< Measurement using a solder >

CAUTION:

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.

Install the input shaft, output shaft and center differential as a set to the clutch housing.
NOTE: If necessary, replace the input shaft, output shaft, center differential case and/or bearings before carrying out these adjustments.

Fig 1: Installing Input Shaft, Output Shaft And Center Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39 in) long] on the input shaft rear bearing at the positions shown in the illustration.

Fig 2: Putting Solders On Input Shaft Rear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39 in) long) on the transaxle case at the positions shown in the illustration.
Install the bearing outer races of the center differential and output shaft.
Install the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 44 +/- 5 N. m (32 +/- 3 ft-lb)

Fig 3: Putting Solders On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 4: Identifying Solders
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transaxle case.
Remove the outer races and take out the crushed solders.
If the solders have not crushed, use thicker solders [1.6 mm (0.063 in) diameter, about 10 mm (0.39 in) long] and repeat steps 4 to 7.
Measure the thickness of the crushed solder with a micrometer and select spacers that will provide the standard end play/preload value.
Standard value:

Input shaft end play: 0.05 -0.17 mm (0.0020 -0.0067 inch)

Output shaft preload: 0.13 -0.18 mm (0.0051 -0.0071 inch)

Center differential case preload: 0.05-0.11 mm (0.0020 -0.0043 inch)

Fig 5: Measuring Thickness Of Crushed Solder With Micrometer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.