Front Axle Total Backlash Check

WARNING: This page is about a different car, the 2005 Mitsubishi Montero. However, it is still accessible from the selected car via links, so may be relevant.

When the ignition switch is in "LOCK" (OFF) position, the front wheel comes to a stop after turning the propeller shaft by hand due to the force applied to front wheel actuator. Inspect the vehicle as follows:

Turn the ignition switch to "LOCK" (OFF) position, and then put the transfer shift lever to the "2H" position.
CAUTION: Do not jack up the vehicle.
Turn the propeller shaft until a click is heard.
Turn the companion flange clockwise until all play is eliminated, and then align the mating mark on the dust cover with the mating mark on the differential carrier.

Fig 1: Aligning Mating Marks On Dust Cover And Differential Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn the companion flange counterclockwise until all play is eliminated and measure the distance through which the mating marks moved.
- Limit: 11 mm (0.4 inch)
If the amount of movement exceeds the limit value, check the following.
- Final drive gear backlash
- Differential gear backlash
- Play in the serrations and splines of the side gears, drive shaft, and drive flange
  
  Fig 2: Measuring Distance Through Which Mating Marks Moved
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.