F2644...
FRONT AXLE
CONTENTS
| SPECIFICATIONS | |
|---|---|
| General Specifications | |
| Service Specifications | ( |
| Lubricants | ; |
| Sealants and Adhesives | 4 |
| SPECIAL TOOLS | 4 |
| SERVICE ADJUSTMENT PROCEDURES | 8 |
| Front Axle Total Backlash Check | 1 |
| Front Axle Gear Oil Level Check | . 8 |
| Drive Shaft Axial Play Check | 9 |
| Differential Carrier Oil Seal Replacement | 1 |
| Solenoid Valve Operation Check | 1 |
| AXLE HUB | 1: |
| AUTOMATIC FREE-WHEELING HUB | 19 |
|---|---|
| MANUAL FREE-WHEELING HUB | 22 |
| KNUCKLE | 23 |
| DRIVE SHAFT | 26 |
| INNER SHAFT | 33 |
| SOLENOID VALVE AND VACUUM HOSE | 36 |
|
DIFFERENTIAL CARRIER AND FREE-
WHEELING CLUTCH 30 |
6-2 |
| FREE-WHEELING CLUTCH | 39 |
| DIFFERENTIAL CARRIER 4 | 1-4 |
SPECIFICATIONS
GENERAL SPECIFICATIONS
<Vehicles built up to October, 1993>
| Items | 2400 | 3000 | 2500D |
|---|---|---|---|
|
Front axle hub bearing
Type |
Taper roller bearing | Taper roller bearing | Taper roller bearing |
|
Drive shaft
Joint type Outer Inner |
Birfield joint
Double-offset joint |
Birfield joint
Double-offset joint |
Birfield joint
Double-offset joint |
|
Differential
Final drive gear type Reduction ratio 2-door models 4-door models Pinion gear type 2-door models 4-door models |
Hypoid gear
4.875 4.875 2 pinion 4 pinion |
Hypoid gear
4.875 4.625 or 4.875* 2 pinion 2 pinion |
Hypoid gear
4.625 or 4.875* 4.875 or 5.285* 2 pinion or 4 pinion* |
| 4-door models | 4 pinion | 2 pinion |
A/1: 2 pinion
M/T: 4 pinion |
NOTE
*: Vehicles with wide fender
<Vehicles built from November, 1993>
| Items |
2400, 3000 –
12VALVE |
3500 | 2500D | 2800D |
3000 –
24VALVE |
|---|---|---|---|---|---|
| Front axle hub bearing | |||||
| Туре |
Taper roller
bearing |
Taper roller
bearing |
Taper roller
bearing |
Taper roller
bearing |
Taper roller
bearing |
| Drive shaft | |||||
| Joint type | |||||
| Outer | Birfield joint | Birfield joint | Birfield joint | Birfield joint | Birfield joint |
| Inner |
Double-offset
joint |
Double-offset
joint |
Double-offset
joint |
Double-offset
joint |
Double-offset
joint |
| Differential | |||||
| Final drive gear type | Hypoid gear | Hypoid gear | Hypoid gear | Hypoid gear | Hypoid gear |
| Reduction ratio | |||||
| 2-door models | 4.875 | 4.636 | 4.625 or 4.875* | 4.636 | 4.636 or 4.875* |
| 4-door models | 4.875 | 4.636 | 4.875 or 5.285* | 4.900 | 4.636 or 4.875* |
| Pinion gear type | |||||
| 2-door models | 2 pinion | 2 pinion |
2 pinion or
4 pinion* |
2 pinion | 2 pinion |
| 4-door models | 2 pinion | 2 pinion |
A/T: 2 pinion
M/T: 4 pinion |
2 pinion | 2 pinion |
NOTE
*: Vehicles with wide fender
E26CA--
Specifications
SERVICE SPECIFICATIONS
Items
Standard value
| Drive shaft axial play mm (in.) | 0.4–0.7 (0.016–0.028) |
|---|---|
| Solenoid valve resistance [at 20°C (60°F)] Ω | 36–46 |
| Front hub play in the axial direction mm (in.) | 0.05 (0.0020) or less |
| Front hub turning resistance Nm (kgcm, in.lbs.) | 0.3–1.3 (3–13, 2.6–11.3) |
| [Spring scale reading] N (kg, lbs.) | 5-18 (0.5-1.8, 1.1-4.0) |
| Automatic free-wheeling hub | |
| Brake assembly thickness mm (in.) | 10.5 (0.413) |
| Setting of D.O.J. boot length mm (in.) | 77–83 (3.03–3.27) |
| Clutch gear play (bearing axial play) mm (in.) | 0.05-0.40 (0.0020-0.0160) |
| Final drive gear backlash mm (in.) | 0.11-0.16 (0.0043-0.0063) |
| Differential gear backlash mm (in.) | |
| <2 pinion differential> | 0-0.076 (0-0.0030) |
| <4 pinion differential> | 0.01-0.25 (0.0004-0.0098) |
| Drive pinion rotation torque Nm (kgcm, in.lbs.) | |
| Without oil seal | 0.3-0.5 (3.0-5.0, 2.6-4.3) |
| With anti-rust agent | 0.15-0.25 (1.5-2.5, 1.3-2.2) |
| With oil seal | 0.5-0.7 (5.0-7.0, 4.3-6.1) |
| With gear oil applied | 0.35-0.45 (3.5-4.5, 3.1-3.9) |
| Limit | |
| Front axle total backlash | |
| Vehicles with free-wheeling hub mm (in.) | 14 (0.55) |
| Vehicles without free-wheeling hub mm (in.) | 11 (0.43) |
| Automatic free-wheeling hub | |
| Free-wheeling hub turning resistance | 1.0 (10, 8.7) |
| Nm (kgcm, in.lbs.) | |
| [Sprint scale reading] N (kg, lbs.) | 14 (1.4, 3.1) |
| Brake assembly thickness mm (in.) | 9.6 (0.378) |
| Return spring deterioration mm (in.) | 35 (1.38) |
| Shift spring deterioration mm (in.) | 30 (1.18) |
| Drive gear runout mm (in.) | 0.05 (0.0020) |
| Differential gear backlash <2 pinion differential> | 0.2 (0.0079) |
| mm (in.) |
LUBRICANTS
E26CD--
| ltems | Specified lubricants | Quantity |
|---|---|---|
|
Front axle gear oil
Front differential |
Hypoid gear oil
API classification GL-5 or higher SAE viscosity No. 90, 80W |
1.20 dm
3
(1.27 U.S. qts., 1.05 lmp. qts) |
| D.O.J. boot grease | Repair kit grease | 100 g (3.5 oz.) |
PWJE9086-E
26-3
SEALANTS AND ADHESIVES
E26CE--
| ltems | Specified sealants and adhesives | Characteristics |
|---|---|---|
|
Contact surface of drive flange or free-wheeling
hub and front axle hub Contact surface of hub cap and drive flange Contact surface of differential cover and differential carrier Free-wheeling clutch assembly |
3M ATD Part No. 8661, 8663 or
equivalent |
Semi-drying sealant |
| Drive gear threaded hole | 3M Stud Locking 4170 or equivalent | Anaerobic sealant |
SPECIAL TOOLS
| ТооІ | Number | Name | Use |
|---|---|---|---|
| мв990212 Мв990211 | MB990590 | Sliding hammer |
Removal of differential carrier oil seal
