Mitsubishi Outlander GS45X. Manual - part 1521

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-33

DISASSEMBLY

M1271005400106

AC703501

15

13

7

12

30

5

21

1

8

9

N

N

4

N

N

N

20 19

11

AB

3

2

N

6

10

11

12

14

13

16 1718

19

20

22

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24

25

26

27

28

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31

32

33

10

17

18

9

N

Disassembly steps 

1.

Filler plug

2.

Gasket

3.

Drain plug

4.

Gasket

5.

Electronic control coupling

6.

Washer

7.

Differential cover assembly

8.

Vent plug

9.

Oil seal

<<

A

>>

10. Pre-disassembly check

<<

B

>>

•

Differential case assembly

<<

B

>>

11. Differential side bearing spacer

<<

B

>>

12. Differential side bearing outer race

<<

C

>>

13. Differential side bearing inner race

<<

D

>>

14. Drive gear

<<

E

>>

15. Lock pin
16. Pinion shaft
17. Pinion gear
18. Pinion washer
19. Side gear

20. Side gear spacer
21. Differential case

<<

F

>>

22. Differential nut
23. Drive pinion assembly
24. Drive pinion front shim (for drive 

pinion rotation torque adjustment)

25. Drive pinion spacer

<<

G

>>

26. Drive pinion rear bearing inner 

race

27. Drive pinion rear shim (for drive 

pinion height adjustment)

28. Drive pinion
29. Oil seal
30. Drive pinion front bearing inner 

race 

<<

H

>>

31. Drive pinion front bearing outer 

race

<<

I

>>

32. Drive pinion rear bearing outer 

race

33. Differential carrier

Disassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-34

Required Special Tools:

• MB990560: Rear Axle Shaft Bearing Remover

• MB990810: Side Bearing Puller

• MB990909: Working Base

• MB990939: Remover Bar

• MB991116: Working Base Adapter

• MB992111: Side Bearing Holder

• MB992112: Lock Nut Wrench

• MB992113: Drive Pinion Holder

DISASSEMBLY SERVICE POINT

.

<<A>> INSPECTION BEFORE DISASSEMBLY

1. Remove the differential case assembly, differential side 

bearing spacer and differential side bearing.

2. Hold special tools MB990909 and MB991116 in a vise, and 

install the differential carrier assembly to the special tool.

3. Use special tool MB992111 to install the differential case 

assembly, differential side bearing spacer and differential 
side bearing to the differential carrier, then perform the 
following checks. 

Tightening torque: 48 

± 6 N⋅m (36 ± 4 ft-lb)

.

DRIVE GEAR BACKLASH

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 (0.003 − 0.006 inch)

2. When the backlash is not within the standard value range, 

adjust the final drive gear backlash. (Refer to 

P.27B-39

.)

3. After adjustment, check the final drive gear teeth contact. 

.

DRIVE GEAR RUNOUT ON BACKSIDE

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

Rotate the drive gear to measure the runout.

Limit: 0.05 mm (0.002 inch)

2. When the runout exceeds the limit value, 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. 

.

AC703503

MB992111

AB

AC612539

AC612540

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-35

DIFFERENTIAL GEAR BACKLASH

1. Drive the wooden wedge 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 (0 − 0.0030 inch)

Limit: 0.2 mm (0.01 inch)

2. When the backlash exceeds the limit value, adjust the 

backlash of the differential gear.(Refer to 

P.27B-39

.)

3. When the adjustment is not possible, replace the side gear 

and the pinion gear as a set. 

.

FINAL DRIVE GEAR TEETH CONTACT 
ADJUSTMENT

Check the final drive gear teeth contact in the following steps:
1. Apply the bearing blue on the drive gear teeth (on both 

sides) thinly and evenly.

2. Insert special tool MB990939 between the differential carrier 

and the drive gear installation side of the differential case. 
While applying load to the drive gear so that the rotation 
torque [approximately 2.5 

− 2.9 N⋅m (22.1 − 25.7 in-lb)] is 

applied to the drive pinion, rotate the drive pinion by hand 
(360 degrees clockwise and counterclockwise 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.

AC703506AB

Side gear 
spacer

Side gear 
spacer

Wedge

AC612541

AC709328AC

MB990939

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-36

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 properly. 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 differential 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 refer-
ence for the reassembly operation.

.

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)

Contact pattern indicating that 
the drive pinion height is too 
high

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

Increase thickness of the drive pinion 
rear shim to bring the drive pinion 
closer to the center 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

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

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

AC703509AB

1

3

2

4

AC703510AB

1

3

2

4

AC703511AB

1

3

2

4

AC703512AB

1

3

2

4

AC703513AB

1

3

2

4