Author: Peter

Adjusting the gear ratio on a Mitsubishi L200 involves several tools and steps. click here for more details on the download manual…..

MItsubishi L200 1998 MODEL 1998 Mitsubishi L200 4D56 diesel Engine exterior.

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Here is a detailed guide on how to perform the adjustment:

– **Necessary tools and Equipment:**
– **Jack and Jack Stands:** To safely lift the vehicle and access the rear differential.
– **Wrench Set:** A complete set of metric and standard wrenches to remove bolts and nuts.
– **Socket Set:** A ratchet and socket set, preferably with extensions, to reach various bolts.
– **Torque Wrench:** To ensure that all fasteners are tightened to manufacturer specifications.
– **Screwdrivers:** Flathead and Phillips screwdrivers for various components.
– **Pry Bar:** Useful for removing stubborn parts or separating components.
– **Differential Gear Set:** Depending on the adjustment desired, you may need to replace the gear set with one that has the desired gear ratio.
– **Gear Oil:** High-quality gear oil suitable for the differential, to replenish after work is done.
– **Sealant or Gasket Material:** For resealing the differential cover after adjustment or replacement.
– **Measuring Tools:** Calipers or a dial gauge to measure backlash and ensure proper spacing between gears.

– **Preparation:**
– **Parking and Safety:** Park the vehicle on a flat, stable surface and engage the parking brake. Use wheel chocks to prevent rolling.
– **Lifting the Vehicle:** Use the jack to lift the rear of the vehicle and securely place jack stands under the frame to support it safely.

– **Accessing the Differential:**
– **Remove the Differential Cover:** Using the wrench or socket set, unbolt the differential cover. Be cautious as gear oil may spill out.
– **Inspect the Gears:** Take a visual inspection of the gears for wear or damage. This is also a good time to clean the housing.

– **Adjusting the Gear Ratio:**
– **Remove Existing Gear Set:** If replacing the gear set, unbolt and carefully remove the ring gear and pinion. You may need to pull the carrier out of the housing to access these.
– **Install New Gear Set:** Follow the manufacturer’s instructions to install the new gear set. Ensure that the new ring gear and pinion are compatible with the L200’s specifications.
– **Set the Pinion Depth:** This is critical for proper gear meshing. Use a dial indicator to measure the depth and adjust accordingly by shimming if necessary.
– **Adjust Backlash:** Measure the backlash using the dial gauge. Adjust the side shims on the carrier to achieve the correct backlash as specified by the manufacturer.

– **Reassembly:**
– **Reattach the Differential Cover:** Once the gear ratio is set, clean the mating surfaces, apply new sealant or use a gasket, and bolt the differential cover back on using the torque wrench to secure it to the proper specifications.
– **Fill with Gear Oil:** Refill the differential with the appropriate gear oil, checking for proper fluid levels as recommended in the owner’s manual.

– **Final Steps:**
– **Lower the Vehicle:** Remove the jack stands and carefully lower the vehicle back to the ground using the jack.
– **Test Drive:** Conduct a test drive to ensure everything functions correctly and listen for any unusual noises that may indicate improper installation or adjustment.

– **Post-Adjustment Check:**
– **Recheck Gear Oil Level:** After the test drive, check the gear oil level again, as it may settle or leak slightly during operation.
– **Inspect for Leaks:** Look around the differential cover for any signs of leaks after the vehicle has been driven.

By following these detailed steps and using the necessary tools, you can successfully adjust the gear ratio on a Mitsubishi L200. Always refer to the specific service manual for your vehicle model for exact specifications and procedures.
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