Removal and installation of inner shaft (Used together with MB990906) |
| MB990628 | Snap ring pliers |
Removal and installation of drive shaft snap
ring Removal and installation of manual free-wheeling hub snap ring |
|
|
MD998051
(MD998001) MD998360 |
Cylinder head
bolt wrench |
Removal and installation of automatic free-wheeling hub | |
|
L : 90 mm (3.54
L : 80 mm (3.15 |
in.) : MD998051 (I
in.) : MD998360 |
MD998001) | |
| MB990954 |
Lock nut
wrench |
Removal and adjustment of lock nut | |
| MB990925 |
Bearing and oil
seal installer set |
Driving-out of front axle hub bearing outer
race (MB990939) Press-fitting of front axle hub bearing outer race (MB990938, MB990935) Driving-out of knuckle needle bearing (MB990939) Driving-out of drive pinion bearing outer race (MB990939) Press-fitting of drive pinion front bearing outer race (MB990938, MB990936) Press-fitting of drive pinion rear bearing outer race (2400, 2500D, 3000-A/T : MB990938, MB990933) (3000-M/T, 3500, 2800D : MB990938, MB990934) Press-fitting of drive shaft oil seal (MB990938, MB990934) |
| ТооІ | Number | Name | Use |
|---|---|---|---|
| MB990985 | Oil seal installer |
Press-fitting of knuckle oil seal
(Used together with MB990938) |
|
| 9 | MB990811 |
Differential
side bearing cup |
Disassembly and reassembly of automatic
free-wheel hub Removal of side bearing inner race (Used together with MB990810) |
| SOFT |
MB991113,
MB990635 or MB991406 |
Steering
linkage puller |
Disconnection of tie rod
Disconnection of upper ball joint (MB991113, MB990635 or MB991406) Disconnection of lower ball joint (MB991406) |
| 5 | MB990956 |
Needle bearing
installer |
Press-fitting of knuckle needle bearing
(Used together with MB990938) |
| MB990906 |
Drive shaft
attachment |
Removal and installation of inner shaft
(Used together with MB990211) |
|
| MB990560 | Bearing remover | Removal and press-fitting of inner shaft bearing | |
| MB990955 | Oil seal installer |
Press-fitting of housing tube dust seal
Press-fitting of front axle hub oil seal (Used together with MB990938). |
|
| MB990799 |
Ball joint
remover and installer |
Installation of free-wheel clutch bearing | |
| 0) | MB991168 |
Differential oil
seal installer |
Installation of free-wheel clutch oil seal |
|
MB990890 or
MB990891 |
Rear
suspension bushing base |
Installation of free-wheel clutch bearing |
| Тооі | Number | Name | Use |
|---|---|---|---|
| MB990909 | Working base | Support of front differential carrier assembly | |
| MB991116 | Adapter | ||
| MB990810 |
Side bearing
puller |
Removal of side bearing inner race
(Used together with MB990811) |
|
| 0 | MB990767 | End yoke holder | Removal and installation of companion flange |
| MB990339 | Bearing puller | Removal of drive pinion front bearing inner race | |
| E | MB990648 | Bearing remover | |
| MB990903 MB9905 |
MB990901
552 |
Pinion height
gauge set |
Measurement of drive pinion height <2400, 2500D, 3000-A/T> |
| MB990819 MB9905 | MB990818 |
Pinion height
gauge set |
Measurement of drive pinion height
<3000-M/T, 3500, 2800D> |
| MB991151 | Torque wrench | Measurement of drive pinion preload | |
| MB990326 | Preload socket |
FRONT AXLE - Special Tools
| ТооІ | Number | Name | Use |
|---|---|---|---|
| MB990802 | Bearing installer |
Press-fitting of drive pinion front bearing inner
race Press-fitting of side bearing inner race |
|
| 3) |
MB990031 or
MB990699 |
Drive pinion oil
seal installer |
Press-fitting of drive pinion oil seal |
| MB990813 | Тар | Removal of adhesive |
26-7
SERVICE ADJUSTMENT PROCEDURES
FRONT AXLE TOTAL BACKLASH CHECK E26FBAA
-
1. If the vehicle vibrates and produces a booming sound, measure the front axle total backlash by the following procedure to see if the differential carrier assembly requires removal.
- (1) On vehicles with free-wheeling hub, shift into 4wheel drive position.
NOTE
On vehicles with manual free-wheeling hub, place the control handle in the LOCK position.
On vehicles with automatic free-wheeling hub, place the transfer shift lever in 4H position and drive the vehicle 1 to 2 meters (3.3 to 6.5 ft.) to engage the hub with the drive shaft.
For vehicles with super select 4WD, place the transfer control lever in 4H position and drive the vehicle until the 4WD indicator changes from flashing to illuminated.
- (2) Hold the wheels and place the transfer control lever in 2H position.
- (3) Turn the companion flange clockwise until all play is removed. Mate mark on the dust cover of the companion flange with that on the differential carrier.
- (4) Turn the companion flange counterclockwise until all play is removed and measure the amount of distance through which the mating marks moved.
Limit:
Vehicles with free-wheeling hub
14 mm (0.55 in.) Vehicles without free-wheeling hub 11 mm (0.43 in.)
2. If the backlash exceeds the limit, remove the differential carrier assembly and final drive gear, and check for differential gear meshing condition and drive shaft or inner shaft spline looseness.
© Mitsubishi Motors Corporation Feb. 1991
FRONT AXLE GEAR OIL LEVEL CHECK E26FCAA
Remove the filler plug, and check the gear oil level. Check that gear oil level is not 8 mm (0.31 in.) below the bottom of filler plug hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher, SAE viscosity No. 90, 80W [1.20 dm3 (1.27 U.S.qts., 1.05 Imp.qts.)]
