Mitsubishi Outlander XL. Manual — part 551
INSPECTION PROCEDURE 2: Constant Noise <DIFFERENTIAL>
M12701000910USA0000010000
DIAGNOSIS
STEP 1. Check the oil level.
ZC5000770000
8 mm
(0.3 in)
Upper
limit
Lower
limit
Gear oil
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):
SAE90, 85W-90, 80W-90, From -34 to -23°C(-30 to -10°F):
SAE80W, 80W-90, Below -34°C(-30°F): SAE75W. 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 P.27B-26).
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 loose, 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 spacer or pinion shaft for wear.
Q:Is the side gear spacer 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 strained or damaged?
YES:
Replace the part. Then go to Step 9.
NO:
Go to Step 8.
REAR AXLE<AWD>
27B-7
REAR AXLE DIAGNOSIS
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 3: Gear Noise while Driving <DIFFERENTIAL>
M12701000911USA0000010000
DIAGNOSIS
STEP 1. Check the oil level.
ZC5000770000
8 mm
(0.3 in)
Upper
limit
Lower
limit
Gear oil
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):
SAE90, 85W-90, 80W-90, From -34 to -23°C(-30 to -10°F):
SAE80W, 80W-90, Below -34°C(-30°F): SAE75W. Then go to
Step 6.
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 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.
27B-8
REAR AXLE<AWD>
REAR AXLE DIAGNOSIS
STEP 6. 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 Coasting <DIFFERENTIAL>
M12701000912USA0000010000
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.
INSPECTION PROCEDURE 5: Bearing Noise while Driving or Coasting
<DIFFERENTIAL>
M12701000913USA0000010000
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 6: Noise while Turning <DIFFERENTIAL>
M12701000914USA0000010000
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.
REAR AXLE<AWD>
27B-9
REAR AXLE DIAGNOSIS
NO:
Start over at Step 1.
INSPECTION PROCEDURE 7: Heat <DIFFERENTIAL>
M12701000915USA0000010000
DIAGNOSIS
STEP 1. Check the oil level.
ZC5000770000
8 mm
(0.3 in)
Upper
limit
Lower
limit
Gear oil
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):
SAE90, 85W-90, 80W-90, From -34 to -23°C(-30 to -10°F):
SAE80W, 80W-90, Below -34°C(-30°F): SAE75W. Then go to
Step 3.
NO:
Go to Step 2.
STEP 2. Check for excessive gear backlash (Refer to P.
27B-33).
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:
Start over at Step 1.
INSPECTION PROCEDURE 8: Oil Leakage <DIFFERENTIAL>
M12701000916USA0000010000
DIAGNOSIS
STEP 1. Check the cover installation.
Q:Is the cover installed correctly?
YES:
Go to Step 2.
NO:
Repair. Then go to Step 4.
STEP 2. Check the oil seal for wear or damage.
Q:Is the oil seal worn or damaged?
YES:
Replace the seal. Then go to Step 4.
NO:
Go to Step 3.
27B-10
REAR AXLE<AWD>
REAR AXLE DIAGNOSIS
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