Mitsubishi L200. Manual — part 385

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-45

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

ACX01051AB

Oil seal

MB990938

MB990934

Use the following special tools to insert the oil seal,
and then apply a thin coat of multipurpose grease to
the lip of the oil seal.

• Installer bar (MB990938)

• Installer adapter (MB990934)

>>B<< DRIVE PINION REAR BEARING OUTER
RACE INSTALLATION

AC004801 AB

MB990938

MB990936

Use the following special tools to press-fit the drive
pinion rear bearing outer races into the gear carrier.

• Installer bar (MB990938)

• Installer adapter (MB990936)

>>C<< DRIVE PINION FRONT BEARING OUTER
RACE INSTALLATION

AC004802

MB990938

MB990934

AB

Use the following special tools to press-fit the drive
pinion rear bearing outer races into the gear carrier.

• Installer bar (MB990938)

• Installer adapter (MB990934)

>>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height as follows:

ACX01054 AB

MB990819

Washer

1. Apply multipurpose grease to the washer of

special tool drive pinion gauge assembly
(MB990819).

2. Install special tool, drive pinion front and rear

bearing inner races to the gear carrier.

CAUTION

There should be no gear oil adhered to the bear-
ing.

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

MB990685

3. Tighten the nut of special tool while measuring the

turning torque of the drive pinion by using the
following special tools. Gradually keep tightening
the nut of special tool until the turning torque of
the drive pinion (without oil seal) is at the standard
value.

• Preload socket (MB990326)

• Torque wrench (MB990685)

• Drive pinion gauge assembly (MB990819)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-46

Standard value:

Bearing
division

Bearing
lubrication

Turning torque

New

None (with anti-
rust agent)

0.83

− 1.19 N⋅m

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 seat of the differential

carrier and bearing caps.

ACX01057 AC

Thickness gauge

MB990819

A

MB991170

Notch

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 (MB991170)

• Drive pinion gauge assembly (MB990819)

6. Use a thickness gauge to measure the clearance

(A) between special tools.

7. Remove the bearing caps and special tools.

ACX01058

MB991170

B

C

AE

MB990819

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 and micrometer to measure the inside
diameter (D) of the bearing cap as shown in the
illustration.

10.Calculate the thickness (E) of the required drive

pinion rear shim by the following formula, and
then select a shim which most closely matches
this thickness.

E = A + B + C - 1/2D - 100.0 mm

ACX01060

Drive
pinion
rear
shim

MB990802

MB990802

AC

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

drive pinion, and press-fit the drive pinion front
bearing inner race by using special tool bearing
installer (MB990802).

>>E<< DRIVE PINION TURNING TORQUE
ADJUSTMENT
Adjust the drive pinion turning torque by using the
following procedure:
1. Insert the drive pinion into the gear carrier, and

then install the drive pinion spacer, the drive
pinion front shim, the drive pinion front bearing
inner race, and the companion flange in that
order.
NOTE: Do not install the oil seal.

AC004803 AB

MB990767

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-47

2. Tighten the companion flange self-locking nut to

the specified torque while holding the companion
flange with special tool front hub and flange yoke
holder (MB990767).

Tightening torque: 216

± 29 N⋅m

CAUTION

There should be no gear oil adhered to the

bearing.

ACX01062AB

MB990326

MB990685

3. Use the following special tools to measure the

drive pinion turning torque (without the oil seal).

• Preload socket (MB990326)

• Torque wrench (MB990685)

Standard value:

Bearing
division

Bearing
lubrication

Turning torque

New

None (with anti-
rust agent)

0.83

− 1.19 N⋅m

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

range of the standard value, adjust the preload by
replacing the drive pinion front shim(s) or the drive
pinion spacer.

NOTE:

ACX01063 AB

Identification
colour

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.

Height of drive pinion
spacer mm

Identification colour

56.67

White

57.01

−

ACX01064 AB

MB990031
or
MB990699

5. Remove the companion flange and drive pinion

again. Then, after inserting the drive pinion front
bearing inner race into the gear carrier, use
special tool oil seal installer (MB990031 or
MB990699) to press-fit the oil seal.

AC004803 AB

MB990767

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-48

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: 216

± 29 N⋅m

ACX01062AB

MB990326

MB990685

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:

Bearing
division

Bearing
lubrication

Turning torque

New

None (with anti-
rust agent)

0.89

− 1.78 N⋅m

Gear oil applied 0.97

− 1.32 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.

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

ACX01066AB

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 drive in the 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.
Measure by the same procedure for the other
pinion gear.
Standard value: 0.01

− 0.250 mm

5. If the backlash exceeds the standard 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. Measure the differential gear backlash once

again, and confirm that it is within the standard.

>>G<< LOCK PIN INSTALLATION

ACX01067AB

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 at two points.

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