PWJE9086
DRIVE SHAFT AXIAL PLAY CHECK VEHICLES WITH AUTOMATIC FREE-WHEELING HUR
1. Place the free-wheeling hub in the free condition. NOTE
The free condition can be obtained by shifting the transfer shift lever to the 2H position and then moving in reverse for 1 to 2 meters (3.3 to 6.5 ft.)
- 2. Jack the vehicle up and remove the front wheels.
- 3. Remove the free-wheeling hub cover.
- 4. Rotate the drive shaft forward, and backward and then set the drive shaft to the position (the position where axial play is maximum) mid-way between where the rotation feels "heavy" for each (where there is a stopping feelina).
- 5. Set the dial gauge as shown in the figure; then move the drive shaft in the axial direction and measure the plav.
Standard value: 0.4-0.7 mm (0.016-0.028 in.)
6. If the play is out of standard value, adjust by adding or removing shims
VEHICLES WITH MANUAL FREE-WHEELING HUB
- 1 Jack the vehicle up and remove the front wheels
- 2. Move the control handle for the free-wheeling hub to the FREE position.
- 3. Remove the free-wheeling hub cover.
- 4. Set the dial gauge as shown in the figure: then move the drive shaft in the axial direction and measure the play.
Standard value: 0.4-0.7 mm (0.016-0.028 in.)
5. If the play is out of standard value, adjust by adding or removing shims.
VEHICLES WITHOUT FREE-WHEELING HUB
- 1. Jack the vehicle up and remove the front wheels.
- 2. Remove the hub cap.
- 3. Manually push the drive shaft in the direction in which it will closely contact the knuckle.
- 4. As shown in the figure, use a thickness gauge to measure the clearance between the drive flange and snap ring.
Standard value: 0.4-0.7 mm (0.016-0.028 in.)
5. If the play is out of standard value, adjust by adding or removing shims.
E26EDAA
DIFFERENTIAL CARRIER OIL SEAL REPLACE. MENT FORFEAE
- 1. Remove the under cover.
- 2. Remove the front hub and knuckle assembly.
- 3 Remove the left drive shaft
Caution
When pulling the left drive shaft from the differential carrier assembly, be careful that the drive shaft spline does not damage the oil seal.
- 4 Remove the right drive shaft from the inner shaft assembly
- 5. After removing the shock absorber (RH) lower mounting bolt, remove the inner shaft.
Caution
When pulling the inner shaft assembly from the differential carrier, be careful that the spline of the inner shaft does not damage the oil seal.
- 6. For vehicles with super select 4WD, remove the actuator mounting bolt from the housing tube and remove the harness from the clamp
- 7. Remove the differential mounting bracket (R.H.) and housing tube.
- 8. Use the special tool to remove the oil seal.
9. Press-fit the oil seal positively by using the special tools. NOTE
For vehicles with 4-pinion type differential there is a white painted identification mark on the metal ring of the oil seal.
10. Apply multi-purpose grease to the lip of the oil seal and install it to the drive shaft (LH).
For the right side, apply multi-purpose grease to the lip of the oil seal and install to the housing tube and differential mounting bracket (RH).
WJE90
11. Install the inner shaft and drive shaft (RH).
Caution
- 1. Do not damage the lip of the oil seal.
- The circlip attached to the BJ side of the drive shaft should be replaced with a new clip.
- 12. Install the actuator and secure the harness with the clamp.
- 13. Install the shock absorber.
- 14. Install the hub and knuckle assembly.
- 15. Install the under cover.
SOLENOID VALVE OPERATION CHECK
- (1) Remove the vacuum hoses (blue stripe, yellow stripe) from the solenoid valves.
- (2) Disconnect the harness connectors.
-
(3) Connect a hand vacuum pump to solenoid valve A. Apply negative pressure and carry out the following inspections.
- 1. Even if the hand pump is operated with no other operation, no negative pressure develops.
- 2. Even when battery voltage is applied to solenoid valve A, the condition is the same as in (1), but when the vacuum hose of solenoid valve B is blocked by bending at the * mark, negative pressure is maintained.
- 3. When battery voltage is applied to solenoid valves A and B, negative pressure is maintained.
-
(4) Connect the hand vacuum pump to solenoid valve B. Apply negative pressure and carry out the following inspections.
- 1. With no other operation, negative pressure is maintained.
- 2. When battery voltage is applied to solenoid valve B, negative pressure equalizes.
- 3. When battery voltage is applied to solenoid valve A, negative pressure equalizes.
- (5) Measure the resistance of the solenoid valves.
Standard value: 36-46 Ω [at 20°C (60°F)]
© Mitsubishi Motors Corporation Feb. 1991
AXLE HUB
REMOVAL AND INSTALLATION (Vehicles without Free-wheeling Hubs)
© Mitsubishi Motors Corporation Feb. 1991
Vehicles with free-wheeling hub MB990628 MB9906 MB990628 MB990628 MB906 MB9
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF REMOVAL
1. REMOVAL OF COVER
(1) Place the free-wheeling hub in the free condition.
The free condition can be obtained by shifting the transfer shift lever to the 2H position and then moving in reverse for 1 to 2 meters (3.3 to 6.5 ft.).
(2) Remove the automatic free-wheeling hub cover.
NOTE
When the cover cannot be loosened by hand, use an oil filter wrench with a protective cloth in between not to damage the cover.
2. REMOVAL OF FREE-WHEELING HUB COVER
- (1) Set the control handle to the FREE position.
- (2) Remove the free-wheeling hub cover.
5. REMOVAL OF SNAP RING
7. REMOVAL OF BOLTS (Vehicles with automatic freewheeling hub)
11. REMOVAL OF FRONT BRAKE ASSEMBLY
- (1) Remove the front brake assembly with the brake hose connected.
- (2) Use wire to suspend the front brake assembly from the upper arm so that the front brake assembly won't fall.
Caution
Do not twist the brake hose.
-
14. REMOVAL OF LOCK NUT/15. FRONT HUB ASSEMB-LY
- (1) After the lock washer has been removed, remove the lock nut with the special tool.
- (2) Remove the front hub assembly from the knuckle together with the inner and outer bearings.
PWJE9086
E26IBAG
Feb. 1991
SERVICE POINTS OF INSTALLATION ADJUSTMENT OF WHEEL BEARING PRELOAD
(1) Using the special tool, tighten the lock nut by the following procedures.
- (2) Install the lock washer. If the hole position is not aligned with the lock nut, move it within a range of not more than 20° until the holes are aligned.
