Mitsubishi L200. Manual - part 395

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-31

REASSEMBLY

M1272002300664

AC508818

AC502387

AC502388

AC502389

AC502391

AD

<Limited 
differential>

Differential gear kit

Final drive gear kit

<Conventional 
differential>

19 ± 3 N·m

29

28

26

25

16

24

23

24

29

28

23

4

14

20

18

18

20

29

25

24

15

23

22

19

20

21

18

17

24

25

26

18 17

20

19

4

5

6

2

10 9

11

27

1

27

3

12

13

14

8

7

N

N

29

28

25

28

19 ± 3 N·m

84 ± 5 N·m

84 ± 5 N·m
<5A/T or except vehicles with 
High power engine>
152 ± 15 N·m
<Vehicles with High power engine 
except 5A/T>

19 ± 3 N·m

19 ± 3 N·m

74 ± 4 N·m

216 ± 29 N·m

Pinion shaft kit

Limited slip differential kit

16

22

21

17

17

<Vehicles without rear differential lock>

Reassembly steps 

1. Differential carrier

>>

A

<< 2. Drive pinion rear bearing outer race

>>

B

<< 3. Drive pinion front bearing outer race

>>

C

<< • Drive pinion height adjustment

4. Drive pinion
5. Drive pinion rear shim (for adjusting 

drive pinion height)

6. Drive pinion rear bearing inner race

>>

D

<< • Drive pinion preload adjustment

7. Drive pinion front bearing inner race

>>

D

<< 8. Oil seal

9. Drive pinion spacer

10. Drive pinion front shim (for adjusting 

drive pinion preload)

11. Drive pinion assembly
12. Companion flange
13. Washer
14. Self-locking nut
15. Differential case
16. Limited slip differential case assembly
17. Side gear spacer
18. Side gear
19. Pinion washer
20. Pinion gear

>>

E

<< • Differential gear backlash adjustment

21. Pinion shaft

Reassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-32

>>

F

<< 22. Lock pin

>>

G

<< 23. Drive gear

>>

H

<< 24. Differential side bearing inner race

25. Differential side bearing outer race
26. Differential case assembly

>>

I

<< 27. Bearing cap

>>

J

<< • Drive gear backlash adjustment

28. Side bearing nut
29. Lock plate

AC804648

AC502387

AC511010

AB

1

20

19

18

32

17

N

<Vehicles with rear differential lock>

31

N

N

152 ± 15 N·m

19 ± 3 N·m

216 ± 29 N·m

32

31

19 ± 3 N·m

6.9 ± 1.0 N·m

15 ± 2 N·m

15 ± 2 N·m

37 ± 6 N·m

74 ± 5 N·m

Final drive gear kit

Differential kit

N

8.9 ± 1.9 N·m

8.9 ± 1.9 N·m

18 ± 3 N·m

4

14

21

25

26

22

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

21

22

23

24

25 26

27

28

29

30

33

Reassembly steps (Continued)

Reassembly steps 

1. Differential carrier

>>

A

<< 2. Drive pinion rear bearing outer race

>>

B

<< 3. Drive pinion front bearing outer race

>>

C

<< • Drive pinion height adjustment

4. Drive pinion
5. Drive pinion rear shim (for adjusting 

drive pinion height)

6. Drive pinion rear bearing inner race

>>

D

<< • Drive pinion preload adjustment

7. Drive pinion front bearing inner race

>>

D

<< 8. Oil seal

9. Drive pinion spacer
10. Drive pinion front shim (for adjusting 

drive pinion preload)

11. Drive pinion assembly
12. Companion flange
13. Washer
14. Self-locking nut
15. Gasket
16. Rear differential lock detection switch
17. Gasket
18. Air pipe assembly (B)
19. Eye bolt
20. Air pipe assembly (A)
21. Differential case

>>

G

<< 22. Drive gear

23. Pressure plate
24. Actuator assembly

Reassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-33

LUBRICATION AND ADHESIVE POINTS

AC508830AC

<Conventional differential>

<Limited slip differential>

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

REASSEMBLY SERVICE POINTS 

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

>>

H

<< 25. Differential side bearing inner race

26. Differential side bearing outer race
27. Differential case assembly

>>

I

<< 28. Bearing cap

>>

J

<< • Drive gear backlash adjustment

29. Bolt

Reassembly steps (Continued)

30. Bolt
31. Side bearing nut
32. Lock plate
33. Hose

Reassembly steps (Continued)

AC102907AI

MB990938

MB990936 or
MB990937

AC602915AB

MB991445

MB990938

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE

27-34

Use the following special tools to press-fit the drive 
pinion rear bearing outer races into the gear carrier.

• Installer bar (MB990938)

• Installer adapter (MB990936) <2WD (except High 

rider)>

• Installer adapter (MB990937) <2WD High rider, 

5A/T or except vehicles with High power engine>

• Bushing remover and installer base (MB991445) 

<Vehicles with High power engine except 5A/T>

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

ACX01107AB

MB990938

MB990934

Use the following special tools to press-fit the drive 
pinion front bearing outer race.

• Installer bar (MB990938)

• Installer adapter (MB990934)

>>C<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following proce-
dures:

(

)

AC004937AG

Washer

MB990820
(MB990819)
or
MB991169

Drive pinion
attachment

MB990819

1. Apply multipurpose grease to the washer of 

special tool pinion gauge (MB990819).

2. Install the following special tools and drive pinion 

front and rear bearing inner races to the gear 
carrier as shown in the illustration.

• Pinion [MB990820 (MB990819)] <2WD (except 

High rider)>

• Drive pinion gauge attachment (MB991169) 

<2WD High rider, 4WD>

•

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

MB990685

Pinion gauge (MB990819)

3. Tighten the nut of special tool a little at a time 

while measuring the turning torque of the drive 
pinion by using the following special tools. Then 
confirm that the turning torque (without oil seal) is 
at the standard value.

• Preload socket (MB990326)

• Torque wrench (MB990685)

Standard value: