Mitsubishi Montero (2002-2004). Manual — part 202

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-5

STEP 2. 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.

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 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 : Repeat from Step 1.

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-6

INSPECTION PROCEDURE 6: Gear Noise while Driving

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, SAE viscosity Number
90, 80W. Then go to Step 7.

NO : Go to Step 2.

STEP 2. Check the gear engagement.
Q: Is the gear engagement in good condition?

YES : Go to Step 3.
NO : Adjust the drive gear and drive pinion. Then go to

Step 6.

STEP 3. Check the drive pinion turning torque. Refer to

P.26-47

.

Q: Is the drive pinion turning torque correct?

YES : Go to Step 4.
NO : Adjust the turning torque. Then go to Step 7.

STEP 4. Check the gear for damage.
Q: Is the gear damaged?

YES : Replace the gear. Then go to Step 7.
NO : Go to Step 5.

STEP 5. 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 7.

NO : Go to Step 6.

STEP 6. Retest the system.
Q: Is the abnormal noise eliminated?

YES : Replace the drive gear and drive pinion. Then go to

Step 7.

NO : The procedure is complete.

STEP 7. Retest the system.
Q: Is the abnormal noise eliminated?

YES : The procedure is complete.
NO : Repeat from Step 1.

AC000439

UPPER LIMIT

LOWER LIMIT

AB

8 mm (0.3 in)

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-7

INSPECTION PROCEDURE 7: Gear Noise while Coasting

DIAGNOSIS

STEP 1. Check the drive pinion turning torque.
Refer to

P.26-47

.

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 :

There is no action to be taken.

STEP 3. Retest the system.

Q: Is the abnormal noise eliminated?

YES :

The procedure is complete.

NO :

Repeat from Step 1.

INSPECTION PROCEDURE 8: Bearing Noise while Driving or Coasting

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 :

There is no action to be taken.

STEP 2. Retest the system.

Q: Is the abnormal noise eliminated?

YES :

The procedure is complete.

NO :

Repeat from Step 1.

INSPECTION PROCEDURE 9: Noise while Turning

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 :

There is no action to be taken.

STEP 3. 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

26-8

INSPECTION PROCEDURE 10: Heat

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, SAE viscosity Number
90, 80W. Then go to Step 3.

NO : Go to Step 2.

STEP 2. Check the gear backlash (excessive) Refer to

P.26-47

.

Q: Is the gear backlash correct?

YES : Go to Step 3.
NO : Adjust the backlash. Then go to step 3.

STEP 3. Retest the system.
Q: Is the heat eliminated?

YES : The procedure is complete.
NO : Repeat from Step 1.

INSPECTION PROCEDURE 11: Oil Leakage

DIAGNOSIS

STEP 1. Check the vent plug for clogging.
Q: Is the vent plug 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 properly?

YES : Go to Step 3.
NO : Repair. Then go to Step 5.

STEP 3. Check the oil seal for wear or damaged.
Q: Is the oil seal worn or damaged?

YES : Replace the seal. Then go to Step 5.
NO : Go to Step 4.

AC000439

UPPER LIMIT

LOWER LIMIT

AB

8 mm (0.3 in)