Mitsubishi Montero Sport (2004+). Manual — part 436

SPECIFICATIONS

TSB Revision

REAR AXLE

27-45

SERVICE SPECIFICATIONS

M1271000300524

LUBRICANTS

M1271000400264

SEALANT AND ADHESIVE

M1271000500119

ITEM

STANDARD VALUE

LIMIT

Rear axle total backlash mm (in)

−

5 (0.2)

Axle shaft end play mm (in)

0

− 0.25 (0 − 0.010)

−

Protruding length of stabilizer bar mounting bolt mm (in)

15

− 17 (0.6 − 0.7)

−

Press-fitting force of retainer N (lb)

Initial press-force

49,000 (11,016) or more

−

Final press-fitting
force

98,000

− 108,000

(22,032

− 24,281)

−

Clearance of snap ring and retainer mm (in)

0

− 0.166 (0 − 0.0065)

−

Distance between bearing case and ABS rotor mm (in)

19.4

− 20.0 (0.76 − 0.79) −

Final drive gear backlash mm (in)

0.13

− 0.18

(0.005

− 0.007)

−

Drive gear runout mm (in)

−

0.05 (0.002)

Differential gear backlash mm (in)

0

− 0.076 (0 − 0.0030)

0.2 (0.01)

Drive pinion rotation
torque
N

⋅m (in-lb)

Without oil seal

With anti-rust agent
(new)

0.6

− 0.9 (5.3 − 8.0)

−

With gear oil applied
(new or used)

0.4

− 0.5 (3.5 − 4.4)

−

With oil seal

With anti-rust agent
(new)

0.85

− 1.15 (7.52 − 10.18) −

With gear oil applied
(new or used)

0.65

− 0.75 (5.75 − 6.64) −

ITEM

SPECIFIED LUBRICANT

QUANTITY

Rear differential gear oil <Conventional differential>

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

<Limited slip differential>
Hypoid gear oil MITSUBISHI Genuine Gear
Oil Part No.8149630 EX or equivalent

3.2 dm

3

(3.4 qt)

ITEM

SPECIFIED SEALANT AND ADHESIVE

Bearing case

3M

 AAD Part No. 8672, 8679, 8678, 8661, 8663 or

equivalent

Dust cover
Axle housing (differential carrier mounting part)
Drive gear and differential case mounting part

3M

 AAD Part No. 8730, 8731 or equivalent

SPECIFICATIONS

TSB Revision

REAR AXLE

27-46

COMPONENT IDENTIFICATION

M1271003800120

SNAP RING

DRIVE PINION SPACER

THICKNESS OF SNAP RING mm (in)

IDENTIFICATION COLOR

2.17 (0.085)

−

2.01 (0.079)

Yellow

1.85 (0.073)

Blue

1.69 (0.067)

Purple

1.53 (0.060)

Red

HEIGHT OF DRIVE PINION SPACER mm (in)

IDENTIFICATION COLOR

52.50 (2.067)

Yellow

52.84 (2.080)

Red

42-1

GROUP 42

BODY

CONTENTS

BODY MOUNTING. . . . . . . . . . .

42-4

REMOVAL AND INSTALLATION .

42-4

HOOD. . . . . . . . . . . . . . . . . . . . .

42-5

BODY DIAGNOSIS . . . . . . . . . . . .

42-5

INTRODUCTION TO HOOD DIAGNOSIS

42-5

HOOD DIAGNOSTIC TROUBLESHOOTING
STRATEGY . . . . . . . . . . . . . . . . . . . . . .

42-5

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

42-5

SYMPTOM PROCEDURES . . . . . . . . .

42-5

HOOD. . . . . . . . . . . . . . . . . . . . . . .

42-7

REMOVAL AND INSTALLATION . . . . .

42-7

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

42-8

FENDER. . . . . . . . . . . . . . . . . . .

42-9

REMOVAL AND INSTALLATION .

42-9

FUEL FILLER LID . . . . . . . . . . .

42-10

REMOVAL AND INSTALLATION .

42-10

WINDOW GLASS . . . . . . . . . . .

42-11

WINDOW GLASS DIAGNOSIS . . .

42-11

INTRODUCTION TO WINDOW GLASS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-11

WINDOW GLASS DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . .

42-11

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

42-11

SYMPTOM PROCEDURES . . . . . . . . .

42-11

SPECIAL TOOL . . . . . . . . . . . . . . .

42-11

WINDOW GLASS . . . . . . . . . . . . . .

42-12

GENERAL INFORMATION . . . . . .

42-12

WINDSHIELD . . . . . . . . . . . . . . . . .

42-14

REMOVAL AND INSTALLATION. . . . . .

42-14

QUARTER WINDOW GLASS . . . .

42-17

REMOVAL AND INSTALLATION. . . . . .

42-17

LIFTGATE WINDOW GLASS. . . . .

