Mitsubishi L200. Manual - part 386

ACX01068AB

Tap

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-49

2. Remove the adhesive adhered to the threaded 

holes of the drive gear by turning the tap (M10 x 
1.25), and then clean the threaded holes by 
applying compressed air.

AC000438 AB

3. Apply the specified adhesive to the threaded 

holes of the drive gear.

Specified adhesive:: LOCKTITE No.271 or 
No.270 or equivalent

4. Install the drive gear onto the differential case with 

the mating marks properly aligned. Tighten the 
bolts to the specified torque in a diagonal 
sequence.

Tightening torque: 84 

± 4 N⋅m

>>I<< DIFFERENTIAL SIDE BEARING INNER 
RACE INSTALLATION

ACX01069AC

MB990802

MB990802

Piece of
metal

Piece of
metal

Use special tool bearing installer (MB990802) to 
press-fit the differential side bearing inner races into 
the differential case.

>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following pro-
cedures:

ACX01070 AB

1. Install the side bearing spacers, which are thinner 

than those removed, to the side bearing outer 
races, and then mount the differential case 
assembly into the gear carrier.
NOTE: Select side bearing spacers with the same 
thickness for both the drive pinion side and the 
drive gear side.

ACX01071AB

2. Push the differential case assembly to one side, 

and measure the clearance between the gear 
carrier and the side bearing adjusting spacer with 
a feeler gauge.

ACX01072 AC

Clearance/2 + 0.05 mm = 
Thickness of the spacer on
one side

3. Measure the thickness of the side bearing 

adjusting spacers on one side, select two pairs of 
spacers which correspond to that thickness plus 
one half of the clearance plus 0.05 mm, and then 
install one pair each to the drive pinion side and 
the drive gear side.

ACX01070 AB

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-50

4. Install the side bearing adjusting spacers and 

differential case assembly, as shown in the 
illustration, to the gear carrier.

ACX01073 AB

MB990939

5. Tap the side bearing adjusting spacers with 

special tool remover bar (MB990939) to fit them to 
the side bearing outer race.

ACX01074AB

6. Align the mating marks on the gear carrier and the 

bearing cap, and then tighten the bearing cap.

Tightening torque: 59 

± 4 N⋅m

ACX01034AB

7. With the drive pinion locked in place, measure the 

drive gear backlash with a dial indicator on the 
drive gear.
NOTE: Measure at four points or more on the cir-
cumference of the drive gear.

Standard value: 0.11 

− 0.16 mm

ACX01075

If backlash is too small

Thinner
spacer

Thicker
spacer

AB

If backlash is too large

Thicker
spacer

Thinner
spacer

8. Change the side bearing adjusting spacers as 

illustrated, and then adjust the drive gear 
backlash between the drive gear and the drive 
pinion.
NOTE: When increasing the number of side bear-
ing adjusting spacers, use the same number for 
each, and as few as possible.

9. Check the drive gear and drive pinion for tooth 

contact. If poor contact is evident, make 
adjustment. (Refer to 

P.26-38

.)

ACX01036 AB

10.Measure the drive gear runout at the shoulder on 

the reverse side of the drive gear.

Limit: 0.05 mm

11.If the drive gear runout exceeds the limit, reinstall 

by changing the phase of the drive gear and 
differential case, and remeasure.

12.If adjustment is not possible, replace the 

differential case or replace the drive gear and 
drive pinion as a set.

SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>

FRONT AXLE

26-51

SOLENOID VALVE AND VACUUM HOSE <4WD except for 

RUSSIA>

REMOVAL AND INSTALLATION

M1262004500083

AC903982

12

2

13

10

16

7

6

5

4

1

3

14

8

12 ± 2 N·m

15

5.0 ± 1.0 N·m

12 ± 2 N·m

AB

12 ± 2 N·m

12

12

9

11

 

 

 

Solenoid valve assembly removal 
steps 

 

 

1.  Solenoid valve connector

 

 

2.  Solenoid valve assembly

 

 

 

Vacuum tank and vacuum hose 
assembly and vacuum pipe assembly 
removal steps 

 

3.  Vacuum hose

 

4.  Vacuum tank

 

5. Vacuum pipe assembly

 

 

6.  Vacuum hose

 

 

7.  Vacuum hose

 

 

8.  Vacuum valve cap

 

 

9.  Vacuum hose

 

 

10.  Breather cap

 

 

11.  Vacuum pipe

 

 

12.  Vacuum hose

 

>>

B

<< 13.  Check valve

 

>>

A

<< 14.  Vacuum hose

 

>>

A

<< 15.  Vacuum pipe assembly

 

>>

A

<< 16.  Vacuum hose assembly

 

 

 

Vacuum tank and vacuum hose 
assembly and vacuum pipe assembly 
removal steps (Continued)

SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>

FRONT AXLE

26-52

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE ASSEMBLY/VACUUM 
PIPE ASSEMBLY/VACUUM HOSE INSTALLATION

AC500427AB

Actuator

Identification
colour (blue)

Identification
colour (yellow)

1. Install the vacuum hoses so that they match the 

identification colours of the actuator assembly 
nipple.

AC500725

AB

Vacuum pipe
assembly

Yellow mark
 and stripe

Blue mark
and stripe

Yellow mark
 and stripe

Blue mark
and stripe

2. Install the vacuum hose assembly and the 

vacuum hoses to the vacuum pipe assembly, so 
that colour mark (yellow or blue) of the vacuum 
pipe assembly will match colour stripe (yellow or 
blue) at the vacuum hose assembly and vacuum 
hoses.

>>B<< CHECK VALVE INSTALLATION

ACX01077AB

Vacuum side

Air direction arrow

Solenoid
valve side

Install so that the air direction arrow points to the 
vacuum side.