Mitsubishi Outlander (2003+). Manual — part 238
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE <4WD>
27B-23
DISASSEMBLY SERVICE POINTS
<<A>> DIFFERENTIAL CASE
ASSEMBLY/DIFFERENTIAL SIDE BEARING
SPACER/DIFFERENTIAL SIDE BEARING OUTER
RACE REMOVAL
CAUTION
When taking out the differential case assembly,
be careful not to drop and damage the differential
side bearing spacers and differential side
bearing outer races.
Use the wooden handle of a hammer to remove the
differential case assembly, differential side bearing
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side
bearing spacers separate, so that they do not
become mixed during reassembly.
<<B>> DIFFERENTIAL SIDE BEARING INNER
RACE REMOVAL
Use special tool side bearing puller (MB990810) to
pull out the side bearing inner races.
NOTE: There are two notches provided (at the
differential case side) for the claw part of the special
tools; use special tool at that position.
<<C>> DRIVE GEAR REMOVAL
1. Make the mating marks to the differential case
and the drive gear.
2. Loosen the drive gear attaching bolts in a
diagonal sequence to remove the drive gear.
<<D>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.
<<E>> SELF-LOCKING NUT REMOVAL
Use special tool end yoke holder (MB990850) to hold
the companion flange, and then remove the
companion flange self-locking nut.
AC102889
AC107274 AB
MB990810
Socket
wrench
AC102891
Mating
marks
AC
AC102892
AC102893AC
MB990850
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE <4WD>
27B-24
<<F>> DRIVE PINION ASSEMBLY/COMPANION
FLANGE REMOVAL
CAUTION
The mating mark made on the companion flange
must not be on the coupling surface of the
companion flange and the front propeller shaft.
1. Make mating marks on the drive pinion and
companion flange.
2. Use special tool side bearing puller (MB990810)
to pull out the companion flange.
<<G>> DRIVE PINION REAR BEARING INNER
RACE REMOVAL
Use the following special tools to pull out the drive
pinion rear bearing inner race.
•
Bearing puller (MB990339)
•
Pinion bearing remover (MB990374)
<<H>> OIL SEAL/DRIVE PINION FRONT
BEARING INNER RACE/DRIVE PINION FRONT
BEARING OUTER RACE REMOVAL
Use special tool bras bar (MB990939) to remove the
oil seal, drive pinion front bearing inner race, and
drive pinion front bearing outer race.
<<I>> DRIVE PINION REAR BEARING OUTER
RACE REMOVAL
Use special tool brass bar (MB990939) to remove
the drive pinion rear bearing outer race.
AC102894
MB990810
AD
Companion
flange
AC102895AD
MB990374
MB990339
AC102896 AC
MB990939
Drive pinion
front bearing
inner race
Oil seal
Drive pinion
front bearing
outer race
AC102897
MB990939
AC
Drive pinion
rear bearing
outer race
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE <4WD>
27B-25
REASSEMBLY
M1272002300288
AC301213
22 23
24
25
26
20
17
10
11
14
13
12
15
16
6
1
3
8
9
7
5
2
34
29
28
27
21
19
18
N
32
N
N
4
N
186 ± 29 N·m
17 18
19
20
24
25
26
64 ± 4 N·m
84 ± 4 N·m
36 ± 5 N·m
49 ± 9 N·m
37 ± 2 N·m
15
5
23
17
18
17
18
20
20
AB
Final drive gear set
Differential gear set
37 ± 2 N·m
N
N
31
30
33
Reassembly steps
1. Differential carrier
>>A<<
2. Oil seal
>>B<<
3. Drive pinion rear bearing outer race
>>C<<
4. Drive pinion front bearing outer race
>>D<<
•
Drive pinion height adjustment
5. Drive pinion
6. Drive pinion rear shim (for adjusting
drive pinion height)
7. Drive pinion rear bearing inner race
8. Drive pinion spacer
>>E<<
•
Drive pinion turning torque
adjustment
9. Drive pinion front shim (for adjusting
drive pinion turning torque)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
>>E<<
12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut
16. Differential case
>>F<<
•
Differential gear backlash adjustment
17. Side gear spacer
18. Side gear
19. Pinion washer
20. Pinion gear
21. Pinion shaft
>>G<<
22. Lock pin
>>H<<
23. Drive gear
>>I<<
24. Differential side bearing inner race
25. Differential side bearing outer race
26. Differential side bearing spacer
27. Differential case assembly
>>J<<
28. Bearing cap
29. Vent plug
30. Differential cover
31. Packing
32. Drain plug
33. Gasket
34. Filler plug
>>J<<
•
Final drive gear backlash adjustment
Reassembly steps (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE <4WD>
27B-26
Lubrication and Adhesive Points
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL PRESS-FITTING
Use the following special tools to press-fit a new oil
seal.
•
Installer bar (MB990938)
•
Oil seal installer (MB991115)
>>B<< DRIVE PINION REAR BEARING OUTER
RACE PRESS-FITTING
AC301214AB
2 3 mm
(bead diameter)
–
Adhesive:
Semi-driying sealant:
3M ATD Part No.8661 or equivalent
3M Stud Locking 4170 or
equivalent
Vent plug
AC102740
MB990938
MB991115
AC
AC102907
MB990938
MB990935
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