Mitsubishi Outlander XL. Manual — part 559

1.

Insert the drive pinion into the differential carrier. From rear
side of the carrier, assemble the drive pinion spacer, drive
pinion front shim and drive pinion front bearing inner race.

NOTE:

Do not assemble the oil seal.

AC302590

ZC3051430000

MB992112

MB992113

2.

Use special tools MB992112 and MB992113 to tighten the
differential nut to the specified torque.

3.

Rotate the drive pinion several turns, and then measure the
drive pinion rotation torque.

Standard value:

Bearing
division

Bearing
lubrication

Rotation torque
N·m (in-lb)

New

None
(coated

with

rust inhibitor oil)

0.7 - 1.0 (6.20 -
8.85)

ZC3051570000

A

4.

When the rotation torque is not within the standard value
range, adjust the torque by selecting the drive pinion front shim
(s).

NOTE:

When selecting the drive pinion front shim(s),

select the drive pinion spacer to minimize the number of
the shims to be used. There are two drive pinion spacers
available:

Drive pinion spacer height A mm (in)
24.3 (0.96)
23.6 (0.93)

AC302590

ZC3051430000

MB992112

MB992113

5.

Use special tools MB992112 and MB992113 to tighten the
differential nut to the specified torque.

ZC3051580000

MB991180

6.

Use special tool MB991180 to press-fit the oil seal.

7.

Rotate the drive pinion several turns, and then measure the
drive pinion rotation torque.

Standard value:

Bearing
division

Bearing
lubrication

Rotation
torque N·m (in-
lb)

New

None (coated with
rust inhibitor oil)

0.7 - 1.0 (6.20 -
8.85)

8.

When the rotation torque is not within the standard value,
check the differential locking nut tightening torque or the oil
seal assembly condition.

REAR AXLE<AWD>

27B-39

DIFFERENTIAL CARRIER ASSEMBLY

>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Adjust the differential gear backlash in the following steps.

ZC3020710000

1.

Assemble the side gear, side gear spacer, pinion gear and
pinion washer into the differential case.

2.

Temporarily assemble the pinion shaft.

NOTE:

Do not assemble the lock pin at this stage.

ZC3001420000

Wedge

Side gear
spacer

Side gear
spacer

3.

Drive a wooden wedge between one of the side gears and the
pinion shaft to fix the side gear.

4.

Set a dial gauge (with the measuring rod extended) against
the pinion gear and measure the backlash. Repeat the same
procedure to measure the backlash at the other pinion gear.

Standard value: 0 - 0.076 mm (0 - 0.0030 inch)
Limit: 0.2 mm (0.01 inch)

5.

When the backlash exceeds the limit value, adjust it by
selecting the side gear spacer.

6.

When the adjustment is not possible, replace the side gear
and the pinion gear as a set.

7.

After the adjustments, make sure that the backlash is within
the limit value and the differential gear rotates smoothly.

>>G<< LOCK PIN INSTALLATION

ZC3021060000

1.

Align the lock pin holes in the pinion shaft and in the differential
case, and drive in the lock pin.

2.

Use a punch to crimp two points.

>>H<< DRIVE GEAR INSTALLATION

1.

Remove adhesive on the drive gear tightening bolts.

27B-40

REAR AXLE<AWD>

DIFFERENTIAL CARRIER ASSEMBLY

ZC3020720000

M8 X 1.0 (pitch)

2.

Use a tap to remove adhesive in the drive gear screw holes,
and clean the holes by blowing air.

ZC3002310000

3.

Apply the specified thread locking compound in the drive gear
screw holes.

Specified sealant: 3M ™ AAD Part No.8730, 8731 or
equivalent

4.

Align the mating marks and assemble the drive gear to the
differential case.

Tightening torque: 41 ± 5 N·m (30 ± 3 ft-lb)

>>I<< DIFFERENTIAL SIDE BEARING INNER RACE
INSTALLATION

ZC3001560000

MB990829

Piece of
metal

Piece of
metal

Use special tool MB990829 to press-fit the differential side
bearing inner race.

>>J<< FINAL DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the final drive gear backlash in the following steps:

1.

To the differential carrier, install the differential case with the
side bearing outer race assembled.

REAR AXLE<AWD>

27B-41

DIFFERENTIAL CARRIER ASSEMBLY

ZC3020730000

2.

Press the differential case to one side, and measure clearance
between the side bearing outer race and the differential
carrier.

3.

Select two pairs of the side bearing spacers. (Thickness: 1/2
of the measured clearance with 0.05 mm (0.002 inch) preload
added)

ZC3001460000

MB990810

Socket
wrench

4.

Use special tool MB990810 to remove the side bearing.

NOTE:

Hook the claws of the special tool on the side

bearing inner race through two cut-off parts in the
differential case.

5.

Assemble the selected side bearing spacers on both sides.

ZC3001560000

MB990829

Piece of
metal

Piece of
metal

6.

Use special tool MB990829 to press-fit the side bearing inner
race into the differential case and install the outer race.

MB992111

ZC3051640000

7.

Use special tool MB992111 to install the differential case to
the differential carrier.

Tightening torque: 23 ± 3 N·m (17 ± 2 ft-lb)

ZC3001410000

8.

Measure the final drive gear backlash at four or more points.

Standard value: 0.10 - 0.15 mm (0.004 - 0.006 inch)

27B-42

REAR AXLE<AWD>

DIFFERENTIAL CARRIER ASSEMBLY