Mitsubishi Outlander GS45X. Manual - part 1524

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-45

3. Drive a wooden wedge between one of the side gears and 

the pinion shaft to fix the side gear.

4. Set a dial gauge (with the measuring rod extended) against 

the pinion gear and measure the backlash. 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)

5. When the backlash exceeds the limit value, adjust it by 

selecting the side gear spacer.

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

and the pinion gear as a set. 

7. After the adjustments, make sure that the backlash is within 

the limit value and the differential gear rotates smoothly.

.

>>F<< LOCK PIN INSTALLATION

1. Align the lock pin holes in the pinion shaft and in the 

differential case, and drive in the lock pin.

2. Use a punch to crimp two points.

.

>>G<< DRIVE GEAR INSTALLATION

1. Remove adhesive on the drive gear tightening bolts.
2. Use a tap to remove adhesive in the drive gear screw holes, 

and clean the holes by blowing air.

3. Apply the specified thread locking compound in the drive 

gear screw holes.

Specified adhesive: 3M 

™ AAD Part No.8730, 8731 or 

equivalent

4. Align the mating marks and assemble the drive gear to the 

differential case. 

Tightening torque: 41 

± 5 N⋅m (30 ± 3 ft-lb)

.

AC703506AB

Side gear 
spacer

Side gear 
spacer

Wedge

AC703533 AB

AC703534AB

M8 X 1.0 (pitch)

AC703535AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-46

>>H<< DIFFERENTIAL SIDE BEARING INNER 
RACE INSTALLATION

Use special tool MB990829 to press-fit the differential side 
bearing inner race.

.

>>I<< FINAL DRIVE GEAR BACKLASH 
ADJUSTMENT

Adjust the final drive gear backlash in the following steps:
1. To the differential carrier, install the differential case with the 

side bearing outer race assembled.

2. Press the differential case to one side, and measure 

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

3. Select two pairs of the side bearing spacers. (Thickness: 1/2 

of the measured clearance with 0.05 mm  (0.002 inch) 
preload added) 

4. Use special tool MB992111 to install the differential case to 

the differential carrier. 

Tightening torque: 48 

± 6 N⋅m (36 ± 4 ft-lb)

5. Measure the final drive gear backlash at four or more points.

Standard value: 0.08 

− 0.15 mm (0.003 − 0.006 inch)

AC703536AB

MB990829

Piece of 
metal

Piece of 
metal

AC612543

AC703503

MB992111

AB

AC612539

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-47

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

move the side bearing spacers as shown in the figure to 
adjust the backlash.
NOTE: Increase the side bearing spacers by the same 
amount as for the decrease.

7. Check the final drive gear teeth contact, and if not proper, 

adjust it.(Refer to 

P.27B-33

.)

8. Measure the drive gear runout on the backside.

Limit: 0.05 mm (0.002 inch)

9. When the runout exceeds the limit, change position of the 

drive gear and differential case, and measure the runout 
again.

10.If the adjustment is not possible, replace the differential 

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

.

>>J<< OIL SEAL PRESS-FITTING

Use special tools MB990938 and MB991115 to press-fit the oil 
seal.

ACX01075 AD

If backlash is too small

If backlash is too large

Thinner
spacer

Thinner
spacer

Thicker
spacer

Thicker
spacer

AC612540

AC703483AB

MB990938

MB991115

NOTES