Mitsubishi Outlander GS45X. Manual — part 1524
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE <AWD>
27B-45
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.
.
>>F<< LOCK PIN INSTALLATION
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.
.
>>G<< DRIVE GEAR INSTALLATION
1. Remove adhesive on the drive gear tightening bolts.
2. Use a tap to remove adhesive in the drive gear screw holes,
and clean the holes by blowing air.
3. Apply the specified thread locking compound in the drive
gear screw holes.
Specified adhesive: 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)
.
AC703506AB
Side gear
spacer
Side gear
spacer
Wedge
AC703533 AB
AC703534AB
M8 X 1.0 (pitch)
AC703535AB
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE <AWD>
27B-46
>>H<< DIFFERENTIAL SIDE BEARING INNER
RACE INSTALLATION
Use special tool MB990829 to press-fit the differential side
bearing inner race.
.
>>I<< 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.
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)
4. Use special tool MB992111 to install the differential case to
the differential carrier.
Tightening torque: 48
± 6 N⋅m (36 ± 4 ft-lb)
5. Measure the final drive gear backlash at four or more points.
Standard value: 0.08
− 0.15 mm (0.003 − 0.006 inch)
AC703536AB
MB990829
Piece of
metal
Piece of
metal
AC612543
AC703503
MB992111
AB
AC612539
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE <AWD>
27B-47
6. When the backlash is not within the standard value range,
move the side bearing spacers as shown in the figure to
adjust the backlash.
NOTE: Increase the side bearing spacers by the same
amount as for the decrease.
7. Check the final drive gear teeth contact, and if not proper,
adjust it.(Refer to
.)
8. Measure the drive gear runout on the backside.
Limit: 0.05 mm (0.002 inch)
9. When the runout exceeds the limit, change position of the
drive gear and differential case, and measure the runout
again.
10.If the adjustment is not possible, replace the differential
case or the drive gear and the drive pinion as a set.
.
>>J<< OIL SEAL PRESS-FITTING
Use special tools MB990938 and MB991115 to press-fit the oil
seal.
ACX01075 AD
If backlash is too small
If backlash is too large
Thinner
spacer
Thinner
spacer
Thicker
spacer
Thicker
spacer
AC612540
AC703483AB
MB990938
MB991115
NOTES
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