Spacer Selection For Input Shaft Preload / Output Shaft Preload / Center Differential Preload Adjustment

< Measurement using solder > 

• If soft solder is not available, select the spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard value cannot be selected using soft solder, select the spacer in accordance with Plastigage method.

1. Install the input shaft, output shaft and center differential as a set to the clutch housing.
   Fig 1: Identifying Input Shaft, Output Shaft

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Put a piece of solder [1.6 mm (0.06 in) diameter, 10 mm (0.39 in) long] on the transaxle case at the positions shown in the illustration.
3. Install the bearing outer races on the pieces of solder.
4. Install the clutch housing to the transaxle case and tighten the bolts to the specified torque.
5. Remove the clutch housing, then remove the bearing outer races and take out crushed pieces of solder.
   NOTE: If the pieces of solder have not crushed, use thicker solders and repeat steps  2 to  3.
   Fig 2: Identifying Solder Diameter

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Measure the thickness of crushed solder with a micrometer, select the spacers that provide the standard preload values and install them.
   • Input shaft

     Input shaft preload 

     Spacer thickness: [T + 0.10 mm (0.0039 inch)] - [T + 0.17 mm (0.0067 inch)] 

     T: Thickness of crushed solder mm (inch) 

     Standard value: 0.10 - 0.17 mm (0.0039 - 0.0067 inch) 

     Fig 3: Identifying Solder Diameter

     Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   • Output shaft

     Output shaft preload 

     Spacer thickness: [T + 0.15 mm (0.0059 inch)] - [T + 0.21 mm (0.0083 inch)] 

     T: Thickness of crushed solder mm (inch) 

     Standard value: 0.15 - 0.21 mm (0.0059 - 0.0083 inch) 

   • Center differential

     Center differential preload 

     Spacer thickness: [T + 0.06 (0.0024 inch)] - [T + 0.12 mm (0.0047 inch)] 

     T: Thickness of crushed solder mm (inch) 

     Standard value: 0.06 - 0.12 mm (0.0024 - 0.0047 inch) 

< Measurement using plastigage > 

1. Install the input shaft, output shaft and center differential as a set to the clutch housing.
   Fig 4: Identifying Input Shaft, Output Shaft

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Install the thinnest spacers in position for measurement.
3. Put a piece of Plastigage [about 10 mm (0.39 in) long] on the transaxle case at the positions shown in the illustration.
4. Install the bearing outer races.
5. Install the clutch housing to the transaxle case and tighten the bolts to the specified torque.
6. Remove the clutch housing, then remove the bearing outer races and take out crushed pieces of Plastigage.
   Fig 5: Identifying Plastigage On Transaxle Case

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. If the pieces of Plastigage have not crushed and clearance measurement is impossible, replace them with thicker ones and repeat steps  3 to  5.
8. Using the scale printed on the Plastigage package, measure the width of crushed pieces of Plastigage at their widest part, select the spacers that provide the standard preload values and install them.
   • Input shaft

     Input shaft preload 

     Spacer thickness: [T1 + T2 + 0.10 mm (0.0039 inch)] - [T1 + T2 + 0.17 mm (0.0067 inch)] 

     Fig 6: Identifying Plastigage On Transaxle Case

     Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

     T1: Thickness of crushed Plastigage mm (inch) 

     T2: Thickness of spacer used for measurement mm (inch) 

     Standard value: 0.10 - 0.17 mm (0.0039 - 0.0067 inch) 

   • Output shaft

     Output shaft preload 

     Spacer thickness: [T1 + T2 + 0.15 mm (0.0059 inch)] - [T1 + T2 + 0.21 mm (0.0083 inch)] 

     T1: Thickness of crushed Plastigage mm (inch) 

     T2: Thickness of spacer used for measurement mm (inch) 

     Standard value: 0.15 - 0.21 mm (0.0059 - 0.0083 inch) 

   • Center differential

     Center differential preload 

     Spacer thickness: [T1 + T2 + 0.06 mm (0.0024 inch)] - [T1 + T2 + 0.12 mm (0.0047 inch)] 

     T1: Thickness of crushed Plastigage mm (inch) 

     T2: Thickness of spacer used for measurement mm (inch) 

     Standard value: 0.06 - 0.12 mm (0.0024 - 0.0047 inch)