Mitsubishi Montero (2002-2004). Manual - part 219

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

NO :  Go to Step 2.

STEP 2. Check for excessive gear backlash. Refer to 
GROUP 26, Differential Carrier 

− Inspection before 

Disassembly 

P.26-41

.

Q: Is the gear backlash correct?

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

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE

27-11

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

YES : The procedure is complete.
NO :  Start over at Step 1.

INSPECTION PROCEDURE 9: Oil Leakage <DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the breather hose for clogging.
Q: Is the breather hose 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 correctly?

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

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

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

STEP 4. 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 : Refill Hypoid gear oil API classification GL-5 or 

higher, SAE viscosity Number 90, 80W. Then go to 
Step 5.

NO :  Go to Step 5.

STEP 5. Retest the system.
Q: Is there oil leakage?

YES : Start over at Step 1.
NO :  The procedure is complete.

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)

ON-VEHICLE SERVICE

TSB Revision

REAR AXLE

27-12

ON-VEHICLE SERVICE

REAR AXLE TOTAL BACKLASH CHECK

M1271001200069

1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position. 

Move the transfer control lever to the neutral position. Apply 
the parking brake. Raise the vehicle on a jack.

3. Turn the companion flange clockwise as far as it will go. 

Make the mating mark on the dust cover of the companion 
flange and on the differential carrier.

4. Turn the companion flange counterclockwise as far as it will 

go, and measure the amount of distance the mating marks 
moved.

Limit: 5 mm (0.2 inch)

5. If the backlash exceeds the limit value, remove the 

differential carrier assembly and check the following.

• Final drive gear backlash

• Differential gear backlash

GEAR OIL LEVEL CHECK

M1272001200040

Check that gear oil level is not 5 mm (0.2 inch) below the bot-
tom of filler plug hole.

Specified gear oil:

   Hypoid gear oil API classification GL-5 or higher 

SAE viscosity Number 90, 80W

WHEEL BEARING AXIAL PLAY CHECK

M1271000900258

1. Remove the rear brake assembly and remove the brake disc 

while holding it with wires to prevent it from falling.

ACX00962AB

MATING MARKS

ACX00964

ACX01083AB

GEAR OIL

UPPER
LIMIT

LOWER
LIMIT

5 mm
(0.2 in)