- (3) Loosen the lock nut approximately 30 to 40 degrees to adjust the front hub's turning resistance and play in the axial direction so that they agree with the standard values
Standard value: 0.3-1.3 Nm (3–13 kgcm, 2.6–11.3 in.lbs.) [Spring scale reading] 5-18 N (0.5–1.8 kg. 1.1–4.0 lbs.) Standard value: 0.05 mm (0.0020 in.) or less
NOTE
If adjustment is not possible, the bearing may be incorrectly installed: check and, if necessary, repair. The lubrication condition should as also be checked.
(4) Mount the lock washer. If the lock washer holes do not align with the lock nut holes. loosen the lock nut to align them.
8. INSTALLATION OF AUTOMATIC FREE-WHEELING HUB ASSEMBLY
- (1) Align the key of the brake (B) and the keyway of knuckle spindle and loosely install the automatic freewheeling hub assembly.
- (2) Check that the hub proper and automatic free-wheeling hub assembly are brought into intimate contact when the assembly is forced lightly against the hub proper. If not, turn the hub until intimate contact is achieved.
PW.JE9086
ADJUSTMENT OF AUTOMATIC FREE-WHEELING HUB TURNING RESISTANCE
Check the automatic free-wheeling hub turning resistance by the following procedure.
(1) Use a spring scale to measure the front hub turning resistance again. Subtract the value measured before the installation of the automatic free-wheeling hub from that measured here to find the turning resistance of the free-wheeling hub.
Limit: 1.0 Nm (10 kgcm, 8.7 in. lbs.) [Spring scale reading] 14 N (1.4 kg, 3.1 lbs.)
(2) If the free-wheeling hub turning resistance exceeds the limit, disassemble and reassemble the freewheeling hub again.
• ADJUSTMENT OF DRIVE SHAFT AXIAL PLAY
After the installation of shim and snap ring, check the drive shaft axial play by the following procedure.
<Vehicles with drive flange>
- (1) Install the shim and snap ring to the drive shaft.
- (2) Push the drive shaft in by hand towards the knuckle until they touch.
- (3) Measure the clearance between the drive flange and the spacer with a thickness gauge as shown in the illustration.
Standard value: 0.4-0.7mm (0.016-0.028in.)
(4) If the amount of play is outside the standard value, adjust by selecting a shim that will bring the play to the standard value.
<Vehicles with free-wheeling hubs>
- (1) Rotate the drive shaft forward, and backward and then set the drive shaft to the position (the position where axial play is maximum) mid-way between where the rotation feels "heavy" for each (where there is a stopping feeling).
- (2) Set the dial gauge as shown in the figure; then move the drive shaft in the axial direction and measure the play.
Standard value: 0.4-0.7 mm (0.016-0.028 in.)
(3) If the play is out of standard value, adjust by adding or removing shims.
DISASSEMBLY AND REASSEMBLY (Front Axle Hub)
E26II--
Outer bearing Inner bearing MB990939 11W590 11W591
Outer bearing MB990938 MB990935 11W588 11W5
SERVICE DOINTS OF DISASSEMBLY
5. REMOVAL OF BRAKE DISC
Make the mating marks on the brake disc and front hub and then separate the front hub and brake disc, if necessarv
Caution
Lock disc in vise and grip with copper or aluminum board.
REARING REPLACEMENT
- (1) Wipe off grease from the front hub interior.
- (2) Using the special tool, drive out the inner and outer bearing outer races by tapping them uniformly
(3) Press-fit the inner and outer bearing outer races by using the special tools.
NOTE
The bearing inner race and bearing outer race should be replaced as an assembly.
SERVICE POINTS OF REASSEMBLY
2. INSTALLATION OF OIL SEAL
AUTOMATIC FREE-WHEELING HUB DISASSEMBLY AND REASSEMBLY Attaching surfaces 11 30104 Parts 3, 8-22 Parts 3-22 (Housing (Housing kit) assembly) 11E0133 11E0134 Brake kit Housing kit Automatic free-wheeling hub kit Disassembly steps 1. Hub cover 12. Return spring 2. O-ring 13. Retainer (B) 3. Housing 14. Retainer bearing 4. Housing C-ring 5. Brake (B) 15. Drive gear snap ring 16. Retainer (A) 6. Brake (A) 17. Drive gear 18. Slide gear C-ring 7. Brake spring 8. Housing snap ring 9. Retainer (B) C-ring 19. Cam 20. Spring holder 10. Drive gear assembly 11. Slide gear assembly 21. Shift spring
© Mitsubishi Motors Corporation Feb. 1991
22. Slide gear
SERVICE POINTS OF DISASSEMBLY
4. REMOVAL OF HOUSING C-RING
NOTE
The ring is easily removable by pushing the brake (B) in and using a small-end screwdriver, etc.
9. REMOVAL OF RETAINER (B) C-RING
Using a special tool, lightly push the drive gear in and remove the retainer (B) C-ring.
NOTE
Since the return spring relaxes approx. 40 mm (1.57 in.), the stroke of the press should be set to more than 40 mm (1.57 in.)
Caution
- 1. Place a protective cover not to damage the cover attaching surface of the housing before setting on the press table.
- 2. Make sure that the pressing force does not exceed 200 N (20 kg, 44.1 lbs.).
10. REMOVAL OF DRIVE GEAR ASSEMBLY/11. SLIDE GEAR ASSEMBLY/12. RETURN SPRING
Slowly reduce the pressure of the press until the return spring fully relaxes.
Caution
When the pressure of press is removed, make sure that the retainer (A) is not caught by the retainer (B).
18. REMOVAL OF SLIDE GEAR C-RING
Push the cam in and remove the slide gear C-ring with the spring compressed.
INSPECTION
BRAKE ASSEMBLY THICKNESS
E26ICAC
26-21
Check the brake assembly thickness by following the steps below
(1) Assemble brake (A) and brake (B) and then use slide calipers to measure the thickness of the assembly at the two lugs on brake (A).
Standard value: 10.5 mm (0.413 in.) Limit: 9.6 mm (0.378 in.)
NOTE
Measure each side separately.
(2) If the measured value is below the limit, replace brake (A) and brake (B) as a set.
DETERIORATION OF RETURN SPRING
Check the return spring for deterioration by following the steps below.
(1) Measure the dimension A shown in illustration at the opposite side of spring end.
Limit: 35 mm (1.38 in.)
Caution
To measure the dimension A shown in illustration, measure the dimension from the outermost extremity of one wire diameter to that of the other wire diameter.
