Mitsubishi L200. Manual - part 384

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-41

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

CAUTION

When taking out the differential case assembly, 
be careful not to drop and damage the differential 
side bearing spacers and differential side bear-
ing outer races.

ACX01040AB

Use the wooden handle of a hammer to remove the 
differential case assembly, differential side bearing 
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side 
bearing adjusting spacers separate, so that they do 
not become mixed during assembly.

<<C>> DIFFERENTIAL SIDE BEARING INNER 
RACE REMOVAL

ACX01041AC

MB990811

MB990810

Use the following special tools to pull out the side 
bearing inner races.

• Side bearing puller (MB990810)

• Differential side bearing cap (MB990811)

NOTE: There are two notches provided (at the differ-
ential case side) for the claw part of the special tools; 
use special tools at that position.

<<D>> DRIVE GEAR REMOVAL

AC102891

Mating
marks

AC

1. Make the mating marks to the differential case 

and the drive gear.

2. Loosen the drive gear attaching bolts in diagonal 

sequence to remove the drive gear.

<<E>> LOCK PIN REMOVAL

ACX01048AB

Punch

Drive out the lock pin with a punch.

<<F>> SELF-LOCKING NUT REMOVAL

AC004732 AB

MB990767

Use special tool front hub and flange yoke holder 
(MB990767) to hold the companion flange, and then 
remove the companion flange self-locking nut.

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-42

<<G>> DRIVE PINION ASSEMBLY REMOVAL

CAUTION

The mating mark made on the companion flange 
must not be on the coupling surface of the flange 
yoke and the front propeller shaft.

AC004790 AB

Mating marks

1. Make mating marks on the drive pinion and 

companion flange.

2. Drive out the drive pinion together with the drive 

pinion spacer and drive pinion shims.

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

ACX01045 AB

MB990339

MB990648

Use the following special tools to pull out the front 
bearing inner race.

• Bearing puller (MB990339)

• Bearing remover (MB990648)

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

ACX01046AB

MB990939

Use special tool remover bar (MB990939) to remove 
the drive pinion front bearing outer race.

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

ACX01047 AB

MB990939

Use special tool remover bar (MB990939) to remove 
the drive pinion rear bearing outer race.

<<K>> OIL SEAL REMOVAL

AC004791 AB

MB990590

Use special tool rear axle shaft oil seal remover 
(MB990590) to remove the oil seal.

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-43

REASSEMBLY

M1262002500258

AC501704AB

17

23

24 25

27

22

1817

10

11

12

8

9

13

7

14

6

5

34

1

2

26

29

28

21

20

33

30

N

N

N

4

3

N

N

32

31

15

16

18

19

19

18 ± 3 N·m

50 ± 10 N·m

84 ± 4 N·m

59 ± 4 N·m

65 ± 5 N·m

216 ± 29 N·m

5

15

17

18

20

23

20

17 18

22

21

Pinion shaft kit

Differential gear set

Final drive gear set

Reassembly 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 pinion height 

adjustment)

7. Drive pinion rear bearing inner race

>>

E

<< •

Drive pinion turning torque adjustment

8. Drive pinion spacer
9. Drive pinion front shim (for turning torque 

adjustment)

10. Drive pinion assembly
11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut

 

16. Differential case
17. Side gear spacer

18. Side gear
19. Pinion washer
20. Pinion gear

>>

F

<< •

Differential gear backlash adjustment

21. Pinion shaft

>>

G

<< 22. Lock pin

>>

H

<< 23. Drive gear

>>

I

<< 24. Differential side bearing inner race

25. Differential side bearing outer race
26. Differential side bearing adjusting spacer

>>

J

<< •

Drive gear backlash adjustment

27. Differential case assembly
28. Bearing cap
29. Vent plug <Vehicles with Easy select 

4WD>

30. Differential cover
31. Packing
32. Drain plug
33. Gasket
34. Filler plug

Reassembly steps (Continued)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-44

LUBRICATION, SEALING AND ADHE-
SIVE POINTS

AC501723

AC501724

AC502341

A

A

Section A-A

2 - 3 mm

AF

Semi-drying sealant: 
ThreeBond 1217 or equivalent

<Vehicles with
Easy select 4WD>

Adhesive:
LOCTITE No.271 or No.270 or equivalent