Mitsubishi Montero Sport (2004+). Manual — part 405

taper roller bearing is mounted on the knuckle
spindle. For vehicles with ABS, a rotor for detect-
ing the wheel speed is press-fitted into the front
hub.

4WD

• The front axle consists of the hub assembly, drive

shaft, inner shaft, front differential. The features
are:

• The wheel bearing uses a double taper roller

bearing. For vehicles with ABS, a rotor for detect-
ing the wheel speed is bolted to the brake disc.

• Drive shafts of almost identical length reduce

torque steer. In addition, a DOJ-BJ-type constant
velocity ball joint has high power transmission
efficiency and reduces vibration and noise.

• Full time 4WD mechanism has been adopted.

• There are two types of differential gear. The dif-

ference between them is gear ratio.

NOTE:

DOJ: Double Offset Joint
BJ: Birfield Joint

FRONT AXLE DIAGNOSIS

INTRODUCTION TO FRONT AXLE DIAGNOSIS

M1261005500179

The full time 4WD mechanism has been adopted for
the 4WD vehicles.

Noise from the driveshaft, inner shaft or differential
can be caused by a component defect.

FRONT AXLE DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1261005600198

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
front 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 malfunction is eliminated.

SYMPTOM CHART

M1261005700214

SYMPTOM

INSPECTION
PROCEDURE

REFERENCE PAGE

Driveshaft,
inner shaft

Noise during wheel rotation

P.26-3

Noise due to excessive wheel play in
turning direction

P.26-3

Differential

Constant noise

P.26-4

Gear noise while driving

P.26-5

Gear noise while coasting

P.26-6

Bearing noise while driving or coasting

Noise while turning

Heat

Oil leakage

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-3

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise during Wheel Rotation

DIAGNOSIS

STEP 1. Check the housing tube and inner shaft
for bending.

Q: Is the housing tube and inner shaft bent?

YES :

Replace the part. Then go to Step 4.

NO :

Go to step 2.

STEP 2. Check the inner shaft bearing for wear.

Q: Is the inner shaft bearing worn?

YES :

Replace the bearings. Then go to Step 4.

NO :

Go to Step 3.

STEP 3. Check the driveshaft assembly for wear,
damage or bending.

Q: Is the driveshaft assembly worn, damaged or bent?

YES :

Replace the driveshaft assembly. Then go

to Step 4.

NO :

There is no action to be taken.

STEP 4. Retest the system.

Q: Is the abnormal noise eliminated?

YES :

The procedure is complete.

NO :

Repeat from Step 1.

INSPECTION PROCEDURE 2: Noise Due to Excessive Wheel Play in Turning Direction

DIAGNOSIS

STEP 1. Check for play in the inner shaft and side
gear serration, the driveshaft and side gear, or
the driveshaft and drive flange.

Q: Is play found?

YES :

Adjust or replace the part. Then go to Step

NO :

The procedure is complete.

STEP 2. Retest the system.

Q: Is the abnormal noise eliminated?

YES :

The procedure is complete.

NO :

Repeat from Step 1.

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-4

INSPECTION PROCEDURE 3: Constant Noise

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.

STEP2. Check the tooth contact (engagement) of the drive

gear and drive pinion. Refer to

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.

STEP3. 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.

AC000439

UPPER LIMIT

LOWER LIMIT

8 mm (0.3 in)

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Mitsubishi Montero Sport (2004+). Manual — part 405

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