Workshop Manual PAJERO SPORT

27-1REARAXLECONTENTS27109000277GENERAL INFORMATION .................. 2Rear Axle Total Backlash Check .............. 7Axle Shaft Axial Play Check .................. 7Axle Shaft Axial Play Adjustment .............. 7Gear Oil Level Check ........................ 8SERVICE SPECIFICATIONS ................. 3LUBRICANTS .............................. 3AXLE ASSEMBLY .......................... 9SEALANTS ................................ 4AXLE SHAFT ............................. 11SPECIAL TOOLS .......................... 4DIFFERENTIAL CARRIER ................. 18ON-VEHICLE SERVICE ..................... 7

27-2REAR AXLE General InformationGENERAL INFORMATION27100010248The rear axle is a banjo-type semi-floating type.As the axle shaft bearings, double taper rollerto the axle shaft.A hybrid type LSD has a high performance against driving on unstable surfaces such asbearings are used.ABSrotorispress-fittedmuddyroads.REAR AXLEDIFFERENTIALNOTE*: Vehicles with hybrid type LSDCONSTRUCTION DIAGRAMItem6G7, 4D5 4D5 Drive gear typeHypoid gearReduction ratio4.6364.900Limited slip differential typeTorque sensitivity type and rpm sensitivity typeDifferential gear type (type x quantity)Side gearStraight bevel gear x 2Helical bevel gear x 2*Pinion gearStraight bevel gear x 2Helical bevel gear (short), helical bevel gear (long) x 4*Number of teethDrive gear5149Drive pinion1110Side gear19, 22*Pinion gear10, 7*Bearing (O.D. x I.D.) mmSide80 x 45Front68 x 30Rear79 x 37ItemSpecificationsAxle housing typeBanjo typeAxle shaftSupport methodSemi-floating typeShaft O.D. (Bearing part x Centre x Length) mm40.0 x 34.5 x 744.5Bearing typeDouble taperBearing (O.D. x I.D.) mm80.0 x 40.0

27-3REAR AXLE ServiceSpecifications/LubricantsSERVICESPECIFICATIONS27100030350LUBRICANTS27100040148ItemSpecified lubricantsQuantityRear differential gear oilConventional differential:Hypoid gear oilAPI classification GL-5 or higher SAE viscosity No. 90, 80 WLimited slip differential:Hypoid gear oilMITSUBISHI Genuine Gear Oil Part No. 8149630 EX,CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD(GL-5, SAE 80W-90) or equivalent2.6 LItemStandard valueLimitRear axle total backlash mm5Axle shaft axial play mm0 0.25Protruding length of stabilizer bar mounting bolt mm15 17Axle shaft retainer press-fitting force NInitial press-fitting force49,000 or moreFinal press-fitting force9,800 108,000Clearance between axle shaft retainer and snap ring mm0 0.166Distance between bearing case and ABS rotor mm19.4 20.0Drive gear backlash mm0.13 0.18Drive gear runout mm0.05Differential gear backlash mm0 0.0760.2Drive pinion turning torque NmWithout oil sealWhen replacing(with anti-rust agent)0.59 0.88When replacing or reusing(with gear oil applied)0.39 0.49With oil sealWhen replacing(with anti-rust agent)0.83 1.13When replacing or reusing(with gear oil applied)0.64 0.74

27-4REARAXLESealants/SpecialToolsSEALANTS27100050110SPECIAL TOOLS27100060298MB990241, MB990211)ToolNumberNameUseBAMB990590A: MB990212B: MB990211Rear axle shaft oil seal removerA: AdapterB: Sliding hammerRemoval of axle shaft (Use together withRemoval of axle housing oil sealMB990241Rearaxleshaft pullerRemoval of axle shaft (Use together with MB990211)MB990925Bearingandoil seal installer setPress-fitting of oil sealInspection of drive gear tooth contactRemoval of bearing outer raceFor details of each installer, refer to GROUP26 Special Tools.MB991552Axle shaft bearing and case removerRemoval of the axle shaft bearing and bearing caseMB990560Bearing removerRemoval of bearing inner raceMB990799Bearing inner race installerRemoval of axle shaft bearing inner racePress-fitting of the axle shaft bearing inner racePress-fitting of the axle shaft retainerMB990890 or MB990891Rearsuspension bushing basePress-fitting of bearing outer raceItemsSpecified sealantsRemarksBearing case3M ATD Part No. 8663 or equivalentSemi-drying sealantAxle housing (differential carrier mounting part)Drive gear and differential case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant

