Mitsubishi Outlander XL. Manual - part 556

ZC6000010000

12

23

30

5

29

22

21

27

32

25

24

26

28

33

1

9

16

N

N

4

N

N

31

N

19

18

17

11

3

2

N

6

10

9

7

8

10

11

12

14 13

15 1617

18

19

20

Disassembly steps

<<A>>

·

Inspection before disassembly

1.

Filler plug

2.

Gasket

3.

Drain plug

4.

Gasket

5.

Electronic control coupling

6.

Washer

7.

Differential cover assembly

8.

Vent plug

<<B>>

9.

Differential case assembly

<<B>>

10. Differential side bearing spacer

<<B>>

11. Differential side bearing outer race

<<C>>

12. Differential side bearing inner race

<<D>>

13. Drive gear

Disassembly steps

<<E>>

14. Lock pin
15. Pinion shaft
16. Pinion gear
17. Pinion washer
18. Side gear
19. Side gear spacer
20. Differential case

<<F>>

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

pinion rotation torque adjustment)

24. Drive pinion spacer

<<G>>

25. Drive pinion rear bearing inner race
26. Drive pinion rear shim (for drive pinion

height adjustment)

REAR AXLE<AWD>

27B-27

DIFFERENTIAL CARRIER ASSEMBLY

Disassembly steps

27. Drive pinion
28. Oil seal
29. Drive pinion front bearing inner race

<<H>>

30. Drive pinion front bearing outer race

Disassembly steps

<<I>>

31. Drive pinion rear bearing outer race
32. Oil seal
33. Differential carrier

 

Required Special Tools:

｠

MB990560: Rear Axle Shaft Bearing Remover

｠

MB990810: Side Bearing Puller

｠

MB990909: Working Base

｠

MB990939: Brass 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 cover.

ZC3001400000

MB990909 or
MB991116

2.

Hold special tools MB990909 and MB991116 in a vise, and
install the differential carrier assembly to the special tool.

 

FINAL DRIVE GEAR BACKLASH

MB992111

ZC3051640000

1.

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

Tightening torque: 23 ± 3 N·m (17 ± 2 ft-lb)

27B-28

REAR AXLE<AWD>

DIFFERENTIAL CARRIER ASSEMBLY

ZC3001410000

2.

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: 0.10 - 0.15 mm (0.004 - 0.006 inch)

3.

When  the  backlash  is  not  within  the  standard  value  range,
adjust the final drive gear backlash. (Refer to P.27B-33.)

4.

After adjustment, check the final drive gear teeth contact.

DRIVE GEAR RUNOUT ON BACKSIDE

MB992111

ZC3051640000

1.

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

Tightening torque: 23 ± 3 N·m (17 ± 2 ft-lb)

ZC3001430000

2.

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)

3.

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.

4.

When the runout measured in step 2 is normal, change the
position of the drive gear and differential case, and measure
the runout again.

5.

If the adjustment is not possible, replace the differential case
or the drive gear and the drive pinion as a set.

DIFFERENTIAL GEAR BACKLASH

ZC3001420000

Wedge

Side gear
spacer

Side gear
spacer

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-33.)

3.

When the adjustment is not possible, replace the side gear
and the pinion gear as a set.

REAR AXLE<AWD>

27B-29

DIFFERENTIAL CARRIER ASSEMBLY

FINAL DRIVE GEAR TEETH CONTACT ADJUSTMENT
Check the final drive gear teeth contact in the following steps:

ZC3001440000

1.

Apply the bearing blue on the drive gear teeth (on both sides)
thinly and evenly.

ZC3008990000

MB990939

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).

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)

ZC3001380000

1

3

2

4

Contact  pattern  indicating  that
the drive pinion height is too high

ZC3002150000

1

3

2

4

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

ZC3002160000

1

3

2

4

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

ZC3002170000

1

3

2

4

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

ZC3002180000

1

3

2

4

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.

27B-30

REAR AXLE<AWD>

DIFFERENTIAL CARRIER ASSEMBLY