Mitsubishi L200. Manual — part 389

B991367

SPECIAL TOOLS

REAR AXLE

27-7

MB991367

Special spanner

Removal and adjustment of the
side bearing nut

B991385

MB991385

Pin

MB990810

MB990810

Side bearing puller Removal of the side bearing

inner race

MB991407

MB991407

Differential rear
support arbour

Removal of the side bearing
inner race

MB990850

MB990850

End yoke holder

Removal of the companion
flange

MD998801

Bearing remover

Removal of the drive pinion rear
bearing inner race

MB991445

Bushing remover
and installer base

Press-fitting of the drive pinion
rear bearing outer race (Use
together with MB990938)
<Vehicles with High power
engine except 5A/T>

MB991171

A

B

C

C

A

MB991171

A: MB990819
B: MB991170
C: MB991169

Pinion height
gauge set

A: Pinion gauge
B: Cylinder gauge
C: Drive pinion

gauge
attachment

Measurement of the pinion
height

MB991534

MB991534

Cylinder gauge

Tool

Number

Name

Use

MB990326

ON-VEHICLE SERVICE

REAR AXLE

27-8

ON-VEHICLE SERVICE

REAR AXLE TOTAL BACKLASH CHECK

M1271001200393

1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral

position or the selector lever to the "N" position.
Then place the transfer sift lever to the "2H"
position <4WD>. Apply the parking brake. Raise
the vehicle on a jack.

ACX00962 AB

Mating marks

3. Turn the companion flange clockwise as far as it

will go. Make the mating mark on the dust cover of
the companion flange and on the differential
carrier.

ACX00964

4. Turn the companion flange anti-clockwise as far

as it will go, and measure the amount of distance
the mating marks moved.

Limit: 5 mm

MB990326

Preload socket

Measurement of drive pinion
turning torque

MB990685

Torque wrench

MB991168

MB991168

Differential oil seal
installer

Press-fitting of the drive pinion
oil seal

MB990802

MB990802

Bearing installer

Press-fitting of the drive pinion
rear bearing inner race

MB990728

MB990728

Side and rear
bearing inner race
installer

Installation of side bearing inner
race

Tool

Number

Name

Use

ON-VEHICLE SERVICE

REAR AXLE

27-9

5. If the backlash exceeds the limit value, remove

the differential carrier assembly and check the
following.

• Drive gear backlash (Refer to

P.27-27

)

• Differential gear backlash (Refer to

P.27-27

)

GEAR OIL LEVEL CHECK

M1272001200556

<Up to September>

AC505405

Gear oil

Upper
limit

Lower
limit

8 mm

AB

1. Check that gear oil level is not 8 mm below the

bottom of filler plug hole.

2. If the gear oil level is lower than the lower limit,

add the specified gear oil until the level comes to
the lower portion of the filler plug hole.

Specified gear oil:
Gear oil API classification GL-5 or higher
SAE 80W

3. Tighten the filler plug to the specified torque

(Refer to

P.27-24

).

<From October>

CAUTION

Be careful not to drop the inspection tool into the
differential.

ACB00137AH

A

Gear oil
level

Bottom edge
of the filler
plug hole

Inspection tool

1. Insert an inspection tool as shown so that it

touches the bottom of the filler plug. The
inspection tool: 6 mm-diameter L shaped bar (e.g.
6 mm-diameter angled hexagon wrench).

2. Pull out the wrench, and then check that the

dimension to the gear oil level is within 24 mm.

Specified gear oil:
Gear oil API classification GL-5 or higher
SAE 80W

3. Tighten the filler plug to the specified torque

(Refer to

P.27-24

).

GEAR OIL REPLACEMENT

M1272004600683

<Up to September>

1. Remove the filler plug.
2. Remove the drain plug and drain oil.
3. Tighten the drain plug to the specified torque

(Refer to

P.27-24

).

4. Add the oil until the level comes to the lower

portion of the filler plug hole.

Specified gear oil:

Gear oil API classification GL-5 or higher SAE

80W

Amount to use:

1.5 L <2WD (except High rider)>
2.6 L <2WD (High rider), 4WD (5A/T or

except vehicles with High power
engine)>

3.2 L <Vehicles with High power engine

except 5A/T>

5. Tighten the filler plug to the specified torque

(Refer to

P.27-24

).

<From October>

1. Remove the filler plug.
2. Remove the drain plug and drain oil.
3. Tighten the drain plug to the specified torque

(Refer to

P.27-24

).

ACB00140AC

24 mm

Gear oil
level

Bottom edge
of the filler
plug hole

4. Refill the gear oil until the level satisfies the

specification.

Specified gear oil:

Gear oil API classification GL-5 or higher SAE

80W

Amount to use:

1.5 L <2WD (except High rider)>

ON-VEHICLE SERVICE

REAR AXLE

27-10

2.1 L <2WD (High rider), 4WD (5A/T or

except vehicles with High power
engine)>

2.1 L <Vehicles with High power engine

except 5A/T>

5. Tighten the filler plug to the specified torque

(Refer to

P.27-24

).

AXLE SHAFT AXIAL PLAY CHECK

M1271001300107

AC004839 AB

1. Measure the axle shaft axial play by using a dial

indicator.

Standard value: 0

− 0.25 mm

2. If not within specifications, replace the axle shaft

assembly.

AXLE SHAFT AXIAL PLAY ADJUSTMENT

M1271001400104

The axle shaft axial play is preset at factory. It can
not be adjusted.

HUB BOLT REPLACEMENT

M1271001000623

1. Remove the brake drum.

AC711177AC

MB990767

MB991618

2. Use the following special tools to remove the hub

bolts.

• Front hub and flange yoke holder (MB990767)

•

AC711178

Plain washer

AC

MB990767

Hub bolt remover (MB991618)

3. Install the plain washer to the new hub bolt, and

install the bolt with a nut.

4. Install the brake drum.

REAR DIFFERENTIAL LOCK DETECTION
SWITCH CHECK <4WD>

M1272001000091

1. Jack up the vehicle.
2. Remove the air pipe and air hose connection.

1 2

AC508806AB

Pressure
gauge

Air
pressure

Air valve

Air regulator

3. Connect a pressure gauge and air regulator to the

air pipe.

CAUTION

Do not apply a higher pressure so as not to dam-
age the air regulator.
4. Adjust the outside air pressure with the air

regulator until the pressure gauge shows approx.
24.5 kPa.

5. Lock the wheel on one side of the vehicle, and

slowly turn the wheel on the other side.

6. Check for continuity in the rear differential lock

detection switch.