27-5REARAXLESpecialToolsA: Drive piniongauge attach-ToolNumberNameUseMB990787Axle shaft bearing removerInstallation of ABS rotorMB990909Working baseSupporting of the differential carrierMB990201Side bearing adjusting special spannerRemoval and adjustment of the side bearing nutMB990810Side bearing pullerRemoval of the side bearing inner raceMB990811Side bearing cupMB990850End yoke holderRemoval of the companion flangeMB990339Bearing pullerRemoval of the drive pinion rear bearing inner raceMB990648Bearing removerCBAMB991171A: MB990819B: MB991170C: MB991169Pinion height gauge setgaugeB: Cylinder gauge C: Drive pinionmentMeasurement of the pinion height

27-6REAR AXLE Special ToolsToolNumberNameUseMB990685Torque wrenchMeasurement of the starting torque of drive pinionMB990326Preload socketMB990728Bearing installerPress-fitting of the drive pinion rear bearing inner raceMB990727Drive pinion oil seal installerPress-fitting of the drive pinion oil sealMB990813TapRemoval of adhesiveMB990802Bearing installerPress-fitting of the side bearing inner race

27-7REARAXLE On-vehicle ServiceON-VEHICLE SERVICEREAR AXLE TOTAL BACKLASH CHECK271001202001.2.Park the vehicle on a flat, level surface.Move the transmission control lever to the neutral position. Move the transfer control lever to the neutral position. Apply the parking brake. Raise the vehicle on a jack.3.Turn the companion flange clockwise as far as it will go. Make the mating mark on the dust cover of the companion flange and on the differential carrier.Turn the companion flange anti-clockwise as far as it will go, and measure the amount of distance the mating4.marksLimit:If themoved.5 mmbacklash exceeds the limit value, remove the5.differential carrier assembly and check the following.Final drive gear backlash (Refer to P.27-19.)Differential gear backlash (Refer to P.27-20.)AXLESHAFT AXIAL PLAY CHECK27100130081Measure the axle shaft axial play by using a dial indicator.Standard value: 0 0.25 mmIf within specifications, return vehicles to original condition.AXLE SHAFT AXIAL PLAY ADJUSTMENT27100140077The axle shaft axial play is preset at factory. It can not be adjusted.Mating marks

27-8REAR AXLE On-vehicle ServiceGEAR OIL LEVEL CHECK27200120142Check that gear oil level is not 8 mm below the bottom of filler plug hole.Specified gear oil:Hypoid gear oil API classification GL-5 or higherSAE viscosity Number 90, 80WHypoid gear oil MITSUBISHI Genuine Gear oil Part No. 8149630 EX, CASTROL HYPOY LS (GL-5,SAE90), SHELL-LSD (GL-5, SAE 80W-90) orequivalent [Quantity: 2.6 L]8 mm UpperlimitLower limit

27-9REAR AXLE Axle AssemblyAXLE ASSEMBLYREMOVAL AND INSTALLATIONCaution27100170120*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicleontheground in anunladencondition.216 245 Nm*216 245 Nm*34 Nm141512876216 245 Nm*15 Nm688 Nm16949 54 Nm13132216 245 Nm*105216 245 Nm*11417 NmRemoval stepsCaliper assemblyBreak discParking brake shoe assembly(Refer to GROUP 36 ParkingBrake Drum)Parking brake cable connectionSpeed sensor connectionBrake hose and tube connectionSpring supportBreather hose]B}}B]9. Propeller shaft}A] 10. Stabilizer bar mounting bolttransmission jack.Lower armLateral rodShock absorber mounting bolt(lower side only)Axle assemblyCoil springStabilizer bar]A}Support the axle assemblyby a]C}Post-installation OperationBrake Fluid Filling and Air Bleeding (Refer toGROUP 35A On-vehicle Service.)Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 On-vehicle Service.)Pre-removal OperationBrake Fluid Draining

