Mitsubishi L200. Manual — part 382

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-33

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH

<4WD>

REMOVAL AND INSTALLATION

M1262001800201

CAUTION

*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.

Pre-removal and Post-installation Operation
• Under Cover Removal and Installation (Refer to GROUP

51, Under Cover .)

• Front Axle Gear Oil Level Check (Refer to

P.26-11

.)

• Driveshaft Removal and Installation (Refer to

P.26-23

.)

• Inner Shaft Removal and Installation (Refer to

P.26-30

.)

AC804263

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

AC501624

5

N

Sealant:
ThreeBond 1217 or equivalent

Housing
tube end
(Differential
side)

N

105 ± 15 N·m

AC

108 ± 10 N·m

108 ± 10 N·m

90 ± 10 N·m

17 ± 3 N·m

3

6

90 ± 10 N·m

105 ± 15 N·m

25 ± 5 N·m

90 ± 10 N·m

12 ± 2 N·m

59 ± 9 N·m

54 ± 5 N·m

17

18

19

*

*

Removal steps

<<

A

>>

>>

B

<< 1. Front propeller shaft connection

•

Support the differential by a
transmission jack

2.

Self-locking nut

3. Front suspension rear

crossmember assembly mounting
bolt

4. Front suspension rear

crossmember assembly

>>

A

<< 5. Vacuum hose connection

6. Differential mounting bracket bolt
7.

Housing tube, front differential
carrier and differential mounting
bracket

Removal steps (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-34

REMOVAL SERVICE POINT

<<A>> FRONT PROPELLER SHAFT REMOVAL

AC505406

Mating marks

AD

<Vehicles with
Easy select
4WD>

AC804574AC

Mating marks

<Vehicles with
Super select
4WD>

Make mating marks on the flange yoke and the dif-
ferential carrier companion flange. Remove the front
propeller shaft.

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE INSTALLATION

AC500427AB

Actuator

Identification
colour (blue)

Identification
colour (yellow)

Install the vacuum hoses so that they match the
identification colours of the actuator assembly nipple.

>>B<< FRONT PROPELLER SHAFT
INSTALLATION

AC505406

Mating marks

AD

<Vehicles with
Easy select
4WD>

AC804574AC

Mating marks

<Vehicles with
Super select
4WD>

Install the front propeller shaft so that the mating
marks of the flange yoke and the differential carrier
companion flange are aligned.

8.

Differential mounting bracket <RH>

9.

Differential mounting bracket <LH>

10. Pin <Except for Russia>
11. Collar <Except for Russia>
12. Actuator assembly <Except for

Russia>

13. Free wheel engage switch

assembly <Except for Russia>

14. Gasket <Except for Russia>
15. Breather hose <Vehicles with Easy

select 4WD>

16. Breather hose <Vehicles with

Super select 4WD>

17. Housing tube assembly
18. Breather pipe
19. Front differential carrier assembly

Removal steps (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-35

INSPECTION

M1262001900123

FREEWHEEL ENGAGE SWITCH CHECK
<Except for Russia>

ACX01021AB

OFF

ON

1 2

Ball

Shaft (Switch)
position

Tester
connection

Specified
condition

Pressed (ON)

1-2

Continuity (Less
than 2

Ω)

Released (OFF) -

Open circuit

FREE WHEEL CLUTCH DISASSEMBLY
AND REASSEMBLY <Except for Russia>

M1262002900159

AC804392

AC500711

AB

12

11

10

4

13

7

3

2

1

6

5

8

9

14

Disassembly steps

1.

Main shaft assembly

<<

A

>>

>>

F

<<

2.

Main shaft

<<

A

>>

>>

F

<<

3.

Bearing

4.

Clutch sleeve

>>

E

<<

5.

Spacer

>>

D

<<

6.

Spring pin

7.

Shift fork

8.

Shift rod

9.

Bushing

>>

C

<<

10. Oil seal

<<

B

>>

>>

B

<<

11. Clutch gear

<<

B

>>

>>

B

<<

12. Bearing

>>

A

<<

13. Oil seal
14. Housing tube

Disassembly steps (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-36

DISASSEMBLY SERVICE POINTS

<<A>> MAIN SHAFT/BEARING REMOVAL

ACX01023 AB

A

MB990560

1. After special tool bearing remover (MB990560)

has been installed as shown, tighten the nut of
special tool until portion "A" of special tool touches
the bearing outer race.

CAUTION

Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing.

<<B>> CLUTCH GEAR/BEARING REMOVAL

AC505087

AB

MB991318

Rag

Clutch gear

1. Use special tool lower arm bush arbour

(MB991318) to remove the clutch gear and
bearing together.
NOTE: Apply rag inside of the clutch gear so as
not to damage spline part.

AC500716

AB

Iron piece

MB990560

2. Using a press and special tool bearing remover

(MB990560), hold the supports against the
bearing inner race, and separate the clutch gear
and bearing.

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

AC500717

AB

MB990799

Oil seal

Housing tube

Use special tool ball joint remover and installer A
(MB990799) to tap the oil seal until it is flush with the
clutch housing.

>>B<< BEARING/CLUTCH GEAR INSTALLATION

ACX01027AB

MB990799

Bearing

Clutch gear

1. Use special tool ball joint remover and installer A

(MB990799) to press-fit the bearing to the
shoulder of the clutch gear.