Mitsubishi Outlander (2003+). Manual - part 237

 

  Index      Mitsubishi     Mitsubishi Outlander - service repair manual 2003 year

 

Search            

 

 

 

 

 

 

 

  

 

Content   ..  235  236  237  238   ..

 

 

Mitsubishi Outlander (2003+). Manual - part 237

 

 

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-19

DISASSEMBLY

M1272002200203

AC301212AB

24

25 26

32

27

28

22

19

12

18

17

13

16

15

14

17

18

10

15

16

11

8

1

5

10

11

9

9

3

34

31

30

29

23

21

20

N

N

33

N

N

6

N

9

N

2

4

Disassembly steps

•

Inspection before disassembly (Refer 
to 

P.27B-20

).

1. Filler plug
2. Gasket
3. Drain plug
4. Packing
5. Differential cover
6. Vent plug
7. Bearing cap

<<A>>

8. Differential case assembly

<<A>>

9. Differential side bearing spacer

<<A>>

10. Differential side bearing outer race

<<B>>

11. Differential side bearing inner race

<<C>>

12. Drive gear

<<D>>

13. Lock pin
14. Pinion shaft
15. Pinion gear
16. Pinion washer
17. Side gear

18. Side gear spacer
19. Differential case

<<E>>

20. Self-locking nut
21. Washer

<<F>>

22. Drive pinion assembly

<<F>>

23. Companion flange
24. Drive pinion front shim (For adjusting 

preload of drive pinion)

25. Drive pinion spacer

<<G>>

26. Drive pinion rear bearing inner race
27. Drive pinion rear shim (for adjusting 

drive pinion height)

28. Drive pinion

<<H>>

29. Oil seal

<<H>>

30. Drive pinion front bearing inner race

<<H>>

31. Drive pinion front bearing outer race

<<I>>

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

Disassembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-20

INSPECTION BEFORE DISASSEMBLY

1. Remove the cover.

2. Hold the following special tools in a vise, and 

install the differential carrier assembly to the 
special tool.

•

Working base (MB990909)

•

Working base adapter (MB991116)

FINAL DRIVE GEAR BACKLASH

1. With the drive pinion locked in place, use a dial 

gauge to measure the drive gear backlash in four 
or more places on the drive gear. 

Standard value: 0.11 

−

 0.16 mm

2. If the backlash is not within the standard value, 

adjust the final drive gear backlash (Refer to 

P.27B-25

).

3. After the adjustment, inspect the final drive gear 

tooth contact.

DRIVE GEAR RUNOUT

1. Measure the drive gear runout at the shoulder on 

the reverse side of the drive gear. 

Limit: 0.05 mm

2. When runout exceeds the limit value, check for 

foreign material between drive gear rear side and 
differential case, or for loose drive gear 
installation bolts.

3. When step (2) gives normal results, reposition the 

drive gear and differential case and remeasure.

4. If adjustment is impossible, replace the differential 

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

DIFFERENTIAL GEAR BACKLASH

1. Insert a wedge between the side gear and the 

pinion shaft to lock the side gear.

2. While locking the side gear with the wedge, 

measure the differential gear backlash with a dial 
indicator on the pinion gear.
Use the measurement procedure for the other 
pinion gear.

Standard value: 0 

−

 0.076 mm

Limit: 0.2 mm

3. If the backlash exceeds the limit value, adjust it by 

replacing the side gear spacers.

4. If adjustment is not possible, replace the side 

gears and pinion gears as a set.

AC102883

MB990909
and
MB991116

AC

AC102884

AC102886

AC102885

Wedge

Side gear
spacer

AC

Side gear
spacer

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-21

FINAL DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the 
steps below.

1. Apply a thin, uniform coat of machine blue to both 

surfaces of the drive gear teeth.

CAUTION

If the drive gear is rotated too much, the tooth 
contact pattern will become unclear and difficult 
to check.

2. Insert special tool brass bar (MB990939) between 

the differential carrier and the differential case, 
and then rotate the companion flange by hand 
(once in the normal direction, and then once in the 
reverse direction) while applying a load to the 
drive gear so that the revolution torque 
(approximately 2.5 

−

 3.0 N

⋅

m) is applied to the 

drive pinion.

3. Check the tooth contact condition of the drive gear 

and drive pinion.

AC102887

AC102888

MB990939

AC

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-22

NOTE: Check the tooth contact pattern to confirm 
that the adjustments of the pinion height and 
backlash have been done properly. Continue to 
adjust the pinion height and backlash until the 
tooth contact pattern resembles the standard 

pattern. If, even after adjustments have been 
made, the correct tooth contact pattern cannot be 
obtained, it means that the drive gear and the 
drive pinion have become worn beyond the 
allowable limit. Replace the gear set.

Standard tooth contact pattern

Problem

Solution

1. Narrow tooth side
2. Drive-side tooth surface (the side 
applying power during forward movement)
3. Wide tooth side
4. Coast-side tooth surface (the side 
applying power during reverse movement)
   

Tooth contact pattern resulting 
from excessive pinion 
height

The drive pinion is positioned too 
far from the centre of the drive 
gear.

Increase the thickness of 
the drive pinion rear shim, 
and position the drive pinion 
closer to the centre of the 
drive gear. Also, for 
backlash adjustment, 
position the drive gear 
farther from the drive 
pinion.

Tooth contact pattern resulting 
from insufficient pinion 
height.

The drive pinion is positioned too 
close to the centre of the drive 
gear.

Decrease the thickness of 
the drive pinion rear shim, 
and position the drive pinion 
farther from the centre of 
the drive gear. Also, for 
backlash adjustment, 
position the drive gear 
closer to the drive pinion.

ACX01039 AF

1

3

4

2

AC107260

1

2

3

4

AB

AC107261AB

1

2

3

4

AC107262

1

2

3

4

AB

AC107263

1

2

3

4

AB

 

 

 

 

 

 

 

Content   ..  235  236  237  238   ..