Part 3 of 3
CENTER DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARINGS REMOVAL
Remove the taper roller bearings using the special tool.
NOTE:
- Do not reuse the bearing.
- Replace the inner and outer races of the taper roller bearing as a set.
REASSEMBLY SERVICE POINTS
A - SPACERS INSTALLATION
1. Install the spacer, side gear, pinion gear, washer and pinion shaft to the center differential case.
2. Holding down the pinion shaft, select the spacer of maximum thickness that allows the pinion gear to turn lightly and install it to the shaft.
3. Install the side gear, spacer and output gear, and tighten the bolt to specified torque.
4. Select the spacer of maximum thickness that allows the side gear to turn lightly and install it.
5. Check that both side gears turn lightly. Standard value:
Center differential side gear end play: 0.05-0.25 mm (0.0020-0.0010 in.)
B - TAPER ROLLER BEARINGS INSTALLATION
C - BOLTS INSTALLATION
1. Apply the specified sealant to the bolt threads.
Specified sealant: MOPAR Part No.4318031 or MOPAR Part No. 4318032 or equivalent
2. Tighten to specified torque in the order shown.
D - TAPER ROLLER BEARINGS INSTALLATION
NOTE: Apply the special tool to the inner race only.
SHIFT FORK DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINT ~ INTERLOCK PLUNGER INSTALLATION
REASSEMBLY SERVICE POINT
A - SPEEDOMETER DRIVEN GEAR INSTALLATION
Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
SPEEDOMETER GEAR DISASSEMBLY AND ASSEMBLY
REASSEMBLY SERVICE POINT
A - SPEEDOMETER DRIVEN GEAR INSTALLATION
Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - LOCK PIN REMOVAL
CAUTION: Turn the control lever not to allow the lock pin to contact the clutch housing.
B - SPRING PIN REMOVAL
CAUTION: Pull the control shaft in the direction illustrated so that the spring pin will not contact the clutch housing.
C - NEEDLE BEARING REMOVAL
REASSEMBLY SERVICE POINTS
A - NEEDLE BEARINGS INSTALLATION
1. Use a socket wrench to install the needle bearing so that it is flush with the surface A of the clutch housing.
2. Install with the part type stamped side facing the surface A.
B - OIL SEAL INSTALLATION
C - SPRING PIN/LOCK PIN INSTALLATION
CAUTION:
- Do not reuse the spring pin and lock pin.
- Install the spring pin so that its slit will be at right angle to the control shaft center.
TRANSFER ASSEMBLY REMOVAL AND INSTALLATION
Pre-Removal And Installation Operation:
- Drain and refill transfer assembly.
- Remove and install Front Exhaust Pipe
REMOVAL SERVICE POINT
A - TRANSFER ASSEMBLY REMOVAL
CAUTION:
- Do not damage the oil seal lip of the transfer.
- Use the special tool to cover the transaxle case to prevent oil from gushing out or foreign materials from getting Into the transaxle case.
TRANSFER CASE DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
BACKLASH ADJUSTMENT
1. Apply a light and uniform coat of machine blue or red lead to the driven bevel gear teeth (both sides) using a brush.
2. Install the spacer that has been used.
3. Align the transfer case and drive bevel gear mating marks.
4. Align the transfer case adapter and drive bevel gear mating marks.
5. Assemble the transfer case and transfer case adapter and tighten to the specified torque.
6. With the mating marks aligned as in step (3), confirm that the transfer case and drive bevel gear mating marks are matched looking from the cover.
7. Use the special tool to turn the drive bevel gear shaft (one forward turn, one reverse turn).
NOTE: Do not turn the shaft more than one turn in either direction, or a tooth contact pattern will be unclear.
8. Check that the drive bevel gear tooth contact is normal.
NOTE: Refer to the TOOTH CONTACT ADJUSTMENT PROCEDURES for the standard tooth contact.
9. Check that the drive bevel gear and driven bevel backlash is as specified.
Standard value: Bevel gear set backlash 0.08-0.13 mm (0.0031 -0.0051 In.)
A - 0-RING INSTALLATION
CAUTION: Apply transaxle oil to the 0-ring before Installation.
B - EXTENSION HOUSING INSTALLATION
Apply sealant to the adapter flange surface and install the extension housing.
