Mitsubishi Outlander (2003+). Manual - part 238

 

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Mitsubishi Outlander (2003+). Manual - part 238

 

 

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-23

DISASSEMBLY SERVICE POINTS

<<A>> DIFFERENTIAL CASE 
ASSEMBLY/DIFFERENTIAL SIDE BEARING 
SPACER/DIFFERENTIAL SIDE BEARING OUTER 
RACE REMOVAL

CAUTION

When taking out the differential case assembly, 
be careful not to drop and damage the differential 
side bearing spacers and differential side 
bearing outer races.

Use the wooden handle of a hammer to remove the 
differential case assembly, differential side bearing 
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side 
bearing spacers separate, so that they do not 
become mixed during reassembly.

<<B>> DIFFERENTIAL SIDE BEARING INNER 
RACE REMOVAL

Use special tool side bearing puller (MB990810) to 
pull out the side bearing inner races.
NOTE:  There are two notches provided (at the 
differential case side) for the claw part of the special 
tools; use special tool  at that position.

<<C>> DRIVE GEAR REMOVAL

1. Make the mating marks to the differential case 

and the drive gear.

2. Loosen the drive gear attaching bolts in a 

diagonal sequence to remove the drive gear.

<<D>> LOCK PIN REMOVAL

Drive out the lock pin with a punch.

<<E>> SELF-LOCKING NUT REMOVAL

Use special tool end yoke holder (MB990850) to hold 
the companion flange, and then remove the 
companion flange self-locking nut.

AC102889

AC107274 AB

MB990810

Socket
wrench

AC102891

Mating
marks

AC

AC102892

AC102893AC

MB990850

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-24

<<F>> DRIVE PINION ASSEMBLY/COMPANION 
FLANGE REMOVAL

CAUTION

The mating mark made on the companion flange 
must not be on the coupling surface of the 
companion flange and the front propeller shaft.
1. Make mating marks on the drive pinion and 

companion flange.

2. Use special tool side bearing puller (MB990810) 

to pull out the companion flange.

<<G>> DRIVE PINION REAR BEARING INNER 
RACE REMOVAL

Use the following special tools to pull out the drive 
pinion rear bearing inner race.

Bearing puller (MB990339)

Pinion bearing remover (MB990374)

<<H>> OIL SEAL/DRIVE PINION FRONT 
BEARING INNER RACE/DRIVE PINION FRONT 
BEARING OUTER RACE REMOVAL

Use special tool bras bar (MB990939) to remove the 
oil seal, drive pinion front bearing inner race, and 
drive pinion front bearing outer race.

<<I>> DRIVE PINION REAR BEARING OUTER 
RACE REMOVAL

Use special tool brass bar (MB990939) to remove 
the drive pinion rear bearing outer race.

AC102894

MB990810

AD

Companion
flange

AC102895AD

MB990374

MB990339

AC102896 AC

MB990939

Drive pinion
front bearing
inner race

Oil seal

Drive pinion
front bearing
outer race

AC102897

MB990939

AC

Drive pinion
rear bearing
outer race

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-25

REASSEMBLY

M1272002300288

AC301213

22 23

24

25

26

20

17

10

11

14

13

12

15

16

6

1

3

8

9

7

5

2

34

29

28

27

21

19

18

N

32

N

N

4

N

186 ± 29 N·m

17 18

19

20

24

25

26

64 ± 4 N·m

84 ± 4 N·m

36 ± 5 N·m

49 ± 9 N·m

37 ± 2 N·m

15

5

23

17

18

17

18

20

20

AB

Final drive gear set

Differential gear set

37 ± 2 N·m

N

N

31

30

33

Reassembly steps

1. Differential carrier

>>A<<

2. Oil seal

>>B<<

3. Drive pinion rear bearing outer race

>>C<<

4. Drive pinion front bearing outer race

>>D<<

Drive pinion height adjustment

5. Drive pinion
6. Drive pinion rear shim (for adjusting 

drive pinion height)

7. Drive pinion rear bearing inner race
8. Drive pinion spacer

>>E<<

Drive pinion turning torque 
adjustment

9. Drive pinion front shim (for adjusting 

drive pinion turning torque)

10. Drive pinion assembly
11. Drive pinion front bearing inner race

>>E<<

12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut
16. Differential case

>>F<<

Differential gear backlash adjustment

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

>>G<<

22. Lock pin

>>H<<

23. Drive gear

>>I<<

24. Differential side bearing inner race
25. Differential side bearing outer race
26. Differential side bearing spacer
27. Differential case assembly

>>J<<

28. Bearing cap
29. Vent plug
30. Differential cover
31. Packing
32. Drain plug
33. Gasket
34. Filler plug

>>J<<

Final drive gear backlash adjustment

Reassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-26

Lubrication and Adhesive Points 

REASSEMBLY SERVICE POINTS 

>>A<< OIL SEAL PRESS-FITTING

Use the following special tools to press-fit a new oil 
seal.

Installer bar (MB990938)

Oil seal installer (MB991115)

>>B<< DRIVE PINION REAR BEARING OUTER 
RACE PRESS-FITTING

AC301214AB

2    3 mm 
(bead diameter)

 –

Adhesive: 

Semi-driying sealant: 
3M ATD Part No.8661 or equivalent

3M Stud Locking 4170 or
equivalent

Vent plug

AC102740

MB990938

MB991115

AC

AC102907

MB990938

MB990935

AD

 

 

 

 

 

 

 

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