27-10REARAXLE Axle AssemblyREMOVAL SERVICE POINTS]A} CALIPER ASSEMBLY REMOVALSecure the removed caliper assembly with wire to prevent it from falling off.]B} PROPELLER SHAFT REMOVALPlace mating marks on the companion flange and flange yoke. Disconnect the propeller shaft from the companion flange.CautionSuspend the propeller shaft from the body with wire, etc.to prevent it from falling.]C} AXLE ASSEMBLY REMOVALTake out the axle assembly from the rear of the vehicle.CautionSecure the axle assembly to the jack or equivalent. The axle assembly is heavy and unstable and may fall causing damage to the assembly, surrounding equipment, or injuring the installer.INSTALLATION SERVICE POINTS}A] STABILIZER BAR MOUNTING BOLT INSTALLATIONWhen installing the stabilizer bar to the stabilizer bar bracket, check that the amount of projection of the stabilizer bar installation bolt is within the standard value range.Standard value (A): 1517 mmcupRubber}B] PROPELLER SHAFT INSTALLATIONAlign the mating marks on the flange yoke and the companion flange to install the propeller shaft.Joint cupStabilizer barA installationboltJointRubber bushingJoint cup Collarbushing Stabilizer bar Joint cupMating marks

27-11REARAXLEAxleShaftAXLE SHAFT27100250152REMOVALANDINSTALLATION88 Nm1215 Nm938549 59 Nm674Removal stepsBrake tubeCaliper assemblyBrake discParking brake shoe (Refer to Group36 Parking brake drum.)Parking brake cable and speed sensor attaching boltParking brake cableAxle shaft assembly]A}]B}8. O-ring]C} }A] 9. Oil seal7Sealant: 3M ATD Part No. 8663 or equivalent9Apply to entire inside diameter of oil seal lipPost-installation OperationBrake Fluid Supplying and Air Bleeding (Refer toGROUP 35A On-vehicle Service.)Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 On-vehicle Service.)Pre-removal OperationBrake Fluid Draining

27-12REARAXLE Axle ShaftREMOVAL SERVICE POINTS]A} CALIPER ASSEMBLY REMOVALSecure the removed caliper assembly with wire to prevent it from falling off.]B} AXLE SHAFT ASSEMBLY REMOVALCautionBe careful not to damage the oil seal when pulling axle shaft.]C} OIL SEAL REMOVALINSTALLATION SERVICE POINT}A] OIL SEAL INSTALLATIONMB990930MB990938MB990212 MB990211MB990241MB990211

27-13REAR AXLEAxleShaftDISASSEMBLYANDREASSEMBLY27100270110196 235 Nm81 23 941175106Disassembly stepsABS rotor Snap ringRetainer ringAxle shaftBearing caseBacking plateOuter bearing inner raceDust coverInner bearing inner raceOil sealBearing outer raceReassembly steps}A] 11. Bearing outer race}B] 9. Inner bearing inner race}B] 7. Outer bearing inner race}C] 10. Oil seal8. Dust cover6. Backing plate5. Bearing case4. Axle shaft}D] 3. Retainer ring}E] 2. Snap ring}F]1. ABS rotor ]A}]B}]C}]D}10Apply to entire inside diameter of oil seal lip

27-14REARAXLE Axle ShaftDISASSEMBLY SERVICE POINTS]A} RETAINER RING REMOVAL1.Remove one retainer bolt from the backing plate.2.Apply gummed cloth tape around the edge of the bearing case for protection.As shown in the figure, hold the axle shaft. Using a grinder,shave off a point of its circumference locally until the wall thickness becomes as follows:3.1.0 1.5 mm for axle shaft side2.0 mm for bearing sideCautionBe careful not to damage the bearing case and theaxle shaft.4.Fix the axle shaft and shave off the remaining 2.0 mm on the side of the retainer bearing.CautionBe careful not to damage the bearing case and the axle shaft.5.Cut in with a chisel the place where the retainer ring has been shaven and remove the retainer ring.CautionBe careful not to damage the axle shaft.GrinderBearing caseRetainerGrinderGummed cloth tapeBacking plateRetainer bolt

27-15REARAXLE Axle Shaft]B} AXLE SHAFT REMOVAL1.Secure special tool to the bearing case bolts with the nuts and adjust the height of the hanger. Then install the washers, plate and nuts in that order.NOTEThe washers are used to eliminate the difference in height of the bearing case so that the plate and the bearing case are parallel.Place the end of the bolt against the center of the axle shaft, and then tighten the nut to remove the axle shaft from the bearing case assembly.CautionThe hanger and plate should be placed so that theyare parallel.2.]C} OUTER BEARING INNER RACE REMOVALInstall special tool as shown in the illustration, and then use a press to remove the outer bearing inner race from the axle shaft.inner race]D} BEARING OUTER RACE REMOVALReinstall the outer bearing inner race that was removed previously, and then use special tool and a press to remove the outer bearing outer race.REASSEMBLY SERVICE POINTS}A] BEARING OUTER RACE INSTALLATIONUse special tool to press-fit the bearing outer race to the bearing case.MB990890 or MB990891MB990799Bearing outer raceOuter bearing MB990560MB991552 Plate HangerNutNutBolt WasherWasherBearingcase

