Mitsubishi Outlander GS45X. Manual - part 1523

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-41

LUBRICANT/SEALANT APPLICATION POINTS

AC703523

Adhesive: 3M

TM

 AAD Part No. 

8730, 8731 or equivalent

Vent plug

2    3 mm (0.08    0.12 in)
(bead diameter)

–

–

 

AB

Electronic control 
coupling side

Differential side

Semi-drying sealant: 3M

TM

 AAD Part No. 8672,

8679, 8678, 8661, 8663 or equivalent

 

Semi-drying sealant: 3M

TM

 AAD Part No. 8672,

8679, 8678, 8661, 8663 or equivalent

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-42

ASSEMBLY SERVICE POINT

.

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

Use special tools MB990934 and MB990938 to press-fit the 
drive pinion rear bearing outer race.

.

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

Use special tools MB990930 and MB990938 to press-fit the 
drive pinion front bearing outer race.

.

>>C<< DRIVE PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height in the following steps. 
1. Use special tools MB992115, MB992116 and MB992128 to 

assemble the drive pinion front and rear bearing inner races 
onto the differential carrier:

CAUTION

The bearing must be free from gear oil.

2. Measure the drive pinion rotation torque.

Standard value:

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

AC703524 AB

MB990938

MB990934

AC703525 AB

MB990938

MB990930

Bearing 
division

Bearing 
lubrication

Rotation torque  
N

⋅m (in-lb)

New

None 

 

 (coated with 
rust inhibitor oil)

0.7 

− 1.2  

(6.20 

− 10.62)

AC703526 AB

MB992116,
MB992128

MB992115

AC703527AB

MB992115

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-43

3. Set special tool MB992117 on the differential carrier side 

bearing, and use special tool MB992111 to assemble it onto 
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.

Tightening torque: 48 

± 6 N⋅m (36 ± 4 ft-lb)

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

gap between the special tools.
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.

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

pinion. Use special tool 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 differential 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.

2. Use special tools MB992112 and MB992113 to tighten the 

differential nut to the specified torque.

3. Rotate the drive pinion several turns, and then measure the 

drive pinion rotation torque.

Standard value:

AC703528AB

MB992117

A

MB992111

MB992116,
MB992128

Cut-off 
part

Shim

AC703529AB

MD998816

MD998816

Drive pinion 
rear shim

Bearing 
division

Bearing 
lubrication

Rotation torque  
N

⋅m (in-lb)

New

None 

 

 (coated with 
rust inhibitor oil)

0.7 

− 1.2  

(6.20 

− 10.62)

AC703518AB

MB992112

MB992113

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-44

4. When the rotation torque is not within the standard value 

range, adjust the torque by selecting the drive pinion front 
shim(s).
NOTE: 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:

5. Use special tools MB992112 and MB992113 to tighten the 

differential nut to the specified torque.

Tightening torque: 190 

± 3 N⋅m (140 ± 22 ft-lb)

6. Use special tool MB991180 to press-fit the oil seal.
7. Rotate the drive pinion several turns, and then measure the 

drive pinion rotation torque. 

Standard value:

8. When the rotation torque is not within the standard value, 

check the differential locking nut tightening torque or the oil 
seal assembly condition.

.

>>E<< DIFFERENTIAL GEAR BACKLASH 
ADJUSTMENT

Adjust the differential gear backlash in the following steps.
1. Assemble the side gear, side gear spacer, pinion gear and 

pinion washer into the differential case.

2. Temporarily assemble the pinion shaft.

NOTE: Do not assemble the lock pin at this stage.

Drive pinion spacer height A  mm (in)

24.3 (0.96)

23.6 (0.93)

Bearing 
division

Bearing 
lubrication

Rotation 
torque  N

⋅m 

(in-lb)

New

None (coated with 
rust inhibitor oil)

0.7 

− 1.2  

(6.20 

− 10.62)

AC703530AB

A

AC703518AB

MB992112

MB992113

AC703531AB

MB991180

AC703532 AB