Mitsubishi Outlander (2003+). Manual — part 239

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-27

Use the following special tools to press-fit the drive
pinion rear bearing outer race.

•

Installer bar (MB990938)

•

Installer adapter (MB990935)

>>C<< DRIVE PINION FRONT BEARING OUTER
RACE PRESS-FITTING

Use the following special tools to press-fit the drive
pinion front bearing outer race.

•

Installer bar (MB990938)

•

Installer adapter (MB990932)

>>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following
procedures:
1. Apply multipurpose grease to the washer of

special tool drive pinion gauge asseembly
(MB990836).

2. Install special tool, drive pinion front and rear

bearing inner races to the differential carrier as
shown in the illustration.

CAUTION

There should be no gear oil adhered to the
bearing.

3. Tighten the nut of special tool a little at a time,

while measuring the turning torque of the drive
pinion by using the following special tools. Then
confirm that the turning torque (without the drive
pinion oil seal) is at the standard value.

•

Preload socket (MB990326)

•

Torque wrench (MB990685)

Standard value:

NOTE: Because the special tool preload socket
(MB990326) cannot be turned one turn, turn it
several times within the range that it can be
turned; then, after fitting to the bearing, measure
the turning torque.

4. Clean the side bearing seat of the differential

carrier and bearing caps.

AC102908

MB990938

MB990932

AD

AC102909

MB990836

AC

Bearing division

Turning torque

New

0.9

−

1.2 N

⋅

m

AC102910 AD

MB990836

AC102911

MB990326

AC

MB990685

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-28

5. Place the following special tools in the side

bearing seat of the differential carrier, and position
the notch as shown in the illustration. Then install
the bearing caps.

•

Cylinder gauge (MB990392)

•

Drive pinion gauge assembly (MB990836)

6. Use a thickness gauge to measure the clearance

(A) between special tools.

7. Remove the bearing caps and special tools.

8. Use a micrometer to measure the shown

dimensions (B, C) of special tools.

9. Install the bearing cap, and then use a cylinder

gauge to measure the inside diameter (D) of the
bearing cap.

10.Calculate thickness (F) of the required drive

pinion rear shim by the following formula. Select a
shim which most closely matches this thickness.
F = A + B + C

−

1/2D

−

86.00 mm

11.Fit the selected drive pinion rear shim(s) to the

drive pinion, and press-fit the drive pinion rear
bearing inner race by using special tool bearing
installer (MB990728).

>>E<< DRIVE PINION TURNING TORQUE
ADJUSTMENT/OIL SEAL INSTALLATION
Adjust the drive pinion turning torque by the following
procedures:
1. Insert the drive pinion into the differential carrier,

and then install the following parts in sequence
from the carrier rear side: drive pinion spacer,
drive pinion front shim , drive pinion front bearing
inner race and companion flange.
NOTE: Do not install the oil seal.

2. Tighten the companion flange self-locking nut to

the specified torque while holding the companion
flange with special tool end yoke holder
(MB990850).

Tightening torque: 186

±

29 N

⋅

m

AC102912

MB990836

A

AD

Notch

Thickness
gauge

MB990392

AC102913

C

B

AC

AC102914

Cylinder gauge

AC

D

ACX02432

MB990728

MB990728

MB990728

AD

Drive pinion
rear shim

AC201179 AB

MB990850

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-29

CAUTION

There should be no gear oil adhered to the
bearing.

3. Use the following special tools MB990685 and

MB990326 to measure the drive pinion turning
torque (without the drive pinion oil seal).

•

Preload socket (MB990326)

•

Torque wrench (MB990685)

Standard value:

4. If the drive pinion turning torque is not within the

standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE:

When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of
shims to a minimum by selecting the drive pinion
spacers.
Select the drive pinion spacer from the following
two types.

5. Remove the companion flange and drive pinion

again. Then insert the drive pinion front bearing
inner race into the differential carrier. Use special
tool oil seal installer (MB990031 or MB990699) to
press-fit the drive pinion oil seal.

6. Install the drive pinion assembly and companion

flange with the mating marks properly aligned.
Tighten the companion flange self-locking nut to
the specified torque while holding the companion
flange with special tool.

Tightening torque: 186

±

29 N

⋅

m

Bearing division

Turning torque

New

0.9

−

1.2 N

⋅

m

ACX01062

MB990326

AD

MB990685

ACX01063

Identifi-
cation
colour

A

AE

Height of drive pinion
spacer (A) mm

Identification colour

57.08

Red

57.72

−

ACX01064 AG

MB990031
or
MB990699

AC201179 AB

MB990850

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-30

7. Use special tools to measure the drive pinion

turning torque (with drive pinion oil seal) to verify
that the drive pinion turning torque complies with
the standard value.

Standard value:

8. If the turning torque is not within the standard

value, check the tightening torque of the
companion flange self-locking nut, and the
installation of the oil seal.

>>F<< DIFFERENTIAL GEAR BACKLASH
ADJUSTMENT
Adjust the differential gear backlash by the following
procedure:

1. Assemble the side gears, side gear spacers,

pinion gears, and pinion washers into the
differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not assemble the lock pin yet.

3. Insert a wedge between the side gear and the

pinion shaft to lock the side gear.

4. While locking the side gear with the wedge,

measure the differential gear backlash with a dial
indicator on the pinion gear.
Measure by the same procedure for the other
pinion gear.

Standard value: 0

−

0.076 mm

Limit: 0.2 mm

5. If the backlash exceeds the limit value, adjust it by

replacing the side gear spacers.

6. If adjustment is not possible, replace the side

gears and pinion gears as a set.

7. Check that the backlash is within the limit value

and that the differential gear turns smoothly.

>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the

differential case lock pin hole, and drive in the lock
pin.

2. Stake the lock pin with a punch on both sides.

Bearing
division

Companion flange
lubrication

Turning torque

New

None (with anti-rust
agent)

1.0

−

1.3 N

⋅

m

Gear oil applied

0.5

−

0.6 N

⋅

m

ACX01062

MB990326

AD

MB990685

ACX01066

AC102885

Wedge

Side gear
spacer

AC

Side gear
spacer

ACX02429AC