Mitsubishi Pajero Pinin. Manual - part 203

FRONT AXLE – 

Differential Carrier

26-31

2.

If the backlash exceeds the limit, adjust the differential
gear backlash (Refer to P.26-41).

3.

If adjustment is impossible, replace the side gear and
pinion gear as a set.

DRIVE GEAR TOOTH CONTACT

Check the tooth contact of drive gear by following the steps
below.
1.

Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.

2.

Insert the special tool between the differential carrier and
the differential case, and then rotate the companion flange
by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque (approximately 2.5 –
2.9 Nm) is applied to the drive pinion.

Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.

3.

Check the tooth contact condition of the drive gear and
drive pinion.

MB990939

FRONT AXLE – 

Differential Carrier

26-32

Standard tooth contact pattern

Problem

Solution

1

Narrow tooth side

2

Drive-side tooth surface (the side
applying power during forward
movement)

3

Wide tooth side

4

Coast-side tooth surface (the
side applying power during re-
verse movement)

1

2

4

Tooth contact pattern resulting from
excessive pinion height

The drive pinion is positioned too far
from the centre of the drive gear.

1

2

3

4

Increase the thickness of the drive
pinion rear shim, and position the
drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.

1

2

3

4

3

Tooth contact pattern resulting from
insufficient pinion height.

The drive pinion is positioned too
close to the centre of the drive gear.

1

2

3

4

Decrease the thickness of the drive
pinion rear shim, and position the
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.

1

2

3

4

NOTE
Checking the tooth contact pattern is the way to
confirm that the adjustments of the pinion height
and backlash have been done properly. Continue
to adjust the pinion height and backlash until the
tooth contact pattern resembles the standard
pattern.

If, even after adjustments have been made, the
correct tooth contact pattern cannot be obtained,
it means that the drive gear and the drive pinion
have become worn beyond the allowable limit.
Replace the gear set.

FRONT AXLE – 

Differential Carrier

26-33

DISASSEMBLY SERVICE POINTS

A

A

"

DIFFERENTIAL CASE ASSEMBLY REMOVAL

Remove the differential case assembly with a hammer handle
or the like.
Caution
When taking out the differential case assembly, be careful
not to drop and damage the side bearing outer races.

NOTE
Keep the right and left side bearing outer races and side
bearing spacers separate, so that they do not become mixed
at the time of reassembly.

A

B

"

SIDE BEARING INNER RACE REMOVAL

NOTE
There are two notches provided (at the differential case side)
for the jaws of the special tool; use the special tool at that
position.
If the special tool jaws cannot be inserted between the
differential case and the bearing inner race, file the jaw tips
as necessary.

A

C

"

DRIVE GEAR REMOVAL

1.

Make the mating marks on the differential case and the
drive gear.

2.

Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.

A

D

"

SELF-LOCKING NUT REMOVAL

MB990810

MB990811

Mating marks

MB990850

FRONT AXLE – 

Differential Carrier

26-34

A

E

"

DRIVE PINION ASSEMBLY REMOVAL

1.

Make mating marks on the drive pinion and the companion
flange.

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

2.

Use the special tool to drive out the drive pinion.

A

F

"

DRIVE PINION FRONT BEARING INNER RACE
REMOVAL

A

G

"

OIL SEAL/DRIVE PINION REAR BEARING INNER
RACE/DRIVE PINION REAR BEARING OUTER
RACE REMOVAL

A

H

"

DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL

A

I

"

LOCK PIN DRIVE OUT

Companion
flange

MB990810

MB990560

MB990939

MB990939

Punch