Mitsubishi Montero Sport (2004+). Manual - part 406

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-5

STEP 7. Check the drive gear and differential case for 
strain, and the gear for 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.

STEP 8. Check for the engagement of foreign material.
Q: Is foreign material found?

YES : Remove the foreign material and then inspect. 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 :  Repeat from Step 1.

INSPECTION PROCEDURE 4: Gear Noise While Driving

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 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): 

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 7.

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 the drive gear and drive pinion. Then go to 

Step 6.

STEP 3. Check the drive pinion turning torque. Refer to 

P.26-49

.

Q: Is the drive pinion turning torque correct?

YES : Go to Step 4.
NO :  Adjust the turning torque. Then go to Step 7.

AC000439

UPPER LIMIT

LOWER LIMIT

AB

8 mm (0.3 in)

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-6

STEP 4. Check the gear for damage.
Q: Is the gear damaged?

YES : Replace the gear. Then go to Step 7.
NO :  Go to Step 5.

STEP 5. Check for the engagement of foreign material.
Q: Is the foreign material found?

YES : Remove the foreign material and then inspect. If 

necessary, replace the part. Then go to Step 7.

NO :  Go to Step 6.

STEP 6. Retest the system.
Q: Is the abnormal noise eliminated?

YES : Replace the drive gear and drive pinion. Then go to 

Step 7.

NO :  The procedure is complete.

STEP 7. Retest the system.
Q: Is the abnormal noise eliminated?

YES : The procedure is complete.
NO :  Repeat from Step 1.

INSPECTION PROCEDURE 5: Gear Noise while Coasting

DIAGNOSIS

STEP 1. Check the drive pinion turning torque. 

Refer to 

P.26-49

.

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 : 

There is no action to be taken.

STEP 3. Retest the system.

Q: Is the abnormal noise eliminated?

YES : 

The procedure is complete.

NO : 

Repeat from Step 1.

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-7

INSPECTION PROCEDURE 6: Bearing Noise While Driving or Coasting

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 : 

There is no action to be taken.

STEP 2. Retest the system.

Q: Is the abnormal noise eliminated?

YES : 

The procedure is complete.

NO : 

Repeat to Step 1.

INSPECTION PROCEDURE 7: Noise while Turning

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 : 

There is no action to be taken.

STEP 3. Retest the system.

Q: Is the abnormal noise eliminated?

YES : 

The procedure is complete.

NO : 

Repeat from Step 1.

FRONT AXLE DIAGNOSIS

TSB Revision

FRONT AXLE

26-8

INSPECTION PROCEDURE 8: Heat

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 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): 

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.

STEP 2. Check the gear backlash (excessive) Refer to 

P.26-49

.

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 :  Repeat from Step 1.

AC000439

UPPER LIMIT

LOWER LIMIT

AB

8 mm (0.3 in)