27-16REARAXLE Axle Shaft}B] INNER BEARING INNER RACE/OUTER BEARING INNER RACE INSTALLATIONinner race1.Apply multipurpose grease to the roller surface and ends of the bearing.Pass the axle shaft through the bearing case and the inner bearing inner race and outer bearing inner race.Use special tool to press-fit the inner bearing inner race and outer bearing inner race to the axle shaft.CautionBoth bearing inner race, outer race sets should bepress-fitted together.2.3.}C] OIL SEAL INSTALLATION1.2.Apply multipurpose grease to the outside of the oil seal. Use special tools to press-fit the oil seal into the bearing case until it is flush with the face of the bearing case. Apply multipurpose grease to the lips of the oil seal.3.}D] RETAINER RING INSTALLATIONUse special tool to press-fit the retainer ring to the axle shaft. Check that the press-fitting force is at the standard value. If the initial press-fitting force is less than the standard value, replace the axle shaft.Standard value:Initial press-fitting force N49,000 or moreFinal press-fitting force N98,000 108,000Retainer ring MB990799MB990938MB990936Outer bearing Axle shaftInner bearing inner raceBearing case MB990799

27-17REARAXLE Axle Shaft}E] SNAP RING INSTALLATION1.After installing the snap ring, measure clearance (A) between the snap ring and the retainer ring with a thickness gauge, and check that it is within the standard value.Standard value (A): 0 0.166 mmIf the clearance exceeds the standard value, change the snap ring so that the clearance is at the standard value.2.}F] ABS ROTOR INSTALLATIONUse special tool to press-fit the ABS rotor so that the distance(A) to the bearing case is at the standard value.Standard value (A): 19.4 20.0 mmINSPECTION27100280038Check the dust cover for deformation and damage. Checktheinner andouter bearingsfor seizure, discoloration and rough raceway surface.Check the axle shaft for cracks, wear and damage.MB990787ABS rotorAThickness of snap ring mmIdentification color2.172.01Yellow1.85Blue1.69Purple1.53RedSnap ringRetainer ringA

27-18REAR AXLEDifferentialCarrierDIFFERENTIAL CARRIER27200200235REMOVALANDINSTALLATION49 Nm449 59 Nm47 Nm124 Nm59 Nm66 Nm23Removal stepsPropeller shaft connectionBracket Dynamic damper Differential carrier assembly]A} }A]]B}REMOVAL SERVICE POINTS]A} PROPELLER SHAFT REMOVALMake the mating marks on the flange yoke of the propeller shaft and the companion flange of the differential case.CautionSuspend the propeller shaft from the body with wire, etc.Mating marksSealant: 3M ATD Part No.8663 or equivalentPost-installation OperationAxle Shaft Assembly Installation (Refer to P.27-11.)Differential Gear Oil Filling (Refer to P.27-8.)Pre-removal OperationDifferential Gear Oil DrainingAxle Shaft Assembly Removal (Refer to P.27-11.)

27-19REARAXLE Differential Carrier]B} DIFFERENTIAL CARRIER REMOVALRemove the attaching nuts and strike the lower part of differential carrier assembly with a piece of timber several times to loosen, then remove the assembly.CautionUse care not to strike the companion flange.INSTALLATION SERVICE POINT}A] PROPELLER SHAFT INSTALLATIONAlign the mating marks on the flange yoke and the companion flange to install the propeller shaft.INSPECTION BEFORE DISASSEMBLY27200290133Secure the special tool with a vice and install the differential carrier assembly with the attachment. Then carry out the following inspection.DRIVE GEAR BACKLASHPlace a dial gauge against the end of a drive gear tooth and secure the drive pinion. Then turn the drive gear and take measurements at four places or more to check the backlash.Standard value: 0.13 0.18 mmIf the backlash is not within the standard value, replace the side bearing spacer, and then check the drive gear tooth contact.MB990909Attachment

