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Mitsubishi Outlander (2003+). Manual - part 240

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-31

>>H<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.

2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x
1.25). Clean the threaded holes by applying
compressed air.

3. Apply the specifed sealant to the threaded holes

of the drive gear.

Specified sealant: 3M stud locking 4170 or
equivalent

4. Install the drive gear onto the differential case with

the mating marks properly aligned. Tighten the
drive gear attching bolts to the specified torque in
a diagonal sequence.

Tightening torque: 84

4 N

⋅

>>I<< DIFFERENTIAL SIDE BEARING INNER
RACE INSTALLATION

Use special tool bearing installer (MB990728) to
press-fit the differential side bearing inner races into
the differential case.

>>J<< BEARING CAP INSTALLATION/FINAL
DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the final drive gear backlash by the following
procedure:
1. Assemble the differential case with the side

bearing outer race to the differential carrier.

2. Press the differential case to one side to measure

the clearance of the side bearing outer race and
the differential carrier.

3. Select two pairs of side bearing spacers.

Determine the thickness by adding 1/2 of the
clearance to the pre-load 0.05mm.

4. Remove the side bearing by using special tool

side bearing puller (MB990810).
NOTE: Hook the claws of special tool with the
side bearing inner race by using the notches (two
areas) of the differential case side.

5. Assemble the selected side bearing spacers to

each side.

ACX01068

Tap

ACX02430 AB

AC102942

MB990728

Piece of
metal

ACX01071AD

AC107274 AB

MB990810

Socket
wrench

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-32

6. Use special tool bearing installer (MB990728) to

press-fit the side bearing inner race into the
differential case. After installing the outer race,
assemble the differential case to the differential
carrier.

7. Align the mating marks of differential carrier and

the bearing cap with each other and tighten the
bearing cap attaching bolts to the specified
torque.

Tightening torque: 37

2 N

⋅

8. Measure the final drive gear backlash at four

points or more on the circumference of the drive
gear.

Standard value: 0.11

−

0.16 mm

9. If the backlash is not within the standard value,

move the side bearing spacer as shown in the
illustration to adjust the backlash.
NOTE: The increment of side bearing spacer
must be the same as the decreased amount.

10.Inspect the tooth condition at the final drive gear

and replace if required. (Refer to

P.27B-19

11.Measure the drive gear runout.

Limit: 0.05 mm

12.If drive gear runout exceeds the limit, remove the

differential case and then the drive gears, moving
them to different positions and reinstall them.

13.If adjustment is not possible, replace the

differential case or drive gear and drive pinion as
a set.

AC102942

MB990728

Piece of
metal