Mitsubishi Outlander XL. Manual — part 557

NOTE:

1.

Checking the contact pattern is the method to check that the
drive pinion height and the final drive gear backlash are or
are not adjusted properly. Repeat the adjustments of the
drive pinion height and the final drive gear backlash until the
contact pattern similar to the normal pattern.

2.

If the normal contact pattern cannot be obtained even after
making the adjustments, the drive gear and the drive pinion
have been worn exceeding the usage limit. Replace both
gears as a set.

<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL
SIDE BEARING SPACER/DIFFERENTIAL SIDE BEARING
OUTER RACE REMOVAL

When removing the differential case assembly, remove it
slowly with care not to drop the differential side bearing
spacer and the differential side bearing outer race.

ZC3001450000

Use the handle of a hammer to remove the differential case
assembly, differential side bearing spacer and differential side
bearing outer race.

NOTE:

Identify the RH and LH side bearing spacers as a

reference for the reassembly operation.

<<C>> DIFFERENTIAL SIDE BEARING INNER RACE
REMOVAL

ZC3001460000

MB990810

Socket
wrench

Use special tool MB990810 to remove the differential side
bearing inner race.

NOTE:

Hook the claws of the special tool on the

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

REAR AXLE<AWD>

27B-31

DIFFERENTIAL CARRIER ASSEMBLY

<<D>> DRIVE GEAR REMOVAL

ZC3001470000

Mating
marks

1.

Put mating marks on the drive gear and differential case as a
reference for the reassembly operation.

2.

Loosen the drive gear tightening bolts in a diagonal order to
remove the drive gear.

<<E>> LOCK PIN DRIVING OUT

ZC3001480000

Drive out the lock pin with a punch.

<<F>> DIFFERENTIAL NUT REMOVAL

AC302590

ZC3051430000

MB992112

MB992113

Use special tools MB992112 and MB992113 to remove the
differential nut:

27B-32

REAR AXLE<AWD>

DIFFERENTIAL CARRIER ASSEMBLY

<<G>> DRIVE PINION REAR BEARING INNER RACE
REMOVAL

ZC3002200000

MB990560

Use special tool MB990560 to remove the drive pinion rear
bearing inner race.

<<H>> DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL

AC302461

ZC3051450000

MB990939

Drive pinion
rear bearing
outer race

Drive pinion
front bearing
outer race

Use special tool MB990939 to remove the drive pinion front
bearing outer race.

<<I>> DRIVE PINION REAR BEARING OUTER RACE
REMOVAL

ZC3051460000

MB990939

Use special tool MB990939 to remove the drive pinion rear
bearing outer race.

ASSEMBLY

M12701000906USA0000010000

REAR AXLE<AWD>

27B-33

DIFFERENTIAL CARRIER ASSEMBLY

ZC6000020000

16

15

14

18

21

24 23

22

26

25

27

33

19

20

N

N

32

N

31

N

18

190 ± 30 N·m
140 ± 22 ft-lb

48 ± 6 N·m
36 ± 4 ft-lb

41 ± 5 N·m
30 ± 3 ft-lb

23 ± 3 N·m
17 ± 2 ft-lb

32 ± 2 N·m
23 ± 2 ft-lb

48 ± 6 N·m
36 ± 4 ft-lb

5

21

13

16

15

18

16

15

18

3

1

2

9

4

7

5

6

8

10

11

N

12

13

15 16

17

17

25

24

23

22

19

20

32 ± 2 N·m
23 ± 2 ft-lb

N

30

28

29

Pinion shaft kit

Differential gear set

Final drive gear set

Assembly 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 drive pinion
height adjustment)

7.

Drive pinion rear bearing inner race

8.

Drive pinion spacer

>>E<<

·

Drive

pinion

rotation

torque

adjustment

9.

Drive pinion front shim (for drive
pinion rotation torque adjustment)

10. Drive pinion assembly

Assembly steps

11. Drive pinion front bearing inner race

>>E<<

12. Oil seal
13. Differential nut
14. Differential case

>>F<<

·

Differential gear backlash adjustment

15. Side gear spacer
16. Side gear
17. Pinion washer
18. Pinion gear
19. Pinion shaft

>>G<<

20. Lock pin

>>H<<

21. Drive gear

>>I<<

22. Differential side bearing inner race
23. Differential side bearing outer race

27B-34

REAR AXLE<AWD>

DIFFERENTIAL CARRIER ASSEMBLY