Contents: Rear axle half shaft disassembly…⤓ Rear axle half shaft disassembly…⤓ Removal and installation ⤓
The gear ratio of the rear axle is indicated on a plate attached to the bulkhead of the engine compartment. This 4-digit number is listed after the space following the 5-digit transmission code (for example 3545 corresponds to a gear ratio of 3.545:1). The vehicles in question are equipped with a limited-slip differential.
Rear axle half shaft disassembly procedure (except for cars of 1992-98.)
N – subject to replacement; 1. Drum; 2. Handbrake cable mounting bolt; 3. Handbrake cable tip; 4. Brake pipes; 5. Nuts; 6. Half shaft assembly; 7. Adjusting washers; 8. Ring; 9. Lock nut; 10. Kitting washer; 11. Washer; 12. Half shaft; 13. Inner ring; 14. Body; 15, 17. Seal; 16. Outer ring
Rear axle half shaft disassembly procedure (1992-98)
N – subject to replacement; 1. Brake pipes; 2. Rear brake; 3. Disk; 4. Handbrake cable bolt; 5. Handbrake cable tip; 6. Handbrake assembly; 7. Speed sensor; 8. Half shaft assembly; 9. Retaining ring; 10. Bearing retaining ring; 12. 1st inner bearing race; 13. 2nd inner bearing race; 14, 23. Seal; 15. Mud deflector (on cars without ABS system); 16. Rotor (on cars with ABS system); 17. Half shaft; 18. Brake shield; 19. Speed sensor bracket; 20. Outer bearing race; 21. Body; 22. Ring
Removal and installation
Cars 1983-91.
1. Remove the brake drums.
2. Disconnect the handbrake cable.
3. Unscrew the 4 brake shield nuts and remove the axle shaft assembly with the shield, housing and bearing.
4. Remove the ring and adjusting washers (for adjusting the bearing preload), having ensured their safety.
5. Press the oil seal out of the rear axle.
6. Unscrew the nut, remove the washers and press the bearing using a puller (plates with 4 holes opposite the bearing housing studs).
7. Knock out the outer bearing race from the housing and remove the seal.
8. Assembly is carried out in reverse order.
9. Apply grease to the bearing and tighten the nuts and bolts to the required torque.
10. Press the bearing races using a special mandrel (1 – housing, 2 – stop).
11. Press the oil seal in using a special mandrel (1 – bearing housing, 2 – stop).
12. Check the axial play of the axle shaft, which should be 0.05–0.20 mm, adjust if necessary (see subsection 9.4.2).
[The article is based on data from the website: MITSUBISHIMAN]
Cars 1992-98.
1. Remove the brake caliper and disc, disconnect the handbrake cable.
2. On vehicles with ABS, remove the speed sensor.
3. Remove the axle shaft from the rear axle (use an impact wrench if necessary).
4. Remove the retaining ring and knock out the brake shield mounting bolt.
5. To cut off the locking ring, you need to remove one of the studs (1 - brake shield).
6. Clamp the axle shaft in a vice and carefully file down the bearing retaining ring to a thickness of 1–2 mm using a hand grinder (1 – hand grinder, 2 – bearing housing, 3 – retaining ring).
7. After this, knock off the ring with a chisel.
8. Sand the corner of the MB990861 fixture plate and secure the fixture to the axle shaft by fitting washers and tightening the nuts.
9. Press the axle shaft out of the bearing housing.
10. Using the MB990861 tool and a press, remove the bearing race from the axle shaft (1 – machined edge of the plate, 2 – plate, 3, 5 – washer, 4 – housing, 6 – bolt, 7 – nut).
11. On vehicles with ABS, remove the oil seal and dust cover.
12. On vehicles without an ABS system, press the rotor by placing an auxiliary plate 1 mm thick between the rotor and the axle shaft (1, 2 – plate, 3 – support).
Attention! To avoid bending the rotor plate when pressing it out, use a mandrel as a support, the diameter of which corresponds to the diameter of the axle shaft flange.
13. Remove the remaining parts from the axle shaft.
14. Remove the brake shield.
15. Install the removed inner race and use tool MB990799-01 to press off the outer race (1).
16. Secure the bearing with the MB 990560 tool for knocking out the axle shaft.
17. Remove the bearing housing.
18. Remove the ring and press the oil seal out of the rear axle.
19. Replace worn parts. Those parts marked with the letter N are also subject to replacement.
20. Assembly is carried out in reverse order, taking into account the following.
21. Press in the axle shaft seal using tools MB990932-01 and MB990938-01, or equivalent.
22. Lubricate and press in the outer bearing race using tool MB990890-01.
23. Press the rotor onto the axle shaft using tool MB991388.
24. Press in the bearing housing seal using tools MB990936-01 and MB990938-01, after lubricating and installing the inner race of bearing N1.
25. Press the inner race of bearing N₂ onto the axle shaft using tool MB990799.
Attention! Both bearing races must be pressed tightly against each other. The rear axle half shafts with limited slip differential have different lengths (the right axle shaft is longer).
26. Press the bearing retaining ring onto the axle shaft using the MB990799-01 tool with an initial force of 5 Tf and a final force of 10–11 Tf.
Caution! If the final force is less than specified, replace the axle shaft.
27. After installing the retaining ring, check the gap A between the retaining (1) and locking (2) rings, which should not exceed 0.166 mm.
28. Otherwise, select the retaining ring by thickness, using the following thickness color coding: 2.17 mm – none, 2.01 – yellow, 1.85 – blue, 1.69 – pink, 1.53 – red.
29. Tighten all connections to the required torques.