Mitsubishi Pajero Pinin. Manual - part 202

FRONT AXLE – 

Main Shaft

26-27

REMOVAL SERVICE POINT

A

A

"

BEARING REMOVAL

Install the special tool as shown in the illustration, and use
a press to drive out the bearing from the main shaft.

INSTALLATION SERVICE POINTS

"

A

A

OIL SEAL INSTALLATION

"

B

A

BEARING INSTALLATION

"

C

A

OIL SEAL INSTALLATION

MB990673

MB990938

MB990926

MB990663

MB990927

MB990938

FRONT AXLE – 

Differential Carrier

26-28

DIFFERENTIAL CARRIER

REMOVAL AND INSTALLATION

Caution
To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then
fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D

Drive Shaft Removal and Installation 
(Refer to P.26-19.)

D

Stabilizer Bar Removal and Installation 
(Refer to GROUP 33A.)

D

Gear Oil Draining and Refilling (Refer to P.26-11.)

88 Nm

59 – 69 Nm

49 Nm

Sealant:

3M ATD Part No.8661 or
equivalent

4

5

2

6

98 – 118 Nm*

1

3

93 Nm*

93 Nm*

103 Nm

103 Nm

59 – 69 Nm

49 – 59 Nm

Removal steps

A

A

"

D

Support the Engine Assembly

1. Front propeller shaft connection
2. Front differential assembly and 

differential mount crossmember 
assembly

3. Free-wheeling clutch assembly

4. Differential mount bracket assembly

<RH>

5. Differential carrier
6. Differential mount crossmember 

assembly

FRONT AXLE – 

Differential Carrier

26-29

REMOVAL SERVICE POINT

A

A

"

ENGINE ASSEMBLY SUPPORT

Use the special tool to raise the engine assembly until the
mount insulators are free from load.

DISASSEMBLY











































 











Disassembly steps

D

Inspection before disassembly

1. Cover
2. Vent plug
3. Bearing cap

A

A

"

4. Differential case assembly
5. Side bearing spacer
6. Side bearing outer race

A

B

"

7. Side bearing inner race

A

C

"

8. Drive gear

A

D

"

9. Self-locking nut

10. Washer

A

E

"

11. Drive pinion assembly

12. Companion flange
13. Drive pinion spacer
14. Drive pinion rear shim 

(For drive pinion rotation torque
adjustment)

A

F

"

15. Drive pinion front bearing inner

race

16. Drive pinion front shim

(For drive pinion height adjustment)

17. Drive pinion

A

G

"

18

.

Oil seal

A

G

"

19. Drive pinion rear bearing inner race

A

G

"

20. Drive pinion rear bearing outer

race

A

H

"

21. Drive pinion front bearing outer

race

22. Oil seal
23. Differential carrier

A

I

"

24. Lock pin
25. Pinion shaft
26. Pinion gear
27. Pinon washer
28. Side gear
29. Side gear spacer
30. Filler plug
31. Drain plug
32. Differential case

MZ203827

FRONT AXLE – 

Differential Carrier

26-30

INSPECTION BEFORE DISASSEMBLY

1.

Remove the cover.

2.

Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.

DRIVE GEAR BACKLASH

1.

With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.

Standard value: 0.11 – 0.16 mm

2.

If the backlash is not within the standard value, adjust
the backlash of the final drive gear (Refer to P.26-42).

3.

After adjustment, inspect the drive gear tooth contact.

DRIVE GEAR RUNOUT

1.

Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.

Limit: 0.05 mm

2.

When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.

3.

When check (2) gives normal results, reposition drive
gear and differential case and remeasure.

4.

If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.

DIFFERENTIAL GEAR BACKLASH

1.

While locking the side gear with the wedge, measure
the differential gear backlash with a dial indicator on the
pinion gear.

Standard value: 0 – 0.076 mm
Limit: 0.2 mm

Repeat the same procedure for other pinion gear.

MB990909

Side
gear
spacer

Wedge

Side gear
spacer