Mitsubishi L200. Manual — part 396

Bearing type

Bearing
lubrication

Turning torque

New

None (with anti-
rust agent)

0.59

− 0.88 N⋅m

New or reuse

Gear oil applied 0.39

− 0.49 N⋅m

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-35

NOTE: Because 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 hub.

ACX01109 AL

Notch

A

Thickness
gauge

MB990820
(MB990819) or MB991169

MB991170,
MB991534

5. Place the following special tools between the side

bearing hub of the gear carrier, and position the
notch as shown in the illustration. Then tighten
side bearing mounting bolt.

• Cylinder gauge (MB991170) <5A/T or except

vehicles with High power engine>

• Cylinder gauge (MB991534) <Vehicles with High

power engine except 5A/T>

• Pinion [MB990820 (MB990819)] <2WD (except

High rider)>

• Drive pinion gauge attachment (MB991169)

<2WD High rider, 4WD>

6. Use a thickness gauge to measure the clearance

(A) between the special tools.

7. Remove the special tools.

AC102913

C

B

AC

8. Use a micrometer to measure the shown

dimensions (B, C) of special tools.

AC102914

Cylinder gauge

AC

D

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

− 1/2D − 100.00 mm <2WD

(except High rider)>

F = A + B + C

− 1/2D − 115.00 mm <2WD High

rider, 5A/T or except vehicles with High
power engine>

F = A + B + C

− 1/2D − 120.00 mm <Vehicles

with High power engine except 5A/T>

ACX02428 AE

Drive pinion
rear shim

MB990802

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 (MB990802).

>>D<< DRIVE PINION PRELOAD ADJUSTMENT
1. Insert the drive pinion into the gear carrier, and

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

AC201179 AB

MB990850

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-36

2. Tighten the companion flange to the specified

torque by using special tool end yoke holder
(MB990850).

Tightening torque: 216

± 29 N⋅m

ACX01062AB

MB990326

MB990685

3. Use the following special tools to measure the

drive pinion turning torque (without oil seal).

• Preload socket (MB990326)

• Torque wrench (MB990685)

Standard value:

Bearing type

Bearing
lubrication

Turning torque

New

None (with anti-
rust agent)

0.59

− 0.88 N⋅m

New or reuse

Gear oil applied 0.39

− 0.49 N⋅m

ACX01063

Identifi-
cation
colour

A

AE

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.
Also, select the drive pinion spacer from the fol-
lowing two types.

Height of drive
pinion spacer
(A) mm

Identification
colour

Applicable
model

56.67

−

5A/T or except
vehicles with
High power
engine

57.01

White

52.50

Yellow

Vehicles with
High power
engine except
5A/T

52.84

Red

ACX01064 AD

MB991168

5. Remove the companion flange and drive pinion

again. Then insert the drive pinion front bearing
inner race into the gear carrier. Use special tool
differential oil seal installer (MB991168) to press-
fit the oil seal.

AC201179 AB

MB990850

6. Install the drive pinion assembly and companion

flange with mating marks properly aligned.
Tighten the companion flange self-locking nut to
the specified torque using special tool end yoke
holder (MB990850).

Tightening torque: 216

± 29 N⋅m

ACX01062AB

MB990326

MB990685

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-37

7. Use special tools to measure the drive pinion

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

Standard value:

Bearing
division

Companion
flange
lubrication

Turning torque

New

None (with anti-
rust agent)

0.84

− 1.12 N⋅m

Gear oil applied 0.64

− 0.73 N⋅m

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.

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

ACX01066

1. Assemble the side gears, side gear thrust

spacers, pinion gears, and pinion washers into the
differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not assemble the thrust block and lock
pin yet.

ACX01035 AB

Wedge

Side gear
thrust spacer

Side gear
thrust
spacer

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.

Standard value: 0.01

− 0.25 mm

5. Measure by the same procedure for the other

pinion gear.

6. If the backlash exceeds the limit value, replace

side bearing adjustment spacers.

7. If adjustment is not possible, replace the side

gears and pinion gears as a set.

8. Check that the backlash is within the limit value

and that the differential gear turns smoothly.

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

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

ACX02429

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

>>G<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.

ACX01068AB

Tap

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-38

2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x
1.25). Clean the threaded holes by applying
compressed air.

ACX02430

3. Apply specified adhesive to the threaded holes of

the drive gear.

Specified adhesive: LOCTITE No.271 or
No.270 or equivalent

4. Install the drive gear onto the differential case with

the mating marks properly aligned. Tighten the
bolts to the specified torque in a diagonal
sequence.

Tightening torque:

84

± 5 N⋅m <5A/T or except vehicles with High

power engine>

152

± 15 N⋅m <Vehicles with High power

engine except 5A/T>

>>H<< SIDE BEARING INNER RACE
INSTALLATION

AC102942

AC

MB990728

Piece of
metal

Piece of
metal

Use special tool side and rear bearing inner race
installer (MB990728) to press-fit the side bearing
inner races into the differential case.

>>I<< BEARING CAP INSTALLATION

AC004945 AB

74 ± 4 N·m

Align the mating marks on the gear carrier and the
bearing cap, and then tighten the bearing cap.

>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:

AC004921AB

MB991385

MB991367

1. Using the following special tools, temporarily

tighten the side bearing nut to just before
preloading of the side bearing.

• Special spanner (MB991367)

•

AC004946 AB

Pin (MB991385)

2. Measure the drive gear backlash.

Standard value:

0.07

− 0.13 mm <2WD (except High rider)>

0.08

− 0.18 mm <2WD High rider, 4WD>