Mitsubishi L200. Manual — part 394
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE
27-27
DISASSEMBLY
M1272002200560
CAUTION
Do not disassemble the limited slip differential case assembly.
AC611940AC
<Limited slip differential>
<Conventional differential>
4
5
6
13
10
9
11
12
8 7
14
6
5
2
1
13
12
10
11
28
1
2
5 6
7
15
6 5
2
4
1
1
2
3
3
29
27
25
26
17
16
N
N
<Vehicles without rear differential lock>
18
19
20 21
22 23
24
Disassembly steps
<<
A
>>
•
Inspection before disassembly
1. Lock plate
<<
B
>>
2. Side bearing nut
3. Bearing cap
<<
C
>>
4. Differential case assembly
5. Differential side bearing outer race
<<
D
>>
6. Differential side bearing inner race
<<
E
7. Drive gear
<<
F
8. Lock pin
9. Pinion shaft
10. Pinion gear
11. Pinion washer
12. Side gear
13. Side gear spacer
14. Differential case
15. Limited slip differential case assembly
<<
G
>>
16. Self-locking nut
17. Washer
<<
H
>>
18. Companion flange
<<
H
>>
19. Drive pinion assembly
20. Drive pinion front shim (For adjusting
preload of drive pinion)
21. Drive pinion spacer
<<
I
>>
22. Drive pinion rear bearing inner race
23. Drive pinion rear shim (for adjusting
drive pinion height)
24. Drive pinion
<<
J
>>
25. Oil seal
<<
J
>>
26. Drive pinion front bearing inner race
<<
J
>>
27. Drive pinion front bearing outer race
<<
K
>>
28. Drive pinion rear bearing outer race
29. Differential carrier
Disassembly steps (Continued)
AC804640AB
11
10
N
<Vehicles with rear differential lock>
N
N
N
2
2
3
13
12
1
3
4
5
6
7
8
9
14
15
16
17
18
19
20
21
22
23
24 25
26 27 28
29
30 31
32
33
9 8
Disassembly steps
<<
A
>>
•
Inspection before disassembly
1. Hose
2. Lock plate
<<
B
>>
3. Side bearing nut
4. Bolt
5. Bolt
6. Bearing cap
<<
C
>>
7. Differential case assembly
8. Differential side bearing outer race
<<
D
>>
9. Differential side bearing inner race
10. Actuator assembly
11. Pressure plate
<<
E
12. Drive gear
13. Differential case
14. Air pipe assembly (A)
15. Eye bolt
16. Air pipe assembly (B)
17. Gasket
18. Rear differential lock detection switch
19. Gasket
<<
G
>>
20. Self-locking nut
21. Washer
<<
H
>>
22. Companion flange
<<
H
>>
23. Drive pinion assembly
24. Drive pinion front shim (for adjusting
preload of drive pinion)
25. Drive pinion spacer
<<
I
>>
26. Drive pinion rear bearing inner race
27. Drive pinion rear shim (for adjusting
drive pinion height)
28. Drive pinion
<<
J
>>
29. Oil seal
<<
J
>>
30. Drive pinion front bearing inner race
<<
J
>>
31. Drive pinion front bearing outer race
<<
K
>>
32. Drive pinion rear bearing outer race
33. Differential carrier
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE
27-28
DISASSEMBLY SERVICE POINTS
<<A>> INSPECTION BEFORE DISASSEMBLY
Except for the following standard values, inspection
procedure is the same as GROUP 26, inspection
before disassembly .
Drive gear backlash
Standard value:
0.07
− 0.13 mm <2WD (except High rider)>
0.08
− 0.18 mm <2WD High rider, 4WD>
<<B>> SIDE BEARING NUT REMOVAL
AC004921AB
MB991385
MB991367
Use the following special tools, remove the side
bearing nut.
• Special spanner (MB991367)
• Pin (MB991385)
NOTE: Keep the right and left side bearings and side
bearing nuts separate, so that they do not become
mixed at the time of assembly.
Disassembly steps (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE
27-29
<<C>> DIFFERENTIAL CASE ASSEMBLY
REMOVAL
CAUTION
When taking out the differential case assembly,
be careful not to drop and damage the differential
side shims or the side bearing outer races.
ACX02422
Use the wooden handle of a hammer to remove the
differential case assembly, differential side shims and
side bearings.
NOTE: Keep the right and left side bearings and side
bearing outer race separated, so that they do not
become mixed at the time of assembly.
<<D>> SIDE BEARING INNER RACE REMOVAL
AC203814 AC
MB990810
MB991407
Use the following special tools to pull out the side
bearing inner race.
• Side bearing puller (MB990810)
• Differential support bush arbour (MB991407)
NOTE: Attach the prongs of special tools to the inner
race of the side bearing through the openings in the
differential case.
<<E>> DRIVE GEAR REMOVAL
ACX01042AB
Mating
marks
1. Make mating marks to the differential case and
the drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
<<F>> LOCK PIN REMOVAL
ACX01048AB
Punch
Drive out the lock pin with a punch.
<<G>> SELF-LOCKING NUT REMOVAL
ACX01043AB
MB990850
Use special tool end yoke holder (MB990850) to hold
the companion flange, and then remove the compan-
ion flange self-locking nut.
DIFFERENTIAL CARRIER ASSEMBLY
REAR AXLE
27-30
<<H>> DRIVE PINION ASSEMBLY/COMPANION
FLANGE REMOVAL
CAUTION
Do not make mating marks on the contact sur-
faces of the companion flange and propeller
shaft.
1. Make mating marks to the drive pinion and
companion flange.
AC102894
MB990810
AD
Companion
flange
2. Use special tool side bearing puller (MB990810)
to pull out the companion flange.
<<I>> DRIVE PINION REAR BEARING INNER
RACE REMOVAL
AC104970AC
MD998801
Use special tool remover (MD998801) to pull out the
front bearing inner race.
<<J>> OIL SEAL/DRIVE PINION FRONT BEARING
INNER RACE/DRIVE PINION FRONT BEARING
OUTER RACE REMOVAL
ACX01101AB
Drive pinion front
bearing outer race
Drive pinion front
bearing inner
race
Oil seal
Drive pinion rear
bearing outer
race
MB990939
Use special tool brass bar (MB990939) to remove
the drive pinion front bearing outer race.
<<K>> DRIVE PINION REAR BEARING OUTER
RACE REMOVAL
ACX01102 AB
MB990939
Use special tool brass bar (MB990939) to remove
the drive pinion rear bearing outer race.
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