fig. 8: Measuring Thrust Washer Clearance
Courtesy of Chrysler Motors.

9) Subtract dimension "H" from dimension "I". See Fig. 8.

This is the clearance between thrust washer and differential case.
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

Application Ft. Lbs. (N.m)

Used Clutch Plates .................. 25-72 (34-98)

New Clutch Plates ................... 47-72 (64-98)

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
adjusting shims between drive pinion gear and rear pinion bearing.
Using bearing installer, install rear pinion bearing.

Fig. 11: Setting Pinion Height

Courtesy of Chrysler Motors.

DRIVE PINION PRELOAD

 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

Application In. (mm)

2.4L ....................... .0043-.0063 (.109-.160)

3.0L ....................... .0051-.0071 (.130-.180)






















































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
runout.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS






































































Application Ft. Lbs. (N.m)

Axle Bearing Lock Nut (Montero) .................. 130-159 (176-216)

Bearing Cap Bolt ..................................... 40-47 (54-64)
Bearing Case-To-Axle Housing Bolt .................... 36-43 (49-58)
Brake Tube Flare Nut ................................. 10-12 (14-16)
Differential Carrier-To-Axle Housing Nut
2.4L (2WD) ......................................... 18-22 (24-30)
3.0L (4WD) ......................................... 29-40 (39-54)
Drain Plug ........................................... 43-50 (58-68)
Filler Plug .......................................... 29-43 (39-58)
Lock Plate Bolt ...................................... 11-16 (15-22)
Pinion Flange Nut ................................ 137-181 (186-245)
Drive Shaft-To-Flange Bolt ........................... 36-43 (49-58)
Ring Gear Bolt ....................................... 58-65 (79-88)
Side Bearing Lock Plate Bolts ........................ 11-16 (15-22)
Wheel Lug Nut
Montero ........................................... 72-87 (98-118)
Pickup .......................................... 87-101 (118-137)