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Mitsubishi Outlander (2013+). Manual - part 405

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-24

DISASSEMBLY SERVICE POINTS

<<A>> PRE-DISASSEMBLY CHECK

1. Remove the differential case assembly,

differential side bearing spacer and differential
side bearing.

2. Fix the following special tools in a vice, and install

the differential carrier assembly.

• Working base (MB990909)

•

AC505868AC

MB992111

Flange bolt
(M10 × 75 mm)

Working base adapter (MB991116)

3. Use special tool side bearing holder (MB992111)

to install the differential case assembly, differential
side bearing spacer and differential side bearing
to the differential carrier, then perform the
following checks. Then tighten a flange bolt (M10
× 75 mm) to the specified torque.

Tightening torque: 43

± 7 N⋅m

DRIVE GEAR BACKLASH

AC612539

1. Set a dial gauge against the drive gear teeth edge

and fix the drive pinion. Rotate the drive gear to
measure the backlash at four or more points.

Standard value: 0.08

− 0.15 mm

2. When the backlash is not within the standard

value range, adjust the final drive gear backlash.
(Refer to

P.27B-28

3. After the adjustment, check the final drive gear

teeth contact.

DRIVE GEAR RUNOUT ON BACKSIDE

AC612540

1. Set a dial gauge against the backside of the drive

gear. Rotate the drive gear to measure the runout.

Limit : 0.05 mm

2. When the runout exceeds the limit, check for the

foreign material between the backside of the drive
gear and the differential gear case, and looseness
of the drive gear mounting bolt.

3. When the runout measured in step 2 is normal,

change the position of the drive gear and
differential case, and measure the runout again.

4. If the adjustment is not possible, replace the

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

DIFFERENTIAL GEAR BACKLASH

AC102885

Wedge

Side gear
spacer

1. Drive the wooden wage between one of the side

gears and the pinion shaft to fix one side of the
side gear. Then, set a dial gauge (with the
measuring rod extended) against the pinion gear,
and measure the backlash to check that it is within
the standard value. Repeat the same procedure
to measure the backlash at the other pinion gear.

Standard value: 0

− 0.076 mm

Limit : 0.2 mm

2. When the backlash exceeds the limit, adjust the

backlash of the differential gear(Refer to

P.27B-28

3. When the adjustment is not possible, replace the

side gear and the pinion gear as a set.

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-25

FINAL DRIVE GEAR TEETH CONTACT
ADJUSTMENT

Check the final drive gear teeth contact in the follow-
ing steps:

AC612541

1. Apply the bearing blue on the drive gear teeth (on

both sides) thinly and evenly.

AC709328 AB

MB990939

2. Insert special tool remover bar (MB990939)

between the gear carrier and the drive gear
installation side of the differential case. While
applying load to the drive gear rotation so that
approx. 2.5 to 2.9 N

⋅m rotation torque is applied to

the drive pinion, rotate the drive pinion by hand
(360 degrees clockwise and anti-clockwise
respectively).

CAUTION

Do not let the drive gear rotated over 360
degrees. It makes the gear contact pattern
unclear.

3. Check contact of the final drive gear teeth.

Normal contact pattern

Cause

Measures

1. Small-end side
2. Drive-side tooth face (the side
to which the force is applied
while driving forward)
3. Large-end side
4. Coast-side tooth face (the
side to which the force is applied
while driving
backward)

ACX01039

Contact pattern indicating that
the drive pinion height is too
high

AC104880

Drive pinion is too much away
from the centre of the drive gear.

AC104881

Increase thickness of the drive pinion
rear shim to bring the drive pinion
closer to the centre of the drive gear.
Then move the drive gear away from
the drive pinion for the final drive gear
backlash adjustment.

Contact pattern indicating that
the drive pinion height is too
low

AC104882

Drive pinion is too close to the
centre of the drive gear.

AC104883

Reduce thickness of the drive pinion
rear shim to bring the drive pinion away
from the centre of the drive gear. Then
move the drive gear closer to the drive
pinion for the final drive gear backlash
adjustment.

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-26

NOTE:

1. Checking the contact pattern is the method to

check that the drive pinion height and the final
drive gear backlash are or are not adjusted prop-
erly. Repeat the adjustments of the drive pinion
height and the final drive gear backlash until the
contact pattern similar to the normal pattern.

2. If the normal contact pattern cannot be obtained

even after making the adjustments, the drive gear
and the drive pinion have been worn exceeding
the usage limit. Replace both gears as a set.

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

CAUTION

When removing the differential case assembly,
remove it slowly with care not to drop the differ-
ential side bearing spacer and the differential
side bearing outer race.
Remove the differential case assembly, differential
side bearing spacer and differential side bearing
outer race.

NOTE: Identify the RH and LH side bearing spacers
as a reference for the reassembly operation.

<<C>> DIFFERENTIAL SIDE BEARING
INNER RACE REMOVAL

AC102890AB

MB990810

Socket
wrench

Use special side bearing puller (MB990810) to
remove the differential side bearing inner race.

NOTE: Hook the claws of the special tool on the dif-
ferential side bearing inner race through two cut-off
parts on the differential case side.

<<D>> DRIVE GEAR REMOVAL

AC102891

Mating
marks

1. Put mating marks on the drive gear and

differential case as a reference for the reassembly
operation.

2. Loosen the drive gear tightening bolts in a

diagonal order to remove the drive gear.

<<E>> LOCK PIN DRIVING OUT

AC102892

<<F>> DIFFERENTIAL NUT REMOVAL

AC302590

AC505809

MB992112

MB992113

Use the following special tools to remove the differ-
ential nut:

• Locking nut wrench (MB992112)

• Drive pinion holder (MB992113)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-27

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

AC104970 AB

MB990560

Use special rear axle shaft bearing remover
(MB990560) to remove the drive pinion rear bearing
inner race.

<<H>> DRIVE PINION FRONT BEARING
OUTER RACE REMOVAL

AC302461

AC505811AB

MB990939

Drive pinion
rear bearing
outer race

Drive pinion
front bearing
outer race

Use special remover bar (MB990939) to remove the
drive pinion front bearing outer race.

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

AC302462

AC505812

MB990939

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

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