Mitsubishi Montero Sport (2004+). Manual — part 425

27-1

GROUP 27

REAR AXLE

CONTENTS

GENERAL DESCRIPTION. . . . . . . . .

27-2

REAR AXLE DIAGNOSIS . . . . . . . . .

27-2

INTRODUCTION. . . . . . . . . . . . . . . . . . . . .

27-2

TROUBLESHOOTING STRATEGY . . . . . .

27-2

SYMPTOM CHART. . . . . . . . . . . . . . . . . . .

27-2

SYMPTOM PROCEDURES . . . . . . . . . . . .

27-3

SPECIAL TOOLS. . . . . . . . . . . . . . . .

27-14

ON-VEHICLE SERVICE. . . . . . . . . . .

27-17

REAR AXLE TOTAL BACKLASH CHECK .

27-17

AXLE SHAFT END PLAY CHECK . . . . . . .

27-17

AXLE SHAFT END PLAY ADJUSTMENT .

27-17

GEAR OIL LEVEL CHECK . . . . . . . . . . . . .

27-18

AXLE ASSEMBLY . . . . . . . . . . . . . . .

27-19

REMOVAL AND INSTALLATION . . . . . . . .

27-19

AXLE SHAFT ASSEMBLY . . . . . . . . .

27-21

REMOVAL AND INSTALLATION . . . . . . . .

27-21

DISASSEMBLY AND ASSEMBLY . . . . . . .

27-23

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27-27

DIFFERENTIAL CARRIER
ASSEMBLY. . . . . . . . . . . . . . . . . . . . .

27-28

REMOVAL AND INSTALLATION . . . . . . . .

27-28

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

27-30

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

27-34

SPECIFICATIONS . . . . . . . . . . . . . . .

27-44

FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .

27-44

GENERAL SPECIFICATIONS . . . . . . . . . .

27-44

SERVICE SPECIFICATIONS . . . . . . . . . . .

27-45

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .

27-45

SEALANT AND ADHESIVE . . . . . . . . . . . .

27-45

COMPONENT IDENTIFICATION . . . . . . . .

27-46

GENERAL DESCRIPTION

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REAR AXLE

27-2

GENERAL DESCRIPTION

M1271000100188

• The rear axle is a banjo-type semi-floating type.

As the axle shaft bearings, single taper roller
bearings and double taper roller bearings are
used. ABS rotor is press-fitted to the axle shaft
retainer ring.

• The hybrid type LSD, which has superior off-road

driving performance, is offered as an option.

REAR AXLE DIAGNOSIS

INTRODUCTION

M1271004100191

Noise from the drive shaft or differential may be
caused by defects in the components.

TROUBLESHOOTING STRATEGY

M1271004200198

Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
rear axle fault.
1. Gather information from the customer.

2. Verify that the condition described by the

customer exists.

3. Find the malfunction by following the Symptom

Chart.

4. Verify that the malfunction is eliminated.

SYMPTOM CHART

M1271004300195

SYMPTOMS

INSPECTION
PROCEDURE

REFERENCE
PAGE

Axle shaft, axle
housing

Noise while wheels are rotating

1

P.27-3

Grease leakage

2

P.27-3

Differential
(Conventional
differential)

Constant noise

3

P.27-3

Gear noise while driving

4

P.27-5

Gear noise while coasting

5

P.27-6

Bearing noise while driving or coasting

6

P.27-6

Noise while turning

7

P.27-6

Heat

8

P.27-7

Oil leakage

9

P.27-8

Differential
(Limited-slip
differential)

Abnormal noise during driving or shifting

10

P.27-8

Abnormal noise when cornering

11

P.27-9

Gear noise

12

P.27-10

Gear oil leakage

13

P.27-11

Seizure

14

P.27-12

Breakdown

15

P.27-13

Limited slip differential does not function
(on snow, mud, ice, etc.).

16

P.27-13

REAR AXLE DIAGNOSIS

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REAR AXLE

27-3

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise while Wheels are Rotating

DIAGNOSIS

STEP 1. Check whether the axle shaft is bent.

Q: Is the axle shaft bent?

YES :

Replace the part. Then go to Step 3.

NO :

Go to Step 2.

STEP 2. Check the axle shaft bearing for wear or
damage.

Q: Is the axle shaft bearing damaged or worn?

YES :

Replace the part. Then go to Step 3.

NO :

Go to Step 3.

STEP 3. Retest the system.

Q: Is the abnormal noise eliminated?

YES :

The procedure is complete.

NO :

Start over at Step 1.

INSPECTION PROCEDURE 2: Grease Leakage

DIAGNOSIS

STEP 1. Check the oil seal for wear or damage,
and the bearing seal for defects.

Q: Is the oil seal worn, damaged or faulty and the

bearing seal for defects?

YES :

Replace the part and apply grease (Refer to

P.27-21

or

P.27-21

.). Then go to Step 2.

NO :

Go to Step 2.

STEP 2. Retest the system.

Q: Is there grease leakage?

YES :

Start over at Step 1.

NO :

The procedure is complete.

INSPECTION PROCEDURE 3: Constant Noise <Conventional Differential>

DIAGNOSIS

STEP 1. Check the oil level.

Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the

bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and

repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher; Above

−23°C(−10°F):

SAE 90, 85W-90, 80W-90, From

−34 to −23°C(−30 to

−10°F): SAE 80W, 80W-90, Below −34°C(−30°F):

SAE 75W. Then go to Step 9.

NO : Go to Step 2.

ACX01083 AC

8 mm (0.3 in)

UPPER
LIMIT

LOWER
LIMIT

REAR AXLE DIAGNOSIS

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REAR AXLE

27-4

STEP 2. Check the tooth contact (engagement) of the drive
gear and drive pinion. Refer to GROUP 26, Differential

Carrier

− Inspection Before Disassembly

P.26-41

.

Q: Is the tooth contact (engagement) of the drive gear and

drive pinion correct?
YES : Go to Step 3.
NO : Adjust or replace the part. Then go to Step 9.

STEP 3. Check the side bearing for looseness, wear or
damage.
Q: Is the side bearing loosened, worn or damaged?

YES : Adjust or replace the part. Then go to Step 9.
NO : Go to Step 4.

STEP 4. Check the drive pinion bearing for wear or
damage.
Q: Is the drive pinion bearing worn or damaged?

YES : Adjust or replace the part. Then go to Step 9.
NO : Go to Step 5.

STEP 5. Check the drive gear and drive pinion for wear.
Q: Is the drive gear or drive pinion worn?

YES : Replace the part. Then go to Step 9.
NO : Go to Step 6.

STEP 6. Check the side gear thrust washer or pinion shaft
for wear.
Q: Is the side gear thrust washer or pinion shaft worn?

YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.

STEP 7. Check the drive gear and differential case for
strain, and the gear for damage.
Q: Is the drive gear or differential case strained or

damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 8.

STEP 8. Check for the engagement of foreign material.
Q: Is the foreign material found?

YES : Remove the foreign material and then inspect. If

necessary, replace the part. Then go to Step 9.

NO : Go to Step 9.

STEP 9. Retest the system.
Q: Is the abnormal noise eliminated?

YES : The procedure is complete.
NO : Start over at Step 1.