Mitsubishi L200. Manual - part 385

 

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Mitsubishi L200. Manual - part 385

 

 

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-45

REASSEMBLY SERVICE POINTS 

>>A<< OIL SEAL INSTALLATION

ACX01051AB

Oil seal

MB990938

MB990934

Use the following special tools to insert the oil seal, 
and then apply a thin coat of multipurpose grease to 
the lip of the oil seal.

• Installer bar (MB990938)

• Installer adapter (MB990934)

>>B<< DRIVE PINION REAR BEARING OUTER 
RACE INSTALLATION

AC004801 AB

MB990938

MB990936

Use the following special tools to press-fit the drive 
pinion rear bearing outer races into the gear carrier.

• Installer bar (MB990938)

• Installer adapter (MB990936)

>>C<< DRIVE PINION FRONT BEARING OUTER 
RACE INSTALLATION

AC004802

MB990938

MB990934

AB

Use the following special tools to press-fit the drive 
pinion rear bearing outer races into the gear carrier.

• Installer bar (MB990938)

• Installer adapter (MB990934)

>>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height as follows:

ACX01054 AB

MB990819

Washer

1. Apply multipurpose grease to the washer of 

special tool drive pinion gauge assembly 
(MB990819).

2. Install special tool, drive pinion front and rear 

bearing inner races to the gear carrier.

CAUTION

There should be no gear oil adhered to the bear-
ing.

ACX01055 AB

MB990819

ACX01056AB

MB990326

MB990819

MB990685

3. Tighten the nut of special tool while measuring the 

turning torque of the drive pinion by using the 
following special tools. Gradually keep tightening 
the nut of special tool until the turning torque of 
the drive pinion (without oil seal) is at the standard 
value.

• Preload socket (MB990326)

• Torque wrench (MB990685)

• Drive pinion gauge assembly (MB990819)

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-46

Standard value:

Bearing 
division

Bearing 
lubrication

Turning torque

New

None (with anti-
rust agent)

0.83 

− 1.19 N⋅m

NOTE: Because special tool preload socket 
(MB990326) cannot be turned one turn, turn it 
several times within the range that it can be 
turned; then, after fitting to the bearing, measure 
the turning torque.

4. Clean the side bearing seat of the differential 

carrier and bearing caps.

ACX01057 AC

Thickness gauge

MB990819

A

MB991170

Notch

5. Place the following special tools in the side 

bearing seat of the differential carrier, and position 
the notch as shown in the illustration. Then install 
the bearing caps.

• Cylinder gauge (MB991170)

• Drive pinion gauge assembly (MB990819)

6. Use a thickness gauge to measure the clearance 

(A) between special tools.

7. Remove the bearing caps and special tools.

ACX01058

MB991170

B

C

AE

MB990819

8. Use a micrometer to measure the shown 

dimensions (B, C) of special tools.

AC102914

Cylinder gauge

AC

D

9. Install the bearing cap, and then use a cylinder 

gauge and micrometer to measure the inside 
diameter (D) of the bearing cap as shown in the 
illustration.

10.Calculate the thickness (E) of the required drive 

pinion rear shim by the following formula, and 
then select a shim which most closely matches 
this thickness.

E = A + B + C - 1/2D - 100.0 mm

ACX01060

Drive
pinion
rear
shim

MB990802

MB990802

AC

11.Fit the selected drive pinion rear shim(s) to the 

drive pinion, and press-fit the drive pinion front 
bearing inner race by using special tool bearing 
installer (MB990802).

>>E<< DRIVE PINION TURNING TORQUE 
ADJUSTMENT
Adjust the drive pinion turning torque by using the 
following procedure:
1. Insert the drive pinion into the gear carrier, and 

then install the drive pinion spacer, the drive 
pinion front shim, the drive pinion front bearing 
inner race, and the companion flange in that 
order.
NOTE: Do not install the oil seal.

AC004803 AB

MB990767

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-47

2. Tighten the companion flange self-locking nut to 

the specified torque while holding the companion 
flange with special tool front hub and flange yoke 
holder (MB990767).

Tightening torque: 216 

± 29 N⋅m

CAUTION

There should be no gear oil adhered to the 

bearing.

ACX01062AB

MB990326

MB990685

3. Use the following special tools to measure the 

drive pinion turning torque (without the oil seal).

• Preload socket (MB990326)

• Torque wrench (MB990685)

Standard value:

Bearing 
division

Bearing 
lubrication

Turning torque

New

None (with anti-
rust agent)

0.83 

− 1.19 N⋅m

4. If the drive pinion turning torque is not within the 

range of the standard value, adjust the preload by 
replacing the drive pinion front shim(s) or the drive 
pinion spacer.

NOTE: 

ACX01063 AB

Identification
colour

When selecting the drive pinion front shims, if the 
number of shims is large, reduce the number of 
shims to a minimum by selecting the drive pinion 
spacers.
Select the drive pinion spacer from the following 
two types.

Height of drive pinion 
spacer mm

Identification colour

56.67

White

57.01

−

ACX01064 AB

MB990031
or
MB990699

5. Remove the companion flange and drive pinion 

again. Then, after inserting the drive pinion front 
bearing inner race into the gear carrier, use 
special tool oil seal installer (MB990031 or 
MB990699) to press-fit the oil seal.

AC004803 AB

MB990767

DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>

FRONT AXLE

26-48

6. Install the drive pinion assembly and companion 

flange with the mating marks properly aligned. 
Tighten the companion flange self-locking nut to 
the specified torque while holding the companion 
flange with special tool.

Tightening torque: 216 

± 29 N⋅m

ACX01062AB

MB990326

MB990685

7. Use special tools to measure the drive pinion 

turning torque (with drive pinion oil seal) to verify 
that the drive pinion turning torque complies with 
the standard value.

Standard value:

Bearing 
division

Bearing 
lubrication

Turning torque

New

None (with anti-
rust agent)

0.89 

− 1.78 N⋅m

Gear oil applied 0.97 

− 1.32 N⋅m

8. If the turning torque is not within the standard 

value, check the tightening torque of the 
companion flange self-locking nut, and the 
installation of the oil seal.

>>F<< DIFFERENTIAL GEAR BACKLASH 
ADJUSTMENT
Adjust the differential gear backlash by the following 
procedure:

ACX01066AB

1. Assemble the side gears, side gear spacers, 

pinion gears and pinion washers into the 
differential case.

2. Temporarily install the pinion shaft.

NOTE: Do not drive in the lock pin yet.

ACX01035 AB

Wedge

Side gear
thrust spacer

Side gear
thrust 
spacer

3. Insert a wedge between the side gear and the 

pinion shaft to lock the side gear.

4. While locking the side gear with the wedge, 

measure the differential gear backlash with a dial 
indicator on the pinion gear.
Measure by the same procedure for the other 
pinion gear.
Standard value: 0.01 

− 0.250 mm

5. If the backlash exceeds the standard value, adjust 

it by replacing the side gear spacers.

6. If adjustment is not possible, replace the side 

gears and pinion gears as a set.

7. Measure the differential gear backlash once 

again, and confirm that it is within the standard.

>>G<< LOCK PIN INSTALLATION

ACX01067AB

1. Align the pinion shaft lock pin hole with the 

differential case lock pin hole, and drive in the lock 
pin.

2. Stake the lock pin with a punch at two points.

>>H<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.

 

 

 

 

 

 

 

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