1) What a viscous coupling (VC) is — theory
- A VC is a passive torque-transfer device inside the center differential/transfer case. It contains alternating thin metal plates (driven and driving) immersed in a silicone-based viscous fluid.
- Under normal small speed differentials the fluid shears and allows relative rotation with minimal torque transfer. When the speed difference increases (slip, one axle spins faster), shear heating raises the effective viscosity of the silicone and the fluid transmits torque between plate packs, locking the input and output more tightly.
- It is a viscous shear clutch: no electronics, no active control. Its torque transfer depends on fluid properties, plate condition, temperature and clearances.
- Failure modes: fluid degradation or leakage (loss of viscosity), internal mechanical wear or broken plates, contamination, or the unit becoming seized. Symptoms: excessive differential slip (poor traction), shuddering, binding in turns, excessive heat/noise, or erratic lock-up.

2) How the fault manifests on a Mitsubishi 6G72 AWD vehicle
- 6G72-installed AWD models use a viscous unit in the transfer case/center diff. Common symptoms: one axle spinning under acceleration, shudder or judder during acceleration or cornering, harshness/drag on turns, or inability to transfer torque to the slipping axle.
- Cause mapping: slip + reduced lock-up → fluid breakdown or plate wear. Binding in turns → stuck or overlocking plates or warped pack.

3) Diagnose (ordered)
1. Road-test to confirm symptoms: note when shudder, spin or binding occurs and which axle acts up.
2. Visual inspection: check transfer-case seals, output shaft seals, boot condition and for fluid leaks.
3. Lift car safely, support on stands. Spin front and rear shafts by hand/with low rpm and feel for smoothness/freeplay. If one end spins freely while other resists, VC may be failing.
4. Check transfer-case fluid level and condition (metallic particles, burnt smell, thin/watery consistency = degraded VC fluid).
5. If possible, remove access cover (if vehicle allows) to inspect VC pack for obvious damage.

4) Removal and replacement (ordered, safety first)
- Safety: park on level surface, chock wheels, disconnect battery, use rated jack and stands, drain fluids into approved container.
1. Drain transfer case/center diff fluid.
2. Remove propshaft/driveshafts as required to access the transfer case/center diff. Mark orientation for reassembly.
3. Remove transfer-case/center-diff cover or remove unit from vehicle to access VC assembly (follow model removal sequence — bolts, sensors, linkage).
4. Extract the VC assembly from the diff housing. Inspect surrounding bearings, seals, and differential gears for collateral damage.
5. Disassemble VC if reconditioning is attempted: remove end plates, inspect clutch/plate pack, springs, and damper elements. (Most recommended: replace as a complete OE unit; disassembly and refilling with aftermarket fluid rarely restores original characteristics reliably.)
6. Fit new VC assembly or rebuilt OE unit, with new seals/O-rings.
7. Reinstall transfer-case components in reverse order. Replace any worn seals or bearings encountered.
8. Refit driveshafts/propshafts to the marked positions.
9. Refill with the manufacturer-specified transfer-case/VC fluid to the correct level. Use the exact spec (type and viscosity) — VC performance depends on fluid chemistry.
10. Torque fasteners to factory specs, replace gaskets or use correct sealant where required.

5) Post-repair checks (ordered)
1. Start engine, cycle through drive modes/4WD selector if present, check for leaks.
2. With vehicle supported, rotate shafts and check for smooth operation and correct resistance.
3. Road-test under the same conditions that produced symptoms. Confirm elimination of shudder, binding, or slip.
4. Re-check fluid level after warm-up and on follow-up.

6) How the repair fixes the fault (theory tied to steps)
- Replacing the VC restores the correct plate clearances, spring/damper function and the original silicone fluid chemistry. That returns the designed shear characteristics so the unit only locks when a speed differential and shear heating occur.
- If fluid was degraded or contaminated, viscosity and shear-thickening behavior were lost; replacing the fluid/VC re-establishes torque transfer under slip. If plates were worn or broken, mechanical decoupling or irregular contact caused slip or chatter; replacement restores smooth engagement.
- If the VC was seized or partially locked, replacing it removes the source of binding in turns and reduces drivetrain stress.
- Replacing associated seals/bearings eliminates leaks and secondary failures that would otherwise degrade a new unit.

7) Practical notes (short)
- Use OEM or quality equivalent VC — silicone chemistry and plate tolerances matter.
- Avoid “top-up” fixes if fluid is contaminated or plates are worn — they’re usually temporary.
- Observe torque specs and correct fluids; improper fluid or assembly changes the VC engagement characteristics and can reintroduce problems.

End.
rteeqp73

Mitsubishi 6G72 engine, 3.0L, V6, 12 and 24 valves, Tightening torque for crankshaft, connecting ... Mitsubishi 6G72 engine, 3.0L, V6, 12 and 24 valves. Tightening torque for crankshaft, connecting rod, cylinder head.

JDM Mitsubishi 6G72 Engine Compression Test

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