(2) If the measured value is below the limit, replace the spring.
DETERIORATION OF SHIFT SPRING
Check the shift spring for deterioration by following the steps below.
Measure the dimension B shown in illustration at the opposite side of spring end.
Limit: 30 mm (1.18 in.)
Caution
To measure the dimension B shown in illustration, measure the dimension from the outermost extremity of one wire diameter to that of the other wire diameter.
(2) If the measured value is below the limit, replace the spring.
SERVICE POINTS OF REASSEMBLY
E26JDAC
12. INSTALLATION OF RETURN SPRING
Install the return spring with the smaller coil diameter side toward the cam.
MANUAL FREE-WHEELING HUB
E26JA-B
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF DISASSEMBLY E26JBBC 8. REMOVAL OF WHEEL SNAP RING/10. SHAFT SNAP BING
PWJE9086
REMOVAL AND INSTALLATION
Pre-removal and post-installation Operation
- Bemoval and Installation of the Front Hub (Refer to P 26-12)
Removal steps
- 1. Dust cover
- 2. Split pin
- 3. Connection for tie rod assembly and knuckle
- 4. Split pin 5. Connection for lower ball joint and knuckle
-
6. Split pin
- 7. Connection for upper ball joint and knuckle 8. Knuckle
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF REMOVAL
3 DISCONNECTION OF THE ROD ASSEMBLY AND KNUCKI F
Caution
- 1. Use cord to bind the special tool closely so it won't become separated.
- 2. The nut should be loosened only, not removed.
PW.IF9086
E26NA--
E26NBAF
DISASSEMBLY AND REASSEMBLY
5. DISCONNECTION OF LOWER BALL JOINT AND KNUCKLE/7. UPPER BALL JOINT AND KNUCKLE
Caution
- 1. Support the lower arm with a jack when removing the knuckle from the lower ball joint or the upper ball joint.
- After the knuckle has been removed, lower the jack slowly.
- 3. Insert the special tool securely.
E26NJ--
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF DISASSEMBLY 3. REMOVAL OF NEEDLE BEARING
E26NKAB
PWJE908
SERVICE POINTS OF REASSEMBLY
E26NMAB
3. INSTALLATION OF NEEDLE BEARING Caution
Caution Use care to prevent driving the needle bearing too far in.
2. INSTALLATION OF SPACER
Install the spacer to the knuckle with the chamfered side toward the centre of vehicle.
1. INSTALLATION OF OIL SEAL
DRIVE SHAFT
REMOVAL AND INSTALLATION
E26QA--
SERVICE POINTS OF REMOVAL
E26IBAG
1. REMOVAL OF COVER <AUTOMATIC FREE-WHEELING HUB>
(1) Place the free-wheeling hub in the free condition.
The free condition can be obtained by shifting the transfer shift lever to the 2H position and then moving in reverse for 1 to 2 meters (3.3 to 6.5 ft.).
(2) Remove the automatic free-wheeling hub cover.
NOTE
When the cover cannot be loosened by hand, use an oil filter wrench with a protective cloth in between not to damage the cover.
-
1. REMOVAL OF FREE-WHEELING HUB COVER <MANUAL FREE-WHEELING HUB>
- (1) Set the control handle to the FREE position.
- (2) Remove the free-wheeling hub cover.
3. REMOVAL OF SNAP RING
5. REMOVAL OF FRONT BRAKE ASSEMBLY
- (1) Remove the front brake assembly with the brake hose connected.
- (2) Use wire to suspend the front brake assembly from the upper arm so that the front brake assembly won't fall.
Caution
Do not twist the brake hose.
8. DISCONNECTION OF TIE ROD ASSEMBLY AND KNUCKLE
Caution
- 1. Use cord to bind the special tool closely so it won't become separated.
- 2. The nut should be loosened only, not removed.
- 1. Support the lower arm with a jack when removing the knuckle from the lower ball joint or the upper ball joint.
- After the knuckle has been removed, lower the jack slowly.
- 3. Insert the special tool securely.
14. REMOVAL OF DRIVE SHAFT
FOR LEFT DRIVE SHAFT
Caution
When pulling the drive shaft out from the differential carrier, be careful that the spline part of the drive shaft does not damage the oil seal.
INSPECTION
E26QCAC
E26QDAG
• Check ball joint for operating condition and excessive looseness.
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF INSTALLATION
FOR LEFT DRIVE SHAFT
Caution
Be careful not to damage the lip of the oil seal. Replace the circlip which is attached to the B.J. side spline part with a new one.
PWJE9086
DISASSEMBLY AND REASSEMBLY
l eft drive shaft
11148
- -
-
6. Balls 4. D.O.J. outer race .......................................
- 3. Circlip 13. Circlip
- 5. Dust cover
© Mitsubishi Motors Corporation Feb. 1991
13. Circlip
NOTE *: 3000-M/T
9. D.O.J. inner race
11. D.O.J boot 12. B.J. assembly
LUBRICATION POINTS
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF BALLS
E26QFAK
7. REMOVAL OF D.O.J. CAGE
Remove the D.O.J. cage from the D.O.J. inner race in the direction of the B.J.
-
8. REMOVAL OF SNAP RING/10. CIRCLIP
- (1) Remove the snap ring from the drive shaft with special tool, and then withdraw the D.O.J. inner race and D.O.J. cage from the drive shaft.
- (2) Remove the circlip from the drive shaft with special tool.
11. REMOVAL OF D.O.J. BOOT
- (1) Wrap plastic tape around the spline part on the D.O.J. side of the drive shaft so that D.O.J. boot is not damaged when they are removed.
- (2) Withdraw the D.O.J. boot from the drive shaft.
SERVICE POINTS OF REASSEMBLY
7. INSTALLATION OF D.O.J. CAGE/9. D.O.J. INNER RACE/8. SNAP RING/6. BALLS
Install the cage, balls and inner race to the drive shaft, and fit the snap ring securely to the groove in the drive shaft.
Caution
For 3000-M/T, the inner race should be installed so that the large chamfer on the spline section is on the drive shaft side.
4. INSTALLATION OF D.O.J. OUTER RACE
(1) Fill the inside of the D.O.J. outer race and D.O.J. boot with the specified grease.
Specified grease: Repair kit grease 100g (3.5 oz.)
The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint use special grease. Do not mix old and new or different types of grease.
(2) Install the circlip onto the D.O.J. outer race. Place the D.O.J. boot over the D.O.J. outer race, and then use boot band (small) to secure the boot.
