1. Conduct a check before disassembling.
1) Remove the cover and gasket.
2) Fix the special tool MB990909 and special tool MB991116 in a vice, and install the differential cup on the special tools.
3) Check the play of the drive gear using a digital indicator.
Standard clearance: 0.11 - 0.15 mm.
If the pinion backlash value is not within the specification, it is necessary to install the thrust washer according to the specification above.
4) Check the radial runout of the drive gear using a digital indicator.
Standard size: 0.05 mm.
If the pinion radial runout value is not within specification, the pinion must be adjusted or the differential housing or pinion must be replaced.
5) Check the side gear play using a digital indicator. Standard backlash: 0.01mm - 0.25mm. If the backlash value of the side gear is not within the specification, it is necessary to install the thrust washer according to the specification above.
2. Remove the cover (1).
3. Remove the differential housing (2).
Caution: Be careful when removing the differential housing to avoid dropping it and damaging the washers and outer bearing races on the differential side.
1) Remove the differential housing using a wooden hammer handle.
Note: Do not mix bearing shims when disassembling the differential.
4. Remove the side bearing washer (3).
5. Remove the outer ring of the side bearing (4).
6. Remove the inner ring of the side bearing (5).
1) When removing the inner ring of the side bearing, use the special tool MB990810 and the special tool MB990811.
7. Remove the drive gear (6).
1) Apply timing marks to the differential housing and pinion gear.
2) Loosen the drive gear mounting bolts diagonally and remove the drive gear.
8. Return the lock nut (7).
1) Fix the connecting flange using the special tool MB990767, and then unscrew the lock nut.
9. Remove the washer (8).
10. Remove the drive shaft assembly (9).
Caution: The alignment marks on the connecting flange must be applied to the connecting surface of the flange and the front propeller shaft.
1) Apply alignment marks on the drive shaft and connecting flange.
2) Remove the drive shaft together with the special tool MB990810.
11. Remove the connecting flange (10).
12. Remove the drive shaft gasket (11).
13. Remove the front ring of the drive shaft (to adjust the torque) (12).
14. Remove the inner ring of the rear bearing of the drive shaft (13).
1) Remove the inner ring of the rear bearing of the drive shaft using special tool MB990339 and special tool MB990648.
The material is based on data from the website [MITSUBISHIMAN.ru]
15. Remove the rear ring of the drive shaft (to adjust the shaft height) (14).
16. Remove the drive shaft (15).
17. Remove the oil seal (16).
18. Remove the inner ring of the front bearing of the drive shaft (17).
19. Remove the outer ring of the front bearing of the drive shaft (18).
1) Remove the outer ring of the front bearing of the drive shaft using special tool MB990339.
20. Remove the outer ring of the rear bearing of the drive shaft (19).
1) Remove the outer ring of the rear bearing of the drive shaft using special tool MB990939.
21. Remove the oil seal (20).
22. Remove the differential cup (21).
23. Remove the locking pin (22).
1) Remove the locking pin using a punch.
24. Remove the gear shaft (23).
25. Remove the drive gear (24).
26. Remove the gear washer (25).
27. Remove the side gear (26).
28. Remove the side gear washer (27).
29. Remove the filler plug (28).
30. Remove the gasket (29).
31. Remove the drain plug (30).
32. Remove the seal (31).
33. Remove the differential housing (32).