Mitsubishi Pajero Pinin. Manual - part 204

FRONT AXLE – 

Differential Carrier

26-35

REASSEMBLY



34 – 39 Nm*



























 











 



























186 Nm

78 – 88 Nm

35 Nm

59 – 69 Nm

49 Nm

Differential gear set

Final drive gear set

Reassembly steps

1. Differential carrier

"

A

A

2. Oil seal

"

B

A

3. Drive pinion front bearing outer

race

"

C

A

4. Drive pinion rear bearing outer

race

"

D

A D

Drive pinion height adjustment

5. Drive pinion
6. Drive pinion front shim (for drive

pinion height adjustment)

7. Drive pinion front bearing inner

race

8. Drive pinion spacer

"

E

A D

Drive pinion rotation torque adjustment

9. Drive pinion rear shim (for drive

pinion rotation torque adjustment)

10. Drive pinion assembly

11. Drive pinion rear bearing inner race

12. Oil seal
13. Companion flange
14. Washer

15. Self-locking nut
16. Differential case

"

F

A D

Differential gear backlash adjustment

17. Side gear spacer
18. Side gear
19. Pinion washer
20. Pinion gear
21. Pinion shaft

"

G

A

22. Lock pin

"

H

A

23. Drive gear

"

I

A

24. Side bearing inner race
25. Side bearing outer race

"

J

A D

Final drive gear backlash adjustment

26. Side bearing spacer
27. Differential case assembly
28. Bearing cap
29. Vent plug
30. Cover
31. Drain plug
32. Filler plug

NOTE
The fasteners marked by * should be tightened when the
differential gear oil is applied.

FRONT AXLE – 

Differential Carrier

26-36

LUBRICATION, SEALANT AND ADHESIVE POINTS

f 

2 – 3 mm

(Apply to the
entire circumfer-
ence of the lip

Adhesive:

3M Stud Locking 4170 or
equivalent

Sealant:

3M ATD Part No. 8661 or
equivalent

Sealant:

3M ATD Part No. 8661 or
equivalent

(Apply
to the
entire
circum-
ference
of the lip

REASSEMBLY SERVICE POINTS

"

A

A

OIL SEAL INSTALLATION

MB990938

MB991115

FRONT AXLE – 

Differential Carrier

26-37

"

B

A

DRIVE PINION FRONT BEARING OUTER RACE
INSTALLATION

"

C

A

DRIVE PINION REAR BEARING OUTER RACE
INSTALLATION

"

D

A

DRIVE PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height by the following procedure.
1.

Apply multipurpose grease to the washer of the special
tool.

2.

Install the special tool, drive pinion front and rear bearing
inner races to the gear carrier.

3.

Tighten the nut of the special tool while measuring the
rotation torque of the drive pinion. Gradually keep
tightening the nut of the special tool until the rotation
torque of the drive pinion (without oil seal) is at the standard
value.

Standard value:

Bearing division

Bearing lubrication

Rotation torque
Nm

New

None (With
anti-rust agent)

0.88 – 1.17*

1

 

0.29 – 0.49*

2

New or reused

Gear oil applied

0.39 – 0.49*

1

 

0.147 – 0.245*

2

NOTE
*

1

: A/T

*

2

: M/T

MB990938

MB990926

MB990938

MB990929

MB990903
<M/T>

MB990835
<A/T>

MB990836
(MB990835)
<A/T>

Washer

MB990903 <M/T>
MB990835 <A/T>

FRONT AXLE – 

Differential Carrier

26-38

NOTE
The special tool cannot be turned a full revolution, so
turn it several times within the range of movement to
run in the bearing, and then measure the rotation torque.

4.

Clean the side bearing hub.

5.

Install the special tools to the side bearing hub of the
gear carrier, and then install the bearing cap.

NOTE
Always check that the notch is in the shown position
and that the special tools are touching firmly against the
side bearing hub.

6.

Use a thickness gauge to measure the clearance (A)
between the special tools.

7.

Remove the special tools.

8.

Use a micrometer to measure the special tool in the places
(B, C) shown in the illustration.

9.

Install the bearing cap, and then use a cylinder gauge
and micrometer to measure the inside diameter (D) of
the bearing cap as shown in the illustration.

10. Calculate the thickness (E) of the required drive pinion

front shim by the following formula, and then select a
shim which most closely matches this thickness.
E = A + B + C–1/2D–86.0

11. Fit the selected drive pinion front shim(s) to the drive

pinion, and press-fit the drive pinion front bearing inner
race by using the special tool.

MB990326

Notch

Thickness 
gauge

A

MB990903 <M/T>

MB990392 <A/T>

MB991170 <M/T>

MB990836 <A/T>

B

C

D

Bearing cap

Drive
pinion
front
shim

MB990829

MB990829