Mitsubishi Outlander (2013+). Manual - part 406

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-28

REASSEMBLY

M1271005500266

ACB05752

16

15

18

21

24

23 22

26

27

19

20

N

N

N

N

18

AB

N

190 ± 30 N·m

43 ± 7 N·m

41 ± 5 N·m

23 ± 3 N·m

32 ± 2 N·m

32 ± 2 N·m

48 ± 6 N·m

21

15

15

1

2

4

7

5

6

8

13

15

17

17

23

22

28

29

30

31

32

33

3

9

4

10

11

N

12

14

16

17

19

20

24

25

12

14

14

14

17

Differential gear set

Final drive gear set

Pinion shaft kit

Reassembly steps 

1.

Differential carrier

>>

A

<<

2.

Drive pinion rear bearing outer 
race

>>

B

<<

3.

Drive pinion front bearing outer 
race

>>

C

<<

•

Drive pinion height adjustment

4.

Drive pinion

5.

Drive pinion rear shim (for drive 
pinion height adjustment)

6.

Drive pinion rear bearing inner 
race

7.

Drive pinion spacer

>>

D

<<

•

Drive pinion rotation torque 
adjustment

8.

Drive pinion front shim (for drive 
pinion rotation torque adjustment)

9.

Drive pinion assembly

10. Drive pinion front bearing inner 

race 

>>

D

<<

11. Oil seal
12. Differential nut
13. Differential case

>>

E

<<

•

Differential gear backlash 
adjustment

14. Side gear spacer
15. Side gear
16. Pinion washer
17. Pinion gear
18. Pinion shaft

>>

F

<<

19. Lock pin

>>

G

<<

20. Drive gear

>>

H

<<

21. Differential side bearing inner race
22. Differential side bearing outer race
23. Differential side bearing spacer
24. Differential case assembly

>>

I

<<

•

Final drive gear backlash 
adjustment

25. Vent plug
26. Differential cover assembly

Reassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-29

LUBRICANT/SEALANT APPLICATION 
POINTS

ACB05759

Vent plug

AB

Electronic control
coupling side

Differential
side

Semi-drying sealant: 
ThreeBond 1215, 1216, 1217 or equivalent

Semi-drying sealant: 
ThreeBond 1217

Adhesive: 
LOCTITE No.271

Semi-drying sealant: 
ThreeBond 1215, 1216, 
1217 or equivalent

2    3 mm
(bead diameter)

REASSEMBLY SERVICE POINTS

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

>>

J

<<

27. Oil seal
28. Wave washer
29. Electronic control coupling
30. Gasket
31. Drain plug

Reassembly steps (Continued)

32. Gasket
33. Filler plug

Reassembly steps (Continued)

AC302476

AC505817AB

MB990938

MB990934

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-30

Use the following special tools to press-fit the drive 
pinion rear bearing outer race:

• Installer adapter (MB990934)

• Installer bar (MB990938)

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

AC302477

AC505818AB

MB990938

MB990930

Use the following special tools to press-fit the drive 
pinion front bearing outer race:

• Installer adapter (MB990930)

• Installer bar (MB990938)

>>C<< DRIVE PINION HEIGHT 
ADJUSTMENT

Adjust the drive pinion height in the following steps. 

AC505831AB

MB992116,
MB992128

MB992115

1. Use the following special tools to assemble the 

drive pinion front and rear bearing inner laces 
onto the gear carrier:

• Dummy pinion gauge body (MB992115)

• Dummy pinion gauge head (MB992116)

• Hex socket head bolt (MB992128)

CAUTION

The bearing must be free from gear oil.

AC509363AB

MB992115

2. Measure the drive pinion rotation torque.

Standard value:

Bearing type

Bearing 
lubrication

Rotation torque 
N

⋅m

New

None 

 

 (coated with 
rust inhibitor oil)

0.7 

− 1.2

NOTE: After seating the bearing, measure the 
rotation torque.

ACC00528AB

A

MB992111

Shim

MB992116,
MB992128

MB992117

Flange bolt 
(M10 × 75 mm)

3. Set special tool cylinder gauge (MB992117) on 

the differential carrier side bearing, and use 
special tool side bearing holder (MB992111) to 
install it to the differential carrier.

Make sure that the cut-off part of the cylinder 
gauge is positioned as shown in the figure, and 
the cylinder gauge is closely contacted with the 
side bearing. Then tighten a flange bolt (M10 

× 75 

mm) to the specified torque.

Tightening torque: 43 

± 7 N⋅m

4. Select the drive pinion rear shim(s) that 

corresponds to the gap between the special tools.

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-31

NOTE: 

.

1. Clean the side bearing.
2. When setting the special tool, make sure that 
its cut-off part is positioned as shown in the figure, 
and it is closely contacted with the side bearing. 
3. Try to minimize the number of the drive pinion 
rear shim(s) to be used.

ACX02432

MD998816

MB998816

AE

Drive pinion
rear shim

5. Fit the selected drive pinion rear shim(s) onto the 

drive pinion. Use special tool installer adapter 
(MD998816) to press-fit the drive pinion rear 
bearing inner race.

>>D<< DRIVE PINION ROTATION 
TORQUE ADJUSTMENT/OIL SEAL 
PRESS-FITTING

Adjust the drive pinion rotation torque in the following 
steps:
1. Insert the drive pinion into the gear carrier. From 

rear side of the carrier, assemble the drive pinion 
spacer, drive pinion front shim and drive pinion 
front bearing inner race.

NOTE: Do not assemble the oil seal.

AC302590

AC505809

AB

MB992112

MB992113

2. Use the following special tools to tighten the 

differential nut to the specified torque:

• Locking nut wrench (MB992112)

• Drive pinion holder (MB992113)

3. Rotate the drive pinion several turns, and then 

measure the drive pinion rotation torque.

Standard value:

Bearing type

Bearing 
lubrication

Rotation torque 
N

⋅m

New

None 

 

 (coated with 
rust inhibitor oil)

0.7 

− 1.2

4. When the rotation torque is not within the 

standard value range, adjust the torque by 
selecting the drive pinion front shim(s).

NOTE: 

AC505850AB

A

When selecting the drive pinion front shim(s), 
select the drive pinion spacer to minimize the 
number of the shims to be used. There are two 
drive pinion spacers available:

Drive pinion spacer height A mm

24.3

23.6

AC302590

AC505809

AB

MB992112

MB992113

5. Use the following special tools to tighten the 

differential nut to the specified torque:

• Locking nut wrench (MB992112)

• Drive pinion holder (MB992113)

Tightening torque: 190 

± 30 N⋅m