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)