Caution
Do not secure the boot band (large).
(3) Secure the driveshaft, and then move the D.O.J. outer race until it is at the position where the D.O.J. boot assembly dimension is the standard value.
Standard value (A): 77-83 mm (3.03-3.27 in.)
- (4) Remove a part of the D.O.J. boot from the D.O.J. outer race and release the air within the boot.
- (5) Secure the boot band (large) on D.O.J. boot.
Caution
Be sure that the installation direction of the boot bands is correct.
INNER SHAFT
REMOVAL AND INSTALLATION
11. Housing tube
Mitsubishi Motors Corporation Dec. 1993
SERVICE POINTS OF REMOVAL
E26TBAAa
REVISED
4. REMOVAL OF INNER SHAFT
Attach the special tools to the flange of the shaft, and pull the inner shaft out from the front differential carrier.
Caution
PWJE9086-E
When pulling the inner shaft out from the front differential carrier, be careful that the spline part of the inner shaft does not damage the oil seal.
E26TA.
SERVICE POINTS OF INSTALLATION
4 INSTALLATION OF INNER SHAFT
Drive the inner shaft into the front differential carrier by using the special tools (MB990906 and MB990211)
Caution
Be careful not to damage the lin of the dust seal and oil seal
Mitsubishi Motors Corporation Feb. 1991
2 REMOVAL OF BEARING (1) Bend the outside periphery of dust cover inward with a hammer.
PWJE9086
E26TFAC
ESETDAD
© Mitsubishi Motors Corporation Feb. 1991
26-35
PWJE9086
SOLENOID VALVE AND VACUUM HOSE
REMOVAL AND INSTALLATION
<Vehicles built up to October, 1993> <Vehicles built from November, 1993>
- ➡< 5. Solenoid valve assem</li> ➡< 6. Vacuum hose</li>
- 6. vacuum nose 7. Vacuum pipe assembly
- 8. Vacuum tank
- ♦ 9. Vacuum hose
© Mitsubishi Motors Corporation Dec. 1993
SERVICE POINTS OF INSTALLATION
9. INSTALLATION OF VACUUM HOSE
Install the vacuum hose so that the identification colours match those of the pipe assembly and the actuator. Furthermore, there are no identification colours on the vacuum hose at the vacuum tank connection.
6. INSTALLATION OF VACUUM HOSE/5. SOLENOID VALVE ASSEMBLY
Install the vacuum hose and solenoid valve assembly so that the colours of the identification marks are matched.
NOTES
DIFFERENTIAL CARRIER AND FREE-WHEELING CLUTCH REMOVAL AND INSTALLATION
SERVICE POINTS OF REMOVAL
Install the front propeller shaft so that the mating marks of the flange yoke and the differential carrier companion flange are aligned.
Shaft Continuity Contact Pole 11E0047
INSPECTION FREE-WHEEL ENGAGE SWITCH
The switch is normal if there is continuity when the shaft is pushed in, and no continuity when the shaft is released.
SERVICE POINTS OF INSTALLATION
23. INSTALLATION OF FREE-WHEELING CLUTCH ASSEM-BLY
(1) After installing the free-wheeling clutch assembly, select a spacer so that the clutch gear play (bearing looseness) is within the standard value.
Standard value: 0.05-0.40mm (0.0020-0.0160in.)
(2) Install the spacer so that the oil channel side is on the differential gear side.
8. INSTALLATION OF FRONT PROPELLER SHAFT
Install the front propeller shaft so that the mating marks of the flange yoke and the differential carrier companion flange are aligned.
1. INSTALLATION OF VACUUM HOSE
Install the vacuum hoses so that they match the identification colours of the actuator assembly nipple.
(1) Use a press and steel plate to remove the clutch gear and bearing together.
(2) Use a press to hold the supports against the bearing inner race, and separate the clutch gear and bearing.
© Mitsubishi Motors Corporation Jun. 1994
SERVICE POINTS OF REASSEMBLY 14. INSTALLATION OF OIL SEAL
13 INSTALLATION OF CAP
Use an iron bar with an outside diameter of approximately 30–35 mm (1.18–1.38 in.) to push in the sealing cap.
Caution
Be careful not to make a dent in the curved surface of the cylinder cap.
12 INSTALLATION OF NEEDLE BEARING
Use the special tools to press-fit the clutch cap until it is flush with surface A of the clutch gear.
OIL SEAL (1) Use the special tool to press-fit the bearing to the
C Mitsubishi Motors Corporation Feb. 1991
11. INSTALLATION OF BEARING/10. CLUTCH GEAR/9.
shoulder of the clutch gear.
(2) Use the special tool to tap the oil seal until it is flush with the clutch housing.
PWJE90
(3) Use the special tool to press-fit the bearing to the side of the clutch housing.
Caution Place the special tool against the outer race of the bearing.
5. INSTALLATION OF SPRING PIN
Tap the spring pin from the chamfered side of the shift rod until the projection length is at the length shown in the illustration.
1. INSTALLATION OF THRUST BUSHING
Install the thrust bushing in the direction shown in the illustration.
(1) Install the special tool a shown in the figure and tighten the nut of the special tool until the portion "A" touches the bearing outer race.
(2) Remove the bearing from the main shaft with a press.
© Mitsubishi Motors Corporation Jun. 1994
FRONT AXLE – Free-wheeling Clutch
10. REMOVAL OF CLUTCH GEAR / 11. BEARING
(1) Use a press and steel plate to remove the clutch gear and bearing together.
11G0218
SERVICE POINTS OF REASSEMBLY 13. INSTALLATION OF OIL SEAL
12. INSTALLATION OF CAP
der of the clutch gear.
Caution
cylinder cap.
Use the special tool to tap the oil seal until it is flush with the clutch housing.
Use a steel pipe with an outside diameter of approximately 30 – 35 mm (1.18 – 1.38 in.) to push in the sealing cap.
Be careful not to make a dent in the curved surface of the
(1) Use the special tool to press-fit the bearing to the shoul-
11. INSTALLATION OF BEARING / 10. CLUTCH GEAR
MB990799 11G0219
© Mitsubishi Mo
Jun. 1994
PWJE9086-F
(2) Use the special tool to press-fit the bearing to the side of the clutch housing.
Caution
Place the special tool against the outer race of the bearing.
9. INSTALLATION OF OIL SEAL
Use the special tool to tap the oil seal.
5. INSTALLATION OF SPRING PIN
Tap the spring pin from the chamfered side of the shift rod until the projection length is at the length shown in the illustration.
Press in the bearing up to the shoulder of the main shaft.
