Mitsubishi Outlander GS45X. Manual — part 1523

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-41

LUBRICANT/SEALANT APPLICATION POINTS

AC703523

Adhesive: 3M

TM

AAD Part No.

8730, 8731 or equivalent

Vent plug

2 3 mm (0.08 0.12 in)
(bead diameter)

–

–

AB

Electronic control
coupling side

Differential side

Semi-drying sealant: 3M

TM

AAD Part No. 8672,

8679, 8678, 8661, 8663 or equivalent

Semi-drying sealant: 3M

TM

AAD Part No. 8672,

8679, 8678, 8661, 8663 or equivalent

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-42

ASSEMBLY SERVICE POINT

.

>>A<< DRIVE PINION REAR BEARING OUTER
RACE PRESS-FITTING

Use special tools MB990934 and MB990938 to press-fit the
drive pinion rear bearing outer race.

.

>>B<< DRIVE PINION FRONT BEARING OUTER
RACE PRESS-FITTING

Use special tools MB990930 and MB990938 to press-fit the
drive pinion front bearing outer race.

.

>>C<< DRIVE PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height in the following steps.
1. Use special tools MB992115, MB992116 and MB992128 to

assemble the drive pinion front and rear bearing inner races
onto the differential carrier:

CAUTION

The bearing must be free from gear oil.

2. Measure the drive pinion rotation torque.

Standard value:

NOTE: After seating the bearing, measure the rotation
torque.

AC703524 AB

MB990938

MB990934

AC703525 AB

MB990938

MB990930

Bearing
division

Bearing
lubrication

Rotation torque
N

⋅m (in-lb)

New

None

(coated with
rust inhibitor oil)

0.7

− 1.2

(6.20

− 10.62)

AC703526 AB

MB992116,
MB992128

MB992115

AC703527AB

MB992115

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-43

3. Set special tool MB992117 on the differential carrier side

bearing, and use special tool MB992111 to assemble it onto
the differential carrier.
Make sure that the cut-off part of the cylinder gauge is
positioned as shown in the figure, and the cylinder gauge is
closely contacted with the side bearing.

Tightening torque: 48

± 6 N⋅m (36 ± 4 ft-lb)

4. Select the drive pinion rear shim(s) that corresponds to the

gap between the special tools.
NOTE:

.

1. Clean the side bearing.
2. When setting the special tool, make sure that its cut-off

part is positioned as shown in the figure, and it is closely
contacted with the side bearing.

3. Try to minimize the number of the drive pinion rear

shim(s) to be used.

5. Fit the selected drive pinion rear shim(s) onto the drive

pinion. Use special tool MD998816 to press-fit the drive
pinion rear bearing inner race.

.

>>D<< DRIVE PINION ROTATION TORQUE
ADJUSTMENT/OIL SEAL PRESS-FITTING

Adjust the drive pinion rotation torque in the following steps:
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.

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:

AC703528AB

MB992117

A

MB992111

MB992116,
MB992128

Cut-off
part

Shim

AC703529AB

MD998816

MD998816

Drive pinion
rear shim

Bearing
division

Bearing
lubrication

Rotation torque
N

⋅m (in-lb)

New

None

(coated with
rust inhibitor oil)

0.7

− 1.2

(6.20

− 10.62)

AC703518AB

MB992112

MB992113

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-44

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:

5. Use special tools MB992112 and MB992113 to tighten the

differential nut to the specified torque.

Tightening torque: 190

± 3 N⋅m (140 ± 22 ft-lb)

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:

8. When the rotation torque is not within the standard value,

check the differential locking nut tightening torque or the oil
seal assembly condition.

.

>>E<< DIFFERENTIAL GEAR BACKLASH
ADJUSTMENT

Adjust the differential gear backlash in the following steps.
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.

Drive pinion spacer height A mm (in)

24.3 (0.96)

23.6 (0.93)

Bearing
division

Bearing
lubrication

Rotation
torque N

⋅m

(in-lb)

New

None (coated with
rust inhibitor oil)

0.7

− 1.2

(6.20

− 10.62)

AC703530AB

A

AC703518AB

MB992112

MB992113

AC703531AB

MB991180

AC703532 AB