Mitsubishi L200. Manual — part 386

ACX01068AB

Tap

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-49

2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x
1.25), and then clean the threaded holes by
applying compressed air.

AC000438 AB

3. Apply the specified adhesive to the threaded

holes of the drive gear.

Specified adhesive:: LOCKTITE 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

± 4 N⋅m

>>I<< DIFFERENTIAL SIDE BEARING INNER
RACE INSTALLATION

ACX01069AC

MB990802

MB990802

Piece of
metal

Piece of
metal

Use special tool bearing installer (MB990802) to
press-fit the differential side bearing inner races into
the differential case.

>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following pro-
cedures:

ACX01070 AB

1. Install the side bearing spacers, which are thinner

than those removed, to the side bearing outer
races, and then mount the differential case
assembly into the gear carrier.
NOTE: Select side bearing spacers with the same
thickness for both the drive pinion side and the
drive gear side.

ACX01071AB

2. Push the differential case assembly to one side,

and measure the clearance between the gear
carrier and the side bearing adjusting spacer with
a feeler gauge.

ACX01072 AC

Clearance/2 + 0.05 mm =
Thickness of the spacer on
one side

3. Measure the thickness of the side bearing

adjusting spacers on one side, select two pairs of
spacers which correspond to that thickness plus
one half of the clearance plus 0.05 mm, and then
install one pair each to the drive pinion side and
the drive gear side.

ACX01070 AB

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-50

4. Install the side bearing adjusting spacers and

differential case assembly, as shown in the
illustration, to the gear carrier.

ACX01073 AB

MB990939

5. Tap the side bearing adjusting spacers with

special tool remover bar (MB990939) to fit them to
the side bearing outer race.

ACX01074AB

6. Align the mating marks on the gear carrier and the

bearing cap, and then tighten the bearing cap.

Tightening torque: 59

± 4 N⋅m

ACX01034AB

7. With the drive pinion locked in place, measure the

drive gear backlash with a dial indicator on the
drive gear.
NOTE: Measure at four points or more on the cir-
cumference of the drive gear.

Standard value: 0.11

− 0.16 mm

ACX01075

If backlash is too small

Thinner
spacer

Thicker
spacer

AB

If backlash is too large

Thicker
spacer

Thinner
spacer

8. Change the side bearing adjusting spacers as

illustrated, and then adjust the drive gear
backlash between the drive gear and the drive
pinion.
NOTE: When increasing the number of side bear-
ing adjusting spacers, use the same number for
each, and as few as possible.

9. Check the drive gear and drive pinion for tooth

contact. If poor contact is evident, make
adjustment. (Refer to

P.26-38

.)

ACX01036 AB

10.Measure the drive gear runout at the shoulder on

the reverse side of the drive gear.

Limit: 0.05 mm

11.If the drive gear runout exceeds the limit, reinstall

by changing the phase of the drive gear and
differential case, and remeasure.

12.If adjustment is not possible, replace the

differential case or replace the drive gear and
drive pinion as a set.

SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>

FRONT AXLE

26-51

SOLENOID VALVE AND VACUUM HOSE <4WD except for

RUSSIA>

REMOVAL AND INSTALLATION

M1262004500083

AC903982

12

2

13

10

16

7

6

5

4

1

3

14

8

12 ± 2 N·m

15

5.0 ± 1.0 N·m

12 ± 2 N·m

AB

12 ± 2 N·m

12

12

9

11

Solenoid valve assembly removal
steps

1. Solenoid valve connector

2. Solenoid valve assembly

Vacuum tank and vacuum hose
assembly and vacuum pipe assembly
removal steps

3. Vacuum hose

4. Vacuum tank

5. Vacuum pipe assembly

6. Vacuum hose

7. Vacuum hose

8. Vacuum valve cap

9. Vacuum hose

10. Breather cap

11. Vacuum pipe

12. Vacuum hose

>>

B

<< 13. Check valve

>>

A

<< 14. Vacuum hose

>>

A

<< 15. Vacuum pipe assembly

>>

A

<< 16. Vacuum hose assembly

Vacuum tank and vacuum hose
assembly and vacuum pipe assembly
removal steps (Continued)

SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>

FRONT AXLE

26-52

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE ASSEMBLY/VACUUM
PIPE ASSEMBLY/VACUUM HOSE INSTALLATION

AC500427AB

Actuator

Identification
colour (blue)

Identification
colour (yellow)

1. Install the vacuum hoses so that they match the

identification colours of the actuator assembly
nipple.

AC500725

AB

Vacuum pipe
assembly

Yellow mark
and stripe

Blue mark
and stripe

Yellow mark
and stripe

Blue mark
and stripe

2. Install the vacuum hose assembly and the

vacuum hoses to the vacuum pipe assembly, so
that colour mark (yellow or blue) of the vacuum
pipe assembly will match colour stripe (yellow or
blue) at the vacuum hose assembly and vacuum
hoses.

>>B<< CHECK VALVE INSTALLATION

ACX01077AB

Vacuum side

Air direction arrow

Solenoid
valve side

Install so that the air direction arrow points to the
vacuum side.