Mitsubishi Outlander GS45X. Manual - part 1522

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-37

<<C>> DIFFERENTIAL SIDE BEARING INNER 
RACE REMOVAL

Use special tool MB990810 to remove the differential side 
bearing inner race.
NOTE: Hook the claws of the special tool on the differential 
side bearing inner race through two cut-off parts on the differ-
ential case side.

.

<<D>> DRIVE GEAR REMOVAL

1. Put mating marks on the drive gear and differential case as 

a reference for the reassembly operation.

2. Loosen the drive gear tightening bolts in a diagonal order to 

remove the drive gear.

.

<<E>> LOCK PIN DRIVING OUT

Drive out the lock pin with a punch.

.

<<F>> DIFFERENTIAL NUT REMOVAL

Use special tools MB992112 and MB992113 to remove the dif-
ferential nut:

.

AC703515 AB

MB990810

Socket 
wrench

AC703516 AB

Mating 
marks

AC703517AB

AC703518AB

MB992112

MB992113

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-38

<<G>> DRIVE PINION REAR BEARING INNER 
RACE REMOVAL

Use special tool MB990560 to remove the drive pinion rear 
bearing inner race.

.

<<H>> DRIVE PINION FRONT BEARING OUTER 
RACE REMOVAL

Use special tool MB990939 to remove the drive pinion front 
bearing outer race.

.

<<I>> DRIVE PINION REAR BEARING OUTER 
RACE REMOVAL

Use special tool MB990939 to remove the drive pinion rear 
bearing outer race.

AC703519AB

MB990560

AC703520AB

MB990939

Drive pinion 
front bearing
outer race

Drive pinion 
rear bearing
outer race

AC703521AB

MB990939

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-39

ASSEMBLY

M1271005500170

AC703522AB

26

27

33

N

N

32

N

31

N

190 ± 30 N·m
140 ± 22 ft-lb

48 ± 6 N·m
36 ± 4 ft-lb

41 ± 5 N·m
30 ± 3 ft-lb

23 ± 3 N·m
17 ± 2 ft-lb

32 ± 2 N·m
23 ± 2 ft-lb

48 ± 6 N·m
36 ± 4 ft-lb

1

N

32 ± 2 N·m
23 ± 2 ft-lb

N

30

28

29

Pinion shaft kit

Final drive gear set

Differential gear set

7

9

3

2

5

4

6

8

10

11

12

14

16

17

15 18

19 20

22

23

24

25

13

14

16

17

15

21

22

23

24

21

4

12

20

14

17

15

18

19

14

17

15

27

N

Assembly steps 

1.

Differential carrier

>>

A

<< 2.

Drive pinion rear bearing outer 
race

>>

B

<< 3.

Drive pinion front bearing outer 
race

>>

C

<< •

Drive pinion height adjustment

4.

Drive pinion

5.

Drive pinion rear shim (for drive 
pinion height adjustment)

6.

Drive pinion rear bearing inner 
race

7.

Drive pinion spacer

>>

D

<< •

Drive pinion rotation torque 
adjustment

8.

Drive pinion front shim (for drive 
pinion rotation torque adjustment)

9.

Drive pinion assembly

10. Drive pinion front bearing inner 

race 

>>

D

<< 11. Oil seal

12. Differential nut
13. Differential case

>>

E

<< •

Differential gear backlash 
adjustment

14. Side gear spacer
15. Side gear
16. Pinion washer
17. Pinion gear
18. Pinion shaft

>>

F

<<

19. Lock pin

>>

G

<< 20. Drive gear

>>

H

<< 21. Differential side bearing inner race

22. Differential side bearing outer race
23. Differential side bearing spacer
24. Differential case assembly

Assembly steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE <AWD>

27B-40

Required Special Tools:

• MB990810: Side Bearing Puller

• MB990829: Pinion & Side Bearing Installer

• MB990930: Installer Adapter

• MB990934: Installer Adapter

• MB990938: Installer Bar

• MB991115: Oil Seal Installer

• MB991180: Bush Remover & Installer Base

• MB992111: Side Bearing Holder

• MB992112: Lock Nut Wrench

• MB992113: Drive Pinion Holder

• MB992115: Dummy Pinion Gauge body

• MB992116: Dummy Pinion Gauge Head

• MB992117: Cylinder Gauge

• MB992128: Hex Socket Head Bolt

• MD998816: Installer Adapter

>>

I

<<

•

Final drive gear backlash 
adjustment

25. Vent plug
26. Differential cover assembly

>>

J

<

27. Oil seal
28. Washer
29. Electronic control coupling
30. Gasket
31. Drain plug
32. Gasket
33. Filler plug

Assembly steps (Continued)