27-20REARAXLE Differential CarrierDRIVE GEAR RUNOUT1.Measure the drive gear runout at the shoulder on the reverse side of the drive gear.Limit: 0.05 mmIf the runout exceeds the limit value, check that there is no foreign material between the reverse side of the drive gear and the differential case, or that there is no looseness in the drive gear mounting bolt.If step (2) is normal, change the assembly position ofthe drive gear and differential case, and then take another measurement.If adjustment is impossible, replace the differential case or the drive gear and drive pinion as a set.2.3.4.DIFFERENTIAL GEAR BACKLASH1.Tap in a wooden wedge between the side gear and the pinion shaft and secure one side gear. Then place a dial gauge (with the measuring probe extended) against the pinion gear and measure the backlash.Standard value: 0 0.076 mmNOTECheck the other pinion gear by the same procedure.Limit: 0.2 mmIf the backlash exceeds the limit, replace the side gear spacers. (Refer to P.27-30.)If adjustment is not possible, replace the side gears and pinion gears as a set.2.3.DRIVE GEAR TOOTH CONTACTCheck the drive gear tooth contact by the following steps.1.Apply a thin, uniform coat of machine blue to both surfacesof the drive gear teeth.WedgePinion shaft Side gearspacer Side gearspacer

27-21REARAXLE Differential Carrier2.Insert a brass rod 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 Nm) is applied to the drive pinion.CautionIf the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.Check the tooth-contact condition of the drive gear and3.drivepinion.height adjusting shim, and position theAlso, for backlash adjustment, posi-drive pinion.height adjusting shim, and position theNOTEChecking the tooth contact pattern is the way to confirm that the adjustments of the pinion heightand backlash have been done properly. Continue to adjust the pinion height and backlash until the tooth contact pattern resembles the standard pattern.If, evenafter adjustments have been made, thecorrect 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 patternProblemSolutionNarrow tooth sideDrive-side tooth surface (the side applying power during forward movement)Wide tooth sideCoast-side tooth surface (the side applying power during reverse movement)2143Tooth contact pattern resulting from excessive pinion height2143The drive pinion is positioned too far from the centre of the drive gear.2143Increase the thickness of the pinion drive pinion closer to the centre of thedrive gear.tion the drive gear farther from theTooth contact pattern resulting from insufficient pinion height2143The drive pinion is positioned too close to the centre of the drive gear.2143Decrease the thickness of the pinion drive pinion farther from the centre ofthe drive gear.Also, for backlash adjustment, posi- tion the drive gear closer to the drive pinion.MB990939

27-22REAR AXLE Differential CarrierDISASSEMBLYCaution27200220194*:Donot disassemblethe limited slipdifferential case assembly.4516 1321210118371461152929 12102713251712321 222819 20318261624456172156521Disassembly stepsInspection before disassembly(P.27-20.)Lock plateSide bearing nutBearing capDifferential case assemblySide bearing outer raceSide bearing inner raceDrive gearLock pinPinion shaftPinion gearPinion washerSide gearSide gear thrust spacerDifferential caseLimited slip differential case assembly*]F}]G}Self-locking nutWasherDrive pinion assemblyDrive pinion front shim (For adjusting preload of drive pinion)Drive pinion spacerDrive pinion rear bearing inner raceDrive pinion rear shim (For adjustingdrive pinion height)Drive pinionCompanion flangeOil sealDrive pinion front bearing inner raceDrive pinion front bearing outer raceDrive pinion rear bearing outer raceDifferential carrier]A}]B}]C}]D}]E}]H}]I}]I}]I}]J}

27-23REARAXLE Differential CarrierDISASSEMBLY SERVICE POINTS]A} SIDE BEARING NUT REMOVALUse special tool to remove the side bearing nut.NOTEKeep the right and left side bearings and side bearing nuts separate, so that they do not become mixed at the time of assembly.]B} DIFFERENTIAL CASE ASSEMBLY REMOVALUse the handle of a hammer to remove the differential case assembly.CautionWhen taking out the differential case assembly, be careful not to drop and damage the side bearing outer races.NOTEKeep the right and left side bearings and side bearing outer race separate, so that they do not become mixed at the timeof assembly.]C} SIDE BEARING INNER RACE REMOVALUse special tools to pull out the side bearing inner race.NOTEAttach the prongs of special tools to the inner race of the side bearing through the openings in the differential case.]D} DRIVE GEAR REMOVALMake mating marks to the differential case and the drive gear.Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.]E} LOCK PIN REMOVALDrive out the lock pin with a punch.Mating marksMB990810MB990811MB990201

