Mitsubishi Montero (2002-2004). Manual — part 218

SPECIAL TOOLS

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REAR AXLE

27-5

MD998812
Installer cap

−

Press-fitting of the side bearing
inner race

MD998829
Installer adapter

−

MB990925
Bearing and oil seal installer
set
A: MB990926

− MB990937

Installer adapter

B: MB990938

Bar

C: MB990939

Brass bar

MB990925-01 or
General service
tool

• Press-fitting of oil seal

• Inspection of drive gear tooth

contact

• Removal of bearing outer

race

For details of each installer,
refer to GROUP 26

− Special

Tools

P.26-9

.

MB991045
Bushing remover and
installer
A: MB991050
Base (B)

−

Removal of the rear suspension
crossmember bushing

MB991159
Bushing remover and
installer
A: MB991162
Bolt
B: MB991218
Bearing

−

Removal and press-fitting of the
rear suspension crossmember
bushing

MB991816
Bushing remover and
installer base

−

MB990955
Oil seal installer

−

Press-fitting of the rear
suspension crossmember
bushing

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990925

A

B

C

MB991045AB

A

MB991159AB

A

B

MB990955

REAR AXLE DIAGNOSIS

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REAR AXLE

27-6

REAR AXLE DIAGNOSIS

INTRODUCTION

M1271004100102

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

TROUBLESHOOTING STRATEGY

M1271004200109

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 malfunction is eliminated.

SYMPTOM CHART

M1271004300214

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise while Wheels are Rotating <DRIVE SHAFT>

DIAGNOSIS

STEP 1. Check whether the drive shaft is bent.

Q: Is the drive shaft bent?

YES :

Replace the part. Then go to Step 3.

NO :

Go to Step 2.

STEP 2. Check the wheel bearing of rear hub
assembly for wear or damage.

Q: Is the wheel 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.

SYMPTOMS

INSPECTION
PROCEDURE

REFERENCE
PAGE

Drive shaft

Noise while wheels are rotating

1

P.27-6

Grease leakage

2

P.27-7

Differential

Constant noise

3

P.27-7

Gear noise while driving

4

P.27-8

Gear noise while coasting

5

P.27-9

Bearing noise while driving or coasting

6

P.27-10

Noise while turning

7

P.27-10

Heat

8

P.27-10

Oil leakage

9

P.27-11

REAR AXLE DIAGNOSIS

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REAR AXLE

27-7

INSPECTION PROCEDURE 2: Grease Leakage <DRIVE SHAFT>

DIAGNOSIS

STEP 1. Check the DOJ boot and the BJ boot for
wear or damage.

Q: Is the DOJ boot or the BJ boot worn or damaged?

YES :

Replace the part and apply grease (Refer to

P.27-20

.). 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 <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 9.

NO : Go to Step 2.

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.

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)

REAR AXLE DIAGNOSIS

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REAR AXLE

27-8

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 wear
or damage.
Q: Is the drive gear or differential case worn or damaged?

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

STEP 8. Check for foreign material.
Q: Is any foreign material found?

YES : Remove the foreign material and then inspect for

damage. 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.

INSPECTION PROCEDURE 4: Gear Noise while Driving <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 6.

NO : Go to Step 2.

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)