42-19

REMOVAL AND INSTALLATION. . . . . .

42-19

DOOR . . . . . . . . . . . . . . . . . . . .

42-21

GENERAL DESCRIPTION . . . . . . .

42-21

CENTRAL DOOR LOCKING SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . .

42-22

INTRODUCTION TO CENTRAL DOOR
LOCKING SYSTEM DIAGNOSIS. . . . . .

42-22

CENTRAL DOOR LOCKING SYSTEM
TROUBLESHOOTING STRATEGY . . . .

42-22

TROUBLE SYMPTOM CHART . . . . . . .

42-22

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

42-23

POWER WINDOW DIAGNOSIS. . .

42-93

INTRODUCTION TO POWER WINDOWS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-93

POWER WINDOWS DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . .

42-93

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

42-93

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

42-94

Continued on next page

42-2

DOOR DIAGNOSIS . . . . . . . . . . . .

42-122

INTRODUCTION TO GLASS AND DOOR
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-122

GLASS AND DOOR DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . .

42-122

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

42-122

SYMPTOM PROCEDURES . . . . . . . . .

42-123

HOW TO LOCATE WIND NOISES

42-126

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

42-127

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

42-129

DOOR FIT ADJUSTMENT. . . . . . . . . . .

42-129

DOOR WINDOW GLASS ADJUSTMENT

42-130

ADJUSTMENT AND REPLACEMENT
WHEN THERE IS A MALFUNCTION OF
THE POWER WINDOWS . . . . . . . . . . .

42-130

DOOR OUTSIDE HANDLE PLAY CHECK

42-131

POWER WINDOW OPERATING
CURRENT CHECK . . . . . . . . . . . . . . . .

42-131

CIRCUIT BREAKER (INCORPORATED IN
THE POWER WINDOW MOTOR)
CHECK . . . . . . . . . . . . . . . . . . . . . . . . .

42-131

DOOR INSIDE HANDLE PLAY CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . .

42-131

DOOR ASSEMBLY . . . . . . . . . . . .

42-132

REMOVAL AND INSTALLATION . . . . .

42-132

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

42-133

DOOR TRIM AND WATERPROOF
FILM . . . . . . . . . . . . . . . . . . . . . . . .

42-134

REMOVAL AND INSTALLATION . . . . .

42-134

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

42-136

DOOR GLASS AND REGULATOR

42-137

REMOVAL AND INSTALLATION . . . . .

42-137

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

42-139

DOOR HANDLE AND LATCH. . . .

42-140

REMOVAL AND INSTALLATION . . . . .

42-140

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

42-142

WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP

42-145

REMOVAL AND INSTALLATION . . . . .

42-145

LIFTGATE . . . . . . . . . . . . . . . . .

42-146

LIFTGATE DIAGNOSIS. . . . . . . . .

42-146

INTRODUCTION TO LIFTGATE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-146

LIFTGATE DIAGNOSTIC

TROUBLESHOOTING STRATEGY . . . .

42-146

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

42-146

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

42-146

SPECIAL TOOL . . . . . . . . . . . . . . .

42-147

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

42-148

LIFTGATE FIT ADJUSTMENT. . . . . . . .

42-148

LIFTGATE HANDLE PLAY CHECK . . . .

42-148

LIFTGATE. . . . . . . . . . . . . . . . . . . .

42-149

REMOVAL AND INSTALLATION. . . . . .

42-149

LIFTGATE TRIM AND WATERPROOF
FILM . . . . . . . . . . . . . . . . . . . . . . . .

42-151

REMOVAL AND INSTALLATION. . . . . .

42-151

LIFTGATE HANDLE AND LATCH.

42-152

REMOVAL AND INSTALLATION. . . . . .

42-152

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

42-153

KEYLESS ENTRY SYSTEM . .

42-154

GENERAL INFORMATION . . . . . .

42-154

KEYLESS ENTRY SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . .

42-154

INTRODUCTION TO KEYLESS ENTRY
SYSTEM DIAGNOSIS . . . . . . . . . . . . . .

42-154

KEYLESS ENTRY SYSTEM DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . .

42-154

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

42-154

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

42-155

MEASUREMENT AT THE RECEIVER
TERMINALS . . . . . . . . . . . . . . . . . .

42-161

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

42-162

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

42-163

HOW TO REPLACE THE TRANSMITTER
BATTERY . . . . . . . . . . . . . . . . . . . . . . . .

42-163

SECRET CODE REGISTRATION
METHOD . . . . . . . . . . . . . . . . . . . . . . . .

42-163

ETACS-ECU FUNCTION ADJUSTMENT
PROCEDURE. . . . . . . . . . . . . . . . . . . . .

42-166

KEYLESS ENTRY SYSTEM. . . . . .

42-167

REMOVAL AND INSTALLATION. . . . . .

42-167

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

42-168

Continued on next page