Mitsubishi