>> I << Final Drive Gear Backlash Adjustment

WARNING: This page is about a different car, the 2014 Mitsubishi Outlander. However, it is still accessible from the selected car via links, so may be relevant.

Adjust the final drive gear backlash in the following steps:

To the gear carrier, install the differential case with the side bearing outer race assembled.
Press the differential case to one side, and measure clearance between the side bearing outer race and the gear carrier.
Select two pairs of the side bearing spacers. (Thickness: 1/2 of the measured clearance with 0.05mm (0.002 inch) preload added)

Fig 1: Measuring Clearance Between Side Bearing Outer Race And Gear Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool side bearing holder (MB992111) to install the differential case with the selected side bearing spacers to the differential carrier. Then tighten a flange bolt to the specified torque.
Tightening torque: 43 ± 7 N.m (32 ± 5 ft-lb)

Fig 2: Installing Differential Case Assembly Using Special Tool Side Bearing Holder (MB992111)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure the final drive gear backlash at four or more points.
Standard value: 0.08 - 0.15 mm (0.004 - 0.005 inch)

Fig 3: Checking Final Drive Gear Backlash
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
When the backlash is not within the standard value range, change the side bearing spacers as shown in the figure to adjust the backlash.
NOTE: Increase the side bearing spacers by the same amount as for the decrease.
Check the final drive gear teeth contact, and if not proper, adjust it (Refer to DISASSEMBLY ).

Fig 4: Checking Final Drive Gear Teeth Contact
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure the drive gear runout on the backside.
Limit: 0.05 mm (0.002 inch)
When the runout exceeds the limit, change position of the drive gear and differential case, and measure the runout again.
If the adjustment is not possible, replace the differential case or the drive gear and the drive pinion as a set.

Fig 5: Checking Drive Gear Runout On Backside
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.