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

SPECIAL TOOLS

TSB Revision

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

TSB Revision

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

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, 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

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, 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)