27-24REARAXLE Differential Carrier]F} SELF-LOCKING NUT REMOVALUse special tool to hold the companion flange, and then remove the companion flange self-locking nut.]G} DRIVE PINION ASSEMBLY REMOVALMake the mating marks to the drive pinion and companion flange.CautionDo not make mating marks on the contact surfaces of the companion flange and propeller shaft.Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims.]H} DRIVE PINION REAR BEARING INNER RACE REMOVALUse special tools to pull out the front bearing inner race.]I} OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE REMOVALUse special tool to remove drive pinion front bearing outer race.outer racefront bearing]J} DRIVE PINION REAR BEARING OUTER RACE REMOVALUse special tool to remove the drive pinion rear bearing outer race.MB990939MB990939Drive pinion rear bearing outer raceDrive pinionfront bearing Drive pinioninner raceOil sealMB990339MB990648Mating marksMB990850

27-25REAR AXLE Differential CarrierREASSEMBLY272002301732625242919 Nm17182869 78 Nm201922272315 24 251912821 182031781329216 Nm19 Nm45621078 88 Nm9277111412262325 2429 19 Nm2816 24 252819 Nm2978 88 NmReassembly stepsDifferential carrierDrive pinion rear bearing outerraceDrive pinion front bearing outer raceDrive pinion height adjustmentDrive pinionDrive pinion rear shim (For adjustingdrive pinion height)Drive pinion rear bearing inner raceDrive pinion turning torque adjustmentDrive pinion front bearing inner raceOil sealDrive pinion front shim (For adjustingdrive pinion preload)Drive pinion spacerDrive pinion assemblyCompanion flangeWasherSelf-locking nutDifferential caseLimited slip differential case assem-blySide gear thrust spacerSide gearPinion washer}A]}B]}C]20. Pinion gearDifferential gear backlash adjustment}E]21. Pinion shaft}D]}F] 22. Lock pin}G] 23. Drive gear}H] 24. Side bearing inner raceSide bearing outer raceDifferential case assembly}I] 27. Bearing cap}J] Final drive gear backlash adjustmentSide bearing nutLock plate23144Final drive gear set18201820Differential gear set

27-26REARAXLE Differential CarrierLubricationandAdhesivePointsREASSEMBLY SERVICE POINTS}A] DRIVE PINION REAR BEARING OUTER PRESS-FITTINGRACE}B] DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTINGMB990938MB990934MB990938MB990937Adhesive: 3M Stud Locking 4170or equivalent

27-27REARAXLE Differential Carrier}C] DRIVE PINION HEIGHT ADJUSTMENTAdjust the drive pinion height by the following procedures:1.2.Apply multipurpose grease to the washer of special tool. Install special tool and drive pinion front and rear bearing inner races to the gear carrier in the sequence shown in the illustration.3.Tighten the nut of special tool a little at a time while measuring the turning torque of the drive pinion. Thenconfirm the turningStandard value:torqueisatthestandardvalue.4.5.Clean the side bearing hub.Place special tool between the side bearing hub of the gear carrier, and position the notch as shown in theillustration. Then tighten side bearing mounting bolt. Use a thickness gauge to measure the clearance (A) between special tools.6.Thickness7.8.Remove special tools (MB991170, MB991169).Use a micrometer to measure the shown dimensions (B,C) of special tools.CBMB991170 NotchAMB991169gaugeMB990685MB990326MB990819Bearing typeBearing lubricationTurning torqueNewNone(withanti-rust agent)0.59 0.88 NmNew or reuseGear oil applied0.39 0.49 NmMB990819Drive pinion MB991169attachmentMB990819Washer

