Mitsubishi Outlander (2003+). Manual - part 175

CENTER DIFFERENTIAL

MANUAL TRANSMISSION OVERHAUL

22B-53

CENTER DIFFERENTIAL

DISASSEMBLY AND REASSEMBLY

M1222002800051

<W5M42>

DISASSEMBLY SERVICE POINTS

<<A>> TAPER ROLLER BEARING REMOVAL

1. Support the taper roller bearing with special tool 

bearing remover (MD998917), and then set them 
on the press.

AK204225

1

2

5

4

16

8

15

12

11

10

12

13

9

6

7

12

14

17

12

11

9

3

132 ± 5 N·m

AB

Apply gear oil to all
moving parts before
installation.

Disassembly steps

>>D<<

1.

Center differential drive gear

>>C<<

2.

Center differential flange

<<A>>

>>B<<

3.

Taper roller bearing

>>C<<

4.

Snap ring

>>C<<

5.

Front output shaft

>>C<<

6.

Spacer

>>C<<

7.

Side gear

>>C<<

8.

Lock pin

>>C<<

9.

Pinion shaft

>>C<<

10. Pinion shaft holder

>>C<<

11. Pinions

>>C<<

12. Washers

>>C<<

13. Side gear

>>C<<

14. Spacer

<<B>>

>>A<<

15. Taper roller bearing
16. Speed meter drive gear
17. Differential case

AK204264AB

MD998917

CENTER DIFFERENTIAL

MANUAL TRANSMISSION OVERHAUL

22B-54

2. Push down on the differential case with the press 

to remove the bearing.

<<B>> TAPER ROLLER BEARING REMOVAL

1. Support the taper roller bearing with special tools, 

and then set them on the press.

•

Bearing remover (MD998917)

•

Installer adapter (MB990930)

2. Push down on the differential case with the press 

to remove the bearing.

REASSEMBLY SERVICE POINTS

>>A<< TAPER ROLLER BEARING INSTALLATION

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

•

Installer cap (MD998812)

•

Installer adapter (MD998830)

>>B<< TAPER ROLLER BEARING INSTALLATION

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

•

Installer cap (MD998812)

•

Installer adapter (MD998823)

>>C<< SPACER, SIDE GEAR, WASHER, PINION 
AND PINION SHAFT, PINION SHAFT HOLDER, 
LOCK PIN, FRONT OUTPUT SHAFT, SNAP RING, 
CENTER DIFFERENTIAL FLANGE, 
INSTALLATION

1. Mount a spacer on the back surface of the side 

gear, and then install the side gear in the 
differential case.
NOTE: When a new side gear is to be installed, 
use a medium thickness spacer (0.93 to 1.00 
mm).

2. Place the washers on the back of the pinions, and 

simultaneously mesh the four pieces with the side 
gears. Place them into position while rotating 
them. Then, install the pinion shaft holder.

3. Insert the pinion shaft.

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

direction shown.

5. Install the front output shaft on the side gear, and 

install the snap ring.

6. Mount a spacer on the back surface of the side 

gear, and then install the side gear in the 
differential case.
NOTE: When a new side gear is to be installed, 
use a medium thickness spacer.

AK204275AB

MD998917

MB990930

AK204297AB

MD998830

MD998812

AK204308AB

MD998823

MD998812

AK204315

AK204317AC

Differential case

Pinion shaft

Lock pin

CENTER DIFFERENTIAL

MANUAL TRANSMISSION OVERHAUL

22B-55

7. Install the center differential flange by aligning the 

matching marks, and temporarily tighten the four 
machine screws.

8. Measure the backlash between the side gear and 

pinion.

Standard value: 0.025 

−

 0.150 mm

9. If the backlash is out of the standard value, select 

a spacer and re-measure the backlash.
NOTE: Adjust until the backlash on both sides are 
equal.

>>D<< CENTER DIFFERENTIAL DRIVE GEAR 
INSTALLATION

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

AK204389

AK204320AB

AK204318AB

5

3

1

2

4

6

8

10

7

9

TRANSFER

MANUAL TRANSMISSION OVERHAUL

22B-56

TRANSFER

DISASSEMBLY AND REASSEMBLY

M1222004000084

REASSEMBLY SERVICE POINTS

>>A<< O-RING INSTALLATION
Install a O-ring to the transfer, and apply gear oil 
(Hypoid gear oil API classification GL-5 SAE 90) to 
the O-ring.

>>B<< OIL SEAL INSTALLATION
1. Apply gear oil (Hypoid gear oil API classification 

GL-5 SAE 90).

2. Using special tools, press fit the oil seal into the 

transfer cover.

•

Installer adapter (MB990937)

•

Handle (MB990938)

AK204413

23 ± 3 N·m

1

2

8

10

7

3

11

4

5

9

6

AB

Apply gear oil to all
moving parts before
installation.

Disassembly steps

1.

Dust seal guide

>>E<<

2.

Oil seal

>>D<<

3.

Oil seal

>>A<<

4.

O-ring

>>A<<

5.

O-ring

>>A<<

6.

O-ring

>>C<<

7.

Oil seal

>>B<<

8.

Oil seal

>>A<<

9.

O-ring

10. Transfer cover
11. Transfer

AK204414

MB990937

MB990938

AB