Mitsubishi Montero (2002-2004). Manual — part 219
REAR AXLE DIAGNOSIS
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REAR AXLE
27-9
STEP 2. Check the gear engagement.
Q: Is the gear engagement in good condition?
YES : Go to Step 3.
NO : Adjust or replace the part. Then go to Step 6.
STEP 3. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES : Go to Step 4.
NO : Adjust the turning torque. Then go to Step 6.
STEP 4. Check the gear for damage.
Q: Is the gear damaged?
YES : Replace the gear. Then go to Step 6.
NO : Go to Step 5.
STEP 5. Check for foreign material.
Q: Is foreign material found?
YES : Remove the foreign material and then inspect for
damage. If necessary, replace the part. Then go to
Step 6.
NO : Go to Step 6.
STEP 6. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 5: Gear Noise while Coasting <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES :
Go to Step 2.
NO :
Adjust the turning torque. Then go to Step 3.
STEP 2. Check the gear for damage.
Q: Is the gear damaged?
YES :
Replace the gear. 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.
REAR AXLE DIAGNOSIS
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REAR AXLE
27-10
INSPECTION PROCEDURE 6: Bearing Noise while Driving or Coasting <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the drive pinion rear bearing for
cracks or damage.
Q: Is the drive pinion rear bearing cracked or
damaged?
YES :
Replace the part. Then go to Step 2.
NO :
Go to Step 2.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES :
The procedure is complete.
NO :
Start over at Step 1.
INSPECTION PROCEDURE 7: Noise while Turning < DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the side bearing for wear or
damage.
Q: Is the side bearing worn or damaged?
YES :
Replace the part. Then go to Step 3.
NO :
Go to step 2.
STEP 2. Check the side gear, pinion gear or
pinion shaft for damage.
Q: Is the side gear, pinion gear or pinion shaft
damaged?
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 8: Heat <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 5 mm (0.2 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, SAE viscosity Number
90, 80W. Then go to Step 3.
NO : Go to Step 2.
STEP 2. Check for excessive gear backlash. Refer to
GROUP 26, Differential Carrier
− Inspection before
Disassembly
.
Q: Is the gear backlash correct?
YES : Go to Step 3.
NO : Adjust the backlash. Then go to step 3.
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
REAR AXLE DIAGNOSIS
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REAR AXLE
27-11
STEP 3. Retest the system.
Q: Is the heat eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 9: Oil Leakage <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the breather hose for clogging.
Q: Is the breather hose clogged?
YES : Clean or replace the part. Then go to Step 5.
NO : Go to step 2.
STEP 2. Check the cover installation.
Q: Is the cover installed correctly?
YES : Go to Step 3.
NO : Repair. Then go to Step 5.
STEP 3. Check the oil seal for wear or damage.
Q: Is the oil seal worn or damaged?
YES : Replace the seal. Then go to Step 5.
NO : Go to Step 4.
STEP 4. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 5 mm (0.2 inch) below the
bottom of the filler plug hole?
YES : Refill Hypoid gear oil API classification GL-5 or
higher, SAE viscosity Number 90, 80W. Then go to
Step 5.
NO : Go to Step 5.
STEP 5. Retest the system.
Q: Is there oil leakage?
YES : Start over at Step 1.
NO : The procedure is complete.
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
ON-VEHICLE SERVICE
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REAR AXLE
27-12
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
M1271001200069
1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position.
Move the transfer control lever to the neutral position. Apply
the parking brake. Raise the vehicle on a jack.
3. Turn the companion flange clockwise as far as it will go.
Make the mating mark on the dust cover of the companion
flange and on the differential carrier.
4. Turn the companion flange counterclockwise as far as it will
go, and measure the amount of distance the mating marks
moved.
Limit: 5 mm (0.2 inch)
5. If the backlash exceeds the limit value, remove the
differential carrier assembly and check the following.
• Final drive gear backlash
• Differential gear backlash
GEAR OIL LEVEL CHECK
M1272001200040
Check that gear oil level is not 5 mm (0.2 inch) below the bot-
tom of filler plug hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W
WHEEL BEARING AXIAL PLAY CHECK
M1271000900258
1. Remove the rear brake assembly and remove the brake disc
while holding it with wires to prevent it from falling.
ACX00962AB
MATING MARKS
ACX00964
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
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