27-28REARAXLE Differential CarrierInstall the bearing cap, and then use a cylinder gauge to measure inside diameter (D) of the bearing cap.Calculate thickness (F) of the required drive pinion rearshim twice by the following formula. Select a shim which most closely matches this thickness.F = A + B + C 1/2D EE: 115.00 mm11. Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the drive pinion rear bearing inner race by using special tool.}D] DRIVE PINION TURNING TORQUE ADJUSTMENT1.Insert the drive pinion into the gear carrier, and then install the following parts in sequence from the carrier rear side. Drive pinion spacer, drive pinion front shim and drive pinion front bearing inner race, companion flange.NOTEDo not install the oil seal.Tighten the companion flange to the specified torque by using special tool.Tightening torque: 216 NmMeasure the drive pinion turning torque (without the oil seal).Standard value:2.3.4.If the drive pinion turning torque is not within the standard value, adjust the turning torque by replacing the drive pinion front shim(s) or the drive pinion spacer.NOTEWhen 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.Also, select the drive pinion spacer from the following two types.Identifi- cation colourBearing divisionBearing lubricationTurning torqueNewNone(withanti-rust agent)0.59 0.88 NmNew or reuseGear oil applied0.39 0.49 NmMB990685 MB990326216 Nm MB990685MB990850Drive pinion rear shimMB990728Cylinder gauge

27-29REARAXLE Differential Carrier5.Remove the companion flange and drive pinion again. Then insert the drive pinion front bearing inner race into the gear carrier. Use special tool to press-fit the oil seal.6.Install the drive pinion assembly and companion flange with mating marks properly aligned. Tighten the companion flange self-locking nut to the specified torque using special tool.Tightening torque: 216 Nm7.Measure the drive pinion turning torque (with oil seal) to verify that the drive pinion turning torque complies with the standard value.Standard value:MB9906858.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.Bearing divisionBearing lubricationTurning torqueNewNone (with anti-rust agent)0.83 1.13 NmNew or reusingGear oil applied0.64 0.74 NmMB990326216 Nm MB990685MB990850MB990727Height of drive pinion spacer mmIdentifcation colour56.6757.01White

27-30REARAXLE Differential Carrier}E] DIFFERENTIAL GEAR BACKLASH ADJUSTMENTAdjust the differential gear backlash by the following procedure.1.Assemble the side gears, side gear thrust spacers, pinion gears, and pinion washers into the differential case. Temporarily install the pinion shaft.NOTEDo not assemble the thrust block and lock pin yet.2.3.Insert a wedge between the side gear and the pinion shaft to lock the side gear.While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on thepinion gear.Standard value: 0 0.076 mmMeasure by the same procedure for the other pinion gear.Limit: 0.2 mmIf the backlash exceeds the limit value, replace side bearing adjustment spacers.If adjustment is not possible, replace the side gears and pinion gears as a set.Check that the backlash is within the limit value and that the differential gear turns smoothly.4.Sidethrust5.6.7.}F] LOCK PIN INSTALLATIONAlign the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.Stake the lock pin with a punch on both sides.}G] DRIVE GEAR INSTALLATIONClean the drive gear attaching bolts.Remove the adhesive adhered to the threaded holesof the drive gear by turning the special tap (tap M10 x 1.25), and then clean the threaded holes by applying compressed air.MB990813WedgeSide gear gear spacerthrustspacer

27-31REARAXLE Differential Carrier3.Apply the specified adhesive to the threaded holes of the drive gear.Specified adhesive:3M Stud Locking 4170 or equivalentInstall the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence.Tightening torque: 78 88 Nm4.}H] SIDE BEARING INNER RACE INSTALLATIONUse special tool to press-fit the side bearing inner races into the differential case.}I] BEARING CAP INSTALLATIONAlign the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap.}J] FINAL DRIVE GEAR BACKLASH ADJUSTMENTAdjust drive gear backlash as follows:1.Using special tool, temporarily tighten the side bearing nut to just before preloading of the side bearing.2.Measure the drive gear backlash.NOTEMeasure at four points or more on the circumference of the drive gear.Standard value: 0.13 0.18 mmMB99020169 78 NmStrap StrapMB990802

27-32REARAXLE Differential Carrier3.Using special tool (MB990201), adjust the backlash to standard value by moving the side bearing nut as shown.NOTEFirst loosen the side bearing nut then tighten the side bearing nut the same amount as when it was loosened.4.Using special tool, to apply the preload, turn down both right and left side bearing nuts on half the distance between centers of two neighboring holes.5.6.Choose and install the lock plate (two kinds).Check the final drive gear tooth contact. If poor contact is evident, make adjustment. (Refer to P.27-20.)7.Measure the drive gear runout.Limit: 0.05 mmWhen drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstall them.If adjustment is not possible, replace the differential caseor drive gear and drive pinion as a set.8.9.MB092153MB092154MB990201When backlash is insufficientLOOSEN TIGHTENTIGHTEN LOOSENWhen backlash is excessive