Spacer Selection For Differential Case Preload Adjustment

<Measurement using a Solder>

1. Put solders [1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential assembly into the transaxle case.
   NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.
3. Install the clutch housing and tighten the bolts to the specified torque.
Fig 1: Identifying Solders
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb) 

4. Remove the clutch housing, and then remove the differential assembly.
5. Remove the taper bearing outer race and take out crushed solders.
6. If the solders have not crushed, use thicker solders [1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long] and repeat steps  2 to 5.
Fig 2: Measuring Thickness Of Crushed Solder With Micrometer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Measure the thickness of the crushed solder with a micrometer and select a spacer that will provide the standard preload value.

Standard value: 

0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload 

<Measurement using Plastigage>

1. Put plastigage [about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case.
2. Install the thinnest spacer.
3. Install the taper bearing outer race and differential assembly into the transaxle case.
   NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.
4. Install the clutch housing and tighten the bolts to the specified torque.
Fig 3: Identifying Plastigage
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb) 

5. Remove the clutch housing, and then remove the differential assembly.
6. Remove taper bearing outer race and the spacer.
7. If the Plastigage have not crushed, replace the spacer with a thicker one and repeat steps  2 to 7.
8. Measure the width of the crushed Plastigage at its widest part using a scale printed on the Plastigage package.

   Standard value: 

   0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload 

   Fig 4: Measuring Width Of Crushed Plastigage

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.