Mitsubishi L200. Manual — part 384
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
FRONT AXLE
26-41
<<B>> DIFFERENTIAL CASE ASSEMBLY/
DIFFERENTIAL SIDE BEARING SPACER/
DIFFERENTIAL SIDE BEARING OUTER RACE
REMOVAL
CAUTION
When taking out the differential case assembly,
be careful not to drop and damage the differential
side bearing spacers and differential side bear-
ing outer races.
ACX01040AB
Use the wooden handle of a hammer to remove the
differential case assembly, differential side bearing
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side
bearing adjusting spacers separate, so that they do
not become mixed during assembly.
<<C>> DIFFERENTIAL SIDE BEARING INNER
RACE REMOVAL
ACX01041AC
MB990811
MB990810
Use the following special tools to pull out the side
bearing inner races.
• Side bearing puller (MB990810)
• Differential side bearing cap (MB990811)
NOTE: There are two notches provided (at the differ-
ential case side) for the claw part of the special tools;
use special tools at that position.
<<D>> DRIVE GEAR REMOVAL
AC102891
Mating
marks
AC
1. Make the 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.
<<E>> LOCK PIN REMOVAL
ACX01048AB
Punch
Drive out the lock pin with a punch.
<<F>> SELF-LOCKING NUT REMOVAL
AC004732 AB
MB990767
Use special tool front hub and flange yoke holder
(MB990767) to hold the companion flange, and then
remove the companion flange self-locking nut.
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
FRONT AXLE
26-42
<<G>> DRIVE PINION ASSEMBLY REMOVAL
CAUTION
The mating mark made on the companion flange
must not be on the coupling surface of the flange
yoke and the front propeller shaft.
AC004790 AB
Mating marks
1. Make mating marks on the drive pinion and
companion flange.
2. Drive out the drive pinion together with the drive
pinion spacer and drive pinion shims.
<<H>> DRIVE PINION REAR BEARING INNER
RACE REMOVAL
ACX01045 AB
MB990339
MB990648
Use the following special tools to pull out the front
bearing inner race.
• Bearing puller (MB990339)
• Bearing remover (MB990648)
<<I>> DRIVE PINION FRONT BEARING OUTER
RACE REMOVAL
ACX01046AB
MB990939
Use special tool remover bar (MB990939) to remove
the drive pinion front bearing outer race.
<<J>> DRIVE PINION REAR BEARING OUTER
RACE REMOVAL
ACX01047 AB
MB990939
Use special tool remover bar (MB990939) to remove
the drive pinion rear bearing outer race.
<<K>> OIL SEAL REMOVAL
AC004791 AB
MB990590
Use special tool rear axle shaft oil seal remover
(MB990590) to remove the oil seal.
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
FRONT AXLE
26-43
REASSEMBLY
M1262002500258
AC501704AB
17
23
24 25
27
22
1817
10
11
12
8
9
13
7
14
6
5
34
1
2
26
29
28
21
20
33
30
N
N
N
4
3
N
N
32
31
15
16
18
19
19
18 ± 3 N·m
50 ± 10 N·m
84 ± 4 N·m
59 ± 4 N·m
65 ± 5 N·m
216 ± 29 N·m
5
15
17
18
20
23
20
17 18
22
21
Pinion shaft kit
Differential gear set
Final drive gear set
Reassembly steps
1. Differential carrier
>>
A
<< 2. Oil seal
>>
B
<< 3. Drive pinion rear bearing outer race
>>
C
<< 4. Drive pinion front bearing outer race
>>
D
<< •
Drive pinion height adjustment
5. Drive pinion
6. Drive pinion rear shim (for pinion height
adjustment)
7. Drive pinion rear bearing inner race
>>
E
<< •
Drive pinion turning torque adjustment
8. Drive pinion spacer
9. Drive pinion front shim (for turning torque
adjustment)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut
16. Differential case
17. Side gear spacer
18. Side gear
19. Pinion washer
20. Pinion gear
>>
F
<< •
Differential gear backlash adjustment
21. Pinion shaft
>>
G
<< 22. Lock pin
>>
H
<< 23. Drive gear
>>
I
<< 24. Differential side bearing inner race
25. Differential side bearing outer race
26. Differential side bearing adjusting spacer
>>
J
<< •
Drive gear backlash adjustment
27. Differential case assembly
28. Bearing cap
29. Vent plug <Vehicles with Easy select
4WD>
30. Differential cover
31. Packing
32. Drain plug
33. Gasket
34. Filler plug
Reassembly steps (Continued)
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
FRONT AXLE
26-44
LUBRICATION, SEALING AND ADHE-
SIVE POINTS
AC501723
AC501724
AC502341
A
A
Section A-A
2 - 3 mm
AF
Semi-drying sealant:
ThreeBond 1217 or equivalent
<Vehicles with
Easy select 4WD>
Adhesive:
LOCTITE No.271 or No.270 or equivalent
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