2. INSTALLATION OF SPACER
(1) Install the free-wheeling clutch and then select a spacer so that the axial play of the clutch gear (bearing play) is within the standard value.
Standard value: 0.05 - 0.30 mm (0.0020 - 0.0120 in.)
(2) If the axial play is not within the standard value, disassemble the clutch and select a spacer again. NOTE
Spacer thickness is every 0.25 mm (0.010 in.).
PWJE9086-F
DIFFERENTIAL CARRIER
E26WCAC
INSPECTION BEFORE DISASSEMBLY
Remove the cover and gasket. Hold the special tool in a vise, and install the differential carrier assembly to the special tool.
FINAL DRIVE GEAR BACKLASH
Check the final drive gear backlash by following the steps below.
(1) With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference of the drive gear.
Standard value: 0.11-0.16 mm (0.0043-0.0063 in.)
(2) If the backlash is not within the standard value, adjust it by using the side bearing adjustment spacers.
DRIVE GEAR RUNOUT
Check the drive gear runout by following the steps below.(1) Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.0020 in.)
(2) If the runout exceeds the limit, check for improper tightening of the drive gear and differential case.
DIFFERENTIAL GEAR BACKLASH <EXCLUDING 4 PINION DIFFERENTIAL>
Check the differential gear backlash by following the steps below.
(1) While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on the pinion gear.
NOTE
The measurement should be made for both pinion gears individually.
Standard value: 0–0.076 mm (0–0.0030 in.) Limit: 0.2 mm (0.0079 in.)
(2) If the backlash exceeds the limit, adjust by using the side gear thrust spacers.
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps below.
- Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.
- (2) Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5–3.0 Nm (25–30 kgcm, 28–33 in.lbs.)] is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.
(3) Check the tooth-contact condition of the drive gear and drive pinion.
NOTE
Checking the tooth contact pattern is the way to confirm that the adjustments of the pinion height and backlash have been done properly. Continue to adjust the pinion height and backlash until the tooth contact pattern resembles the standard pattern.
If, even after adjustments have been made, the correct tooth contact pattern cannot be obtained, it means that the drive gear and the drive pinion have become worn beyond the allowable limit. Replace the gear set.
FORMO
DISASSEMBLY
SERVICE POINTS OF DISASSEMBLY
3. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
Caution
When taking out the differential case assembly be careful not to drop and damage the side bearing outor races
Keep the right and left side bearings and side bearing adjusting spacers separate, so that they do not become mixed at the time of reassembly.
6. REMOVAL OF SIDE BEARING INNER RACE
There are two notches provided (at the differential case side) for the claw part of the special tool; use the special tool at that position.
8. REMOVAL OF DRIVE GEAR
- (1) Make the mating marks to the differential case and the drive gear.
- (2) Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.
9. REMOVAL OF LOCK PIN
Mitsubishi Motors Corporation Feb. 1991
17. REMOVAL OF COMPANION FLANGE SELF-LOCKING NUT
PWJE9086
11E010
PWJE9086
LUBRICATION, SEALING AND ADHESION POINTS
rs Coi
26-50
(3) Measure the drive pinion rotation torque (without the oil seal) by using the special tools.
Standard value:
|
Bearing
division |
Bearing lubrication | Rotation torque |
|---|---|---|
| New |
None
(With anti-rust agent) |
0.3–0.5 Nm
3.0–5.0 kgcm 2.6–4.3 in.lbs. |
| New/reusing | Gear oil applied |
0.15–0.25 Nm
1.5–2.5 kgcm 1.3–2.2 in.lbs. |
NOTE
- 1. Gradually tighten the nut of the special tool while checking the drive pinion preload.
- Because one rotation can't be made when the special tool is in contact with the gear carrier, move it a few times and, after seating the bearing, measure the rotation torque.
- (4) Position the special tool in the side bearing seat of the gear carrier, and then select a drive pinion front shim of a thickness which corresponds to the gap between the special tools.
NOTE
- 1. Be sure to clean the side bearing seat thoroughly. When positioning the special tool, be sure that the cut-out sections of the special tool are in the position shown in the illustration, and also confirm that the special tool is in close contact with the side bearing seat.
- 2. When selecting the drive pinion front shims, keep the number of shims to a minimum.
- (5) Fit the selected drive pinion front shim(s) to the drive pinion, and press-fit the drive pinion front bearing inner race by using the special tool.
• ADJUSTMENT OF DRIVE PINION TURNING TORQUE
Adjust the drive pinion rotation torque by using the following procedure:
Without Oil Seal
(1) Insert the drive pinion into the gear carrier, and then install, from the front side of the carrier, the drive pinion spacer, the drive pinion rear shim, the drive pinion rear bearing inner race, and the companion flange in that order.
NOTE
Do not install the oil seal.
(2) Tighten the companion flange to the specified torque by using the special tool.
(3) Measure the drive pinion rotation torque (without the oil seal) by using the special tools.
Standard value:
|
Bearing
division |
Bearing lubrication | Rotation torque |
|---|---|---|
| New |
None
(With anti-rust agent) |
0.3–0.5 Nm
3.0–5.0 kgcm 2.6–4.3 in.lbs. |
| New/reusing | Gear oil applied |
0.15-0.25 Nm
1.5-2.5 kgcm 1.3-2.2 in.lbs. |
(4) If the drive pinion rotation torque is not within the range of the standard value, adjust the preload by replacing the drive pinion front shim(s) or the drive pinion spacer.
When selecting the drive pinion rear shims, if the number of shims is large, reduce the number of shims to a minimum by selecting the drive pinion spacers. Also, select the drive pinion spacer from the following
Also, select the drive pinion spacer from the following two types.
| Item |
<2600, 2500D,
3000-A/T> |
<3000-M/T> |
|---|---|---|
| Height of drive |
46.67 (1.837)
With identification colour |
56.67 (2.231)
With identification colour |
| mm (in.) |
47.01 (1.851)
No identification colour |
57.01 (2.244)
No identification colour |
(5) Remove the companion flange and drive pinion once again.
With Oil Seal
- (1) After setting the drive pinion rear bearing inner race, drive the oil seal into the gear carrier front lip by using the special tool.
- (2) Apply multi-purpose grease to the contact surfaces of the companion flange oil seal and the washer companion flange.
- (3) Install the drive pinion assembly and companion flange with mating marks properly aligned, and tighten the companion flange self-locking nut to the specified torque by using the special tools.
(4) Measure the drive pinion rotation torque (with oil seal) by using the special tools to verify that the drive-pinion preload complies with the standard value.
