Mitsubishi Montero (2004+). Manual — part 467

REAR AXLE DIAGNOSIS

TSB Revision

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; 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.

STEP 2. Check the tooth contact (engagement) of the drive
gear and drive pinion. Refer to GROUP 26, Differential

Carrier

− Inspection Before Disassembly

P.26-43

.

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

TSB Revision

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; 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 6.

NO : Go to Step 2.

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)

REAR AXLE DIAGNOSIS

TSB Revision

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

TSB Revision

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; 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 3.

NO : Go to Step 2.

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)