Specified sealant: Mitsubishi genuine Sealant Part No. MD997740 or equivalent
NOTE: Squeeze out sealant from the tube uniformly and continuously in adequate amount.
C - SEALANT APPLICATION TO COVER GASKET
Specified sealant: MOPAR Part No.4318034 or Three Bond Part No.1141 E
TOOTH CONTACT ADJUSTING PROCEDURES
1. Standard tooth contact pattern
A - Small end side
B - Drive side tooth lace (Side on which force acts when running forward)
C - Big end side
D - Coast side tooth face (Side on which force acts when reversing)
2. Tooth contact pattern produced when drive bevel gear height Is too large
Cause: The driven bevel is too close to the drive bevel gear.
Remedy: Use thicker bevel gear mount adjusting spacer to separate the driven bevel gear more from the drive bevel gear.
3. Tooth contact pattern produced when driven bevel gear height is too small
Cause: The driven bevel gear is too separated from the drive bevel gear.
Remedy: Use thinner driven bevel gear mount adjusting spacer to bring the gear closer to the drive bevel gear.
NOTE:
1. If correct tooth contact cannot be obtained even by change of the driven bevel gear mount adjusting spacer, increase or decrease the drive bevel gear preload adjusting spacer and the drive bevel gear mount adjusting spacer as described below and then adjust tooth contact again.
- When the driven bevel gear height is too small even if the thinnest driven bevel gear mount adjusting spacer 0.13 mm (0.0051 in.) is used:
Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thicker and replace the drive bevel preload adjusting spacer that is in use with one that is one rank thinner.
- When the driven bevel gear height is too large even if the thickest driven bevel gear mount adjusting spacer 0.52 mm (0.0205 in.) is used:
Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thinner and replace the drive bevel gear preload adjusting spacer that is in use with one that is one rank thicker.
2. Repeat above steps until the tooth contact pattern equal or close to the standard pattern is obtained.
3. If the tooth contact pattern cannot be adjusted close to the standard pattern by above adjustment, replace the drive bevel gear and driven bevel gear as a set and readjust the tooth contact.
EXTENSION HOUSING DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - OIL SEAL INSTALLATION
AIR BLEEDER INSTALLATION
Apply the specified sealant to the inserting portion before installation.
Specified sealant: MOPAR Part No.4318025 or equivalent
TRANSFER CASE DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - OIL SEAL INSTALLATION
SPACER SELECTION
1. Use the existing spacer to assemble the transfer case.
2. Use the special tool to check that the bevel gear rotating drive torque is within standard range.
Standard value: 1.7-2.5 Nm (1.23-1.81 ft. lbs.)
3. If the rotating drive torque is outside the standard range, adjust using adjusting spacers.
NOTE: For adjustment, use two spacers of which thickness is as close as possible to each other.
C - 0-RING INSTALLATION
CAUTION: Apply transaxle oil to the 0-ring before Installation.
TRANSFER CASE ADAPTER DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - LOCK NUT REMOVAL
1. Unlock the look nut. (Straighten the bent nut.)
2. Holding the driven bevel gear in a vise and using the special tool, remove the look nut.
REASSEMBLY SERVICE POINTS
A - SPACER SELECTION
1. Use the existing spacer to assemble the transfer case adapter.
2. Use the special tool to check that the bevel gear rotating drive torque is within standard range.
Standard value: 1.0-1.7 Nm (0.72-1.23 ft.lbs.)
3. If the rotating drive torque is outside the standard range, adjust using adjusting spacers.
B - TAPER ROLLER BEARING INSTALLATION
C - LOCK NUT INSTALLATION
Holding the driven bevel gear in a vise and using the special tool, tighten the lock nut to specified torque.
DRIVE BEVEL GEAR DISASSEMBLY AND REASSEMBLY
B - DRIVE BEVEL GEAR REMOVAL
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING REMOVAL
REASSEMBLY SERVICE POINTS
A - TRANSFER DRIVE BEVEL GEAR INSTALLATION
Install the drive bevel gear and the drive bevel gear shaft with the mating marks aligned.
B - TAPER ROLLER BEARING INSTALLATION
DRIVEN BEVEL GEAR DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING REMOVAL
A - TAPER ROLLER BEARING INSTALLATION