Standard value:
| Bearing division | Bearing lubrication | Rotation torque |
|---|---|---|
| New |
None
(With anti-rust agent) |
0.5-0.7 Nm
5.0-7.0 kgcm 4.3-6.1 in.lbs. |
| New/reusing | Gear oil applied |
0.35–0.45 Nm
3.5–4.5 kgcm 3.1–3.9 in.lbs. |
(5) If the measured value is not within the standard value range, check for faulty installation of the oil seal or faulty tightening of the self-locking nut.
© Mitsubishi Motors Corporation
ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH <2 PINION>
- (1) Assemble the side gears, side gear thrust spacers, pinion gears, and pinion washers into the differential case.
- (2) Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
- (3) Insert a wedge between the side gear and the pinion shaft to lock the side gear.
- (4) Measure the differential gear backlash with a dial indicator on the pinion gear.
Standard value: 0-0.076 mm (0-0.0030 in.) Limit: 0.2 mm (0.0079 in.)
- (5) If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear thrust spacers.
- (6) Measure the differential gear backlash once again, and confirm that it is within the limit.
If adjustment is not possible, replace the side gears and pinion gears as a set.
24. INSTALLATION OF LOCK PIN
- (1) Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.
- (2) Stake the lock pin with a punch at two points.
26. INSTALLATION OF DRIVE GEAR
- (1) Clean the drive gear attaching bolts.
- (2) Remove the adhesive adhered to the threaded holes of the drive gear by turning the special tool (tap M10 × 1.25), and then clean the threaded holes by applying compressed air.
- (3) Apply the specified adhesive to the threaded holes of the drive gear.
Specified adhesive: 3M Stud Locking 4170 or equivalent
(4) Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torgue in a diagonal sequence.
27. INSTALLATION OF SIDE BEARING INNER RACE
MB990802 MB990802 11G0121
1155
Metal II 🗱
© Mitsubishi Motors Corporation Feb. 1991
ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH Adjust the final drive gear backlash by the following pre-
Adjust the final drive gear backlash by the following procedures:
(1) Install the side bearing spacers, which are thinner than those removed, to the side bearing outer races, and then mount the differential case assembly into the gear carrier.
NOTE
Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side.
(2) Push the differential case assembly to one side, and measure the clearance between the gear carrier and the side bearing adjusting spacer with a thickness gauge.
PWJE9086
© Mitsubishi Motors Corporation Feb. 1991
- (3) Measure the thickness of the side bearing adjusting spacers on one side, select two pairs of spacers which correspond to that thickness plus one half of the clearance plus 0.05 mm (0.002 in.), and then install one pair each to the drive pinion side and the drive gear side.
- (4) Install the side bearing adjusting spacers and differential case assembly, as shown in the illustration, to the gear carrier.
(5) Tap the side bearing adjusting spacers with the special tool to fit them to the side bearing outer race.
(6) Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap.
(7) With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear. NOTE
Measure at four points or more on the circumference of the drive gear.
Standard value: 0.11-0.16 mm (0.004-0.006 in.)
PWJE9086
FRONT AXLE - Differential Carrier
(8) Change the side bearing adjusting spacers as illustrated, and then adjust the final drive gear backlash between the drive gear and the drive pinion. NOTE
When increasing the number of side bearing adjusting spacers, use the same number for each, and as few as possible.
- (9) Check the drive gear and drive pinion for tooth contact. If poor contact is evident, make adjustment. (Refer to P.26-42)
- (10) Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.0020 in.)
(11) If the drive gear runout exceeds the limit, reinstall by changing the phase of the drive gear and differential case, and remeasure.
OVERHAUL (4 PINION CASE ASSEMBLY)
E26WK--
© Mitsubishi Motors Corporation Feb. 1991
SERVICE POINTS OF DISASSEMBLY E26WLAB 1. REMOVAL OF SCREW
(1) Evenly loosen 4 screws on case A and B to remove.(2) Set case B downward and remove case A, side gear spacer (RH) and side gear (RH).
NOTE
Check differential gear backlash to determine necessity of disassembling side gear (RH) and onward.
• DIFFERENTIAL GEAR BACKLASH CHECK
Check differential gear backlash as follows.
- (1) Insert cloth wrapped screwdriver through side of case B and lock side gear (LH) and pinion gear. (one piece)
- (2) Contact dial gauge on pinion gear facing the locked pinion gear and measure backlash within the standard value.
NOTE
Measure 2 pinion gears.
Standard value: 0.01-0.25 mm (0.0004-0.0098 in.)
(3) When backlash exceeds the standard value, adjust side gear spacer (LH).
NOTE
If backlash is within the standard value, assure appropriate gear spacer (RH) thickness and assemble 4 pinion case assembly. (Refer to P.26-57.)
SERVICE POINTS OF REASSEMBLY E26WNAE
BACKLASH ADJUSTMENT ON DIFFERENTIAL GEAR CASE B SIDE
Adjust backlash on differential gear case B side as follows.
(1) Temporarily install side gear spacer (LH), side gear (LH), washers, 2 pinion gears and pinion shaft A on case B.
NOTE
Do not assemble pinion shaft holder, pinion shaft-B or the remaining pinion gears (2).
(2) Insert wrapped screwdriver through side of case B to lock one side of pinion gear and side gear (LH).
FRONT AXLE - Differential Carrier
(3) Place dial gauge on unlocked pinion gear and measure differential gear backlash within the standard value.
NOTE
Measure 2 pinion gears.
Standard value: 0.01-0.25 mm (0.0004-0.0098 in.)
- (4) When backlash exceeds the standard value, adjust with selected side gear spacer (LH).
- (5) Install washers, pinion gears, pinion shaft holder and pinion shaft-A and B. Lock with lock pin through case B.
BACKLASH ADJUSTMENT ON DIFFERENTIAL GEAR CASE A SIDE
Adjust backlash as follows.
- (1) Install side gear (RH) and 2 side gear spacers [1.0 mm (0.039 in.) thick]. Press differential case A to differential case B.
- (2) Measure flange space (C) between differential case A and B with thickness gauge.
- (3) Calculate side gear spacer (RH) thickness (D) as follows:
D=2.0 mm (0.078 in.)-[C+0.2 mm (0.008 in.)]
- (4) Choose spacer with a thickness nearest D in (3) and adjust differential gear backlash on the right side.
- (5) Match the match marks and assemble cases A and B.
- (6) Assure smooth rotation of inner shaft.
© Mitsubishi Motors Corporation Feb. 199
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