Mitsubishi Outlander (2003+). Manual - part 174

TRANSMISSION CASE

MANUAL TRANSMISSION OVERHAUL

22B-49

2. Be sure the bushing is fully seated as shown. It 

must be 3 mm below the housing surface.

>>B<< NEEDLE BEARING INSTALLATION
1. Check the installation direction of the needle 

bearing.

2. Press fit the needle bearing until it is flush with the 

case.

>>C<<OIL SEAL INSTALLATION

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 

75W-85W conforming to API classification GL-4).

2. Using special tool Differential oil seal installer 

(MD998325), press fit the oil seal into the 
transaxle case.

AK204304

3 mm

AC

AK204287

Model number
stamped side

AB

AK204286AB

AK204288

MD998325

AB

DIFFERENTIAL

MANUAL TRANSMISSION OVERHAUL

22B-50

DIFFERENTIAL

DISASSEMBLY AND REASSEMBLY

M1222002500146

<F5M42>

DISASSEMBLY SERVICE POINT

<<A>> TAPER ROLLER BEARING REMOVAL

1. Using special tool Bearing remover (MD998801), 

support the taper roller bearing, and then set them 
on the press.

AK204408

2

3

8

6

5

4

8

132 ± 5 N·m

1

7

5

2

6

9

AB

Apply gear oil to all
moving parts before
installation.

Disassembly steps

>>D<<

1.

Differential drive gear

<<A>>

>>C<<

2.

Taper roller bearing

>>B<<

3.

Lock pin

>>A<<

4.

Pinion shaft

>>A<<

5.

Pinion

>>A<<

6.

Washer

>>A<<

7.

Side gear

>>A<<

8.

Spacer

9.

Differential case

AK204289

MD998801

AB

DIFFERENTIAL

MANUAL TRANSMISSION OVERHAUL

22B-51

2. Push down on the differential case with the press 

and  remove the bearing.

REASSEMBLY SERVICE POINTS

>>A<< SPACER/SIDE 
GEAR/WASHER/PINION/PINION SHAFT 
INSTALLATION

1. After a spacer has been mounted on the back 

surface of the side gear, install the side gear in the 
differential case.
NOTE: When a new side gear is to be installed, 
mount a medium thickness spacer.

2. Set the washer on the back of each pinion, and 

put both pinions simultaneously in mesh with the 
side gears. While rotating them, install them in 
position.

3. Insert the pinion shaft.

4. Measure the backlash between the side gear and 

pinion.

Standard value: 0 

−

 0.15 mm

5. If the backlash is out of specification, select a 

spacer that should get the back lash with in the 
standard value and re-measure the backlash.
NOTE: Repeat until the backlash on  both sides 
are equal.

>>B<< LOCK PIN INSTALLATION

Install the lock pin so that it will be oriented in the 
direction shown.

>>C<< TAPER ROLLER BEARING INSTALLATION

Using special tools, install the taper roller bearing 
with the press.

•

Installer cap (MD998812)

•

Installer adapter (MD998823)

>>D<< DIFFERENTIAL DRIVE GEAR 
INSTALLATION

AKX00768

AKX00770

AKX00766

AK204290

Differential case

Lock pin

Pinion shaft

AB

AK204319

MD998812

Taper roller
bearing

MD998823

AC

AK204320AB

DIFFERENTIAL

MANUAL TRANSMISSION OVERHAUL

22B-52

1. Apply sealant (3M STUD Locking No.4170 or 

equivalent) to the entire threaded portion of the 
bolt.

2. Tighten to the specified torque in the illustrated 

sequence.

Tightening torque: 132 

±

 5 N

⋅

m

AK204221 AC

1

3

4

6

8

7

2

5