Mitsubishi L200. Manual - part 394

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-27

DISASSEMBLY

M1272002200560

CAUTION

Do not disassemble the limited slip differential case assembly.

AC611940AC

<Limited slip differential>

<Conventional differential>

4

5

6

13

10

9

11

12

8 7

14

6

5

2

1

13

12

10

11

28

1

2

5 6

7

15

6 5

2

4

1

1

2

3

3

29

27

25

26

17

16

N

N

<Vehicles without rear differential lock>

18

19

20 21

22 23

24

Disassembly steps 

<<

A

>>

•

Inspection before disassembly

1. Lock plate

<<

B

>>

2. Side bearing nut
3. Bearing cap

<<

C

>>

4. Differential case assembly
5. Differential side bearing outer race

<<

D

>>

6. Differential side bearing inner race

<<

E

>>

7. Drive gear

<<

F

>>

8. Lock pin
9. Pinion shaft
10. Pinion gear
11. Pinion washer
12. Side gear
13. Side gear spacer
14. Differential case
15. Limited slip differential case assembly

<<

G

>>

16. Self-locking nut
17. Washer

<<

H

>>

18. Companion flange

<<

H

>>

19. Drive pinion assembly
20. Drive pinion front shim (For adjusting 

preload of drive pinion)

21. Drive pinion spacer

<<

I

>>

22. Drive pinion rear bearing inner race
23. Drive pinion rear shim (for adjusting 

drive pinion height)

24. Drive pinion

<<

J

>>

25. Oil seal

<<

J

>>

26. Drive pinion front bearing inner race

<<

J

>>

27. Drive pinion front bearing outer race

<<

K

>>

28. Drive pinion rear bearing outer race
29. Differential carrier

Disassembly steps (Continued)

AC804640AB

11

10

N

<Vehicles with rear differential lock>

N

N

N

2

2

3

13

12

1

3

4

5

6

7

8

9

14

15

16

17

18

19

20

21

22

23

24 25

26 27 28

29

30 31

32

33

9 8

Disassembly steps 

<<

A

>>

•

Inspection before disassembly

1. Hose
2. Lock plate

<<

B

>>

3. Side bearing nut
4. Bolt
5. Bolt
6. Bearing cap

<<

C

>>

7. Differential case assembly
8. Differential side bearing outer race

<<

D

>>

9. Differential side bearing inner race
10. Actuator assembly
11. Pressure plate

<<

E

>>

12. Drive gear
13. Differential case
14. Air pipe assembly (A)
15. Eye bolt
16. Air pipe assembly (B)
17. Gasket
18. Rear differential lock detection switch
19. Gasket

<<

G

>>

20. Self-locking nut
21. Washer

<<

H

>>

22. Companion flange

<<

H

>>

23. Drive pinion assembly
24. Drive pinion front shim (for adjusting 

preload of drive pinion)

25. Drive pinion spacer

<<

I

>>

26. Drive pinion rear bearing inner race
27. Drive pinion rear shim (for adjusting 

drive pinion height)

28. Drive pinion

<<

J

>>

29. Oil seal

<<

J

>>

30. Drive pinion front bearing inner race

<<

J

>>

31. Drive pinion front bearing outer race

<<

K

>>

32. Drive pinion rear bearing outer race
33. Differential carrier

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-28

DISASSEMBLY SERVICE POINTS

<<A>> INSPECTION BEFORE DISASSEMBLY
Except for the following standard values, inspection 
procedure is the same as GROUP 26, inspection 
before disassembly .

Drive gear backlash
Standard value:
0.07 

− 0.13 mm <2WD (except High rider)>

0.08 

− 0.18 mm <2WD High rider, 4WD>

<<B>> SIDE BEARING NUT REMOVAL

AC004921AB

MB991385

MB991367

Use the following special tools, remove the side 
bearing nut.

• Special spanner (MB991367)

• Pin (MB991385)

NOTE: Keep the right and left side bearings and side 
bearing nuts separate, so that they do not become 
mixed at the time of assembly.

Disassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-29

<<C>> DIFFERENTIAL CASE ASSEMBLY 
REMOVAL

CAUTION

When taking out the differential case assembly, 
be careful not to drop and damage the differential 
side shims or the side bearing outer races.

ACX02422

Use the wooden handle of a hammer to remove the 
differential case assembly, differential side shims and 
side bearings.
NOTE: Keep the right and left side bearings and side 
bearing outer race separated, so that they do not 
become mixed at the time of assembly.

<<D>> SIDE BEARING INNER RACE REMOVAL

AC203814 AC

MB990810

MB991407

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

• Side bearing puller (MB990810)

• Differential support bush arbour (MB991407)

NOTE: Attach the prongs of special tools to the inner 
race of the side bearing through the openings in the 
differential case.

<<E>> DRIVE GEAR REMOVAL

ACX01042AB

Mating
marks

1. Make 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.

<<F>> LOCK PIN REMOVAL

ACX01048AB

Punch

Drive out the lock pin with a punch.

<<G>> SELF-LOCKING NUT REMOVAL

ACX01043AB

MB990850

Use special tool end yoke holder (MB990850) to hold 
the companion flange, and then remove the compan-
ion flange self-locking nut.

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-30

<<H>> DRIVE PINION ASSEMBLY/COMPANION 
FLANGE REMOVAL

CAUTION

Do not make mating marks on the contact sur-
faces of the companion flange and propeller 
shaft.
1. Make mating marks to the drive pinion and 

companion flange.

AC102894

MB990810

AD

Companion
flange

2. Use special tool side bearing puller (MB990810) 

to pull out the companion flange.

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

AC104970AC

MD998801

Use special tool remover (MD998801) to pull out the 
front bearing inner race.

<<J>> OIL SEAL/DRIVE PINION FRONT BEARING 
INNER RACE/DRIVE PINION FRONT BEARING 
OUTER RACE REMOVAL

ACX01101AB

Drive pinion front
bearing outer race

Drive pinion front
bearing inner 
race

Oil seal

Drive pinion rear
bearing outer
race

MB990939

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

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

ACX01102 AB

MB990939

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