Mitsubishi Pajero Pinin. Manual - part 206

FRONT AXLE – 

Differential Carrier

26-43

3.

Measure the thickness of the side bearing spacers on
one side, select two pairs of spacers which correspond
to that thickness plus one half of the clearance plus 0.05
mm, and then install one pair each to the drive pinion
side and the drive gear side.

4.

Install the selected side bearing spacers and differential
case assembly, as shown in the illustration, to the gear
carrier.

5.

Tap the side bearing spacers with the special tool to fit
them to the side bearing outer race.

6.

Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.

7.

With the drive pinion locked in place, measure the drive
gear backlash with a dial indicator on the drive gear.

NOTE
Measure at four points or more on the circumference
of the drive gear.

Standard value: 0.11 – 0.16 mm

Clearance/2 + 0.05 mm 
= Thickness of the spacer on one
side

MB990939

FRONT AXLE – 

Differential Carrier

26-44

8.

Change the side bearing spacers as illustrated, and then
adjust the drive gear backlash.

NOTE
When increasing the number of side bearing spacers,
decrease the same number of the side bearing spacers
for opposite side.

9.

Check the drive gear and drive pinion for tooth contact.
If poor contact is evident, make adjustment. (Refer to
P. 26-31.)

10. Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.

Limit: 0.05 mm

11. If the drive gear runout exceeds the limit, reinstall by

changing the phase of the drive gear and differential case,
and remeasure.

12. If adjustment is not possible, replace the differential case

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

Thinner
spacer

If backlash is too small

Thicker
spacer

Thicker
spacer

Thinner
spacer

If backlash is too large

FRONT AXLE – 

Free-wheeling Clutch Assembly

26-45

FREE-WHEELING CLUTCH  ASSEMBLY

REMOVAL AND INSTALLATION

Caution

To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then
fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal and Post-installation Operation

D

Gear Oil Draining and Refilling (Refer to P.26-11.)

D

Drive Shaft Removal and Installation
(Refer to P.26-19.)

35 Nm

49 Nm

4

Sealant:
3M ATD Part No.8661 or equivalent

1

4

5

59 – 69 Nm

93 Nm*

103 Nm

49 – 59 Nm

3

 2 – 3 mm

Removal steps

A

A

"

1. Pin
2. Free-wheeling engage switch 

assembly

3. Differential mount bracket assembly

<LH>

4. Free-wheeling clutch housing 

assembly

5. Collar

REMOVAL SERVICE POINT

A

A

"

PIN REMOVAL

1.

Remove the one side of the dust cover from the vacuum
actuator assembly.

2.

Align the pin with the pin hole of the collar, and then
drive out the pin with a punch.

Collar

Dust cover

Pin

FRONT AXLE – 

Free-wheeling Clutch Assembly

26-46

INSPECTION

FREE-WHEELING ENGAGE SWITCH CONTINUITY
CHECK

Shaft (switch) position

Terminal number

1

2

Pushed (ON)

Released (OFF)

DISASSEMBLY AND REASSEMBLY

5

6

4

5

13

8

1

2

3

7

13

10

11

12

11

9

(

Apply to the lip

)

Disassembly steps

"

D

A

1. Clutch sleeve
2. Snap ring
3. Shift fork assembly

"

C

A

4. Spring pin
5. Shift rod
6. Shift fork
7. Clutch gear assembly

8. Circlip

A

A

" "

B

A

9. Bearing

10. Bearing

11. Clutch gear

"

A

A

12. Oil seal
13. Free-wheeling clutch housing

Shaft

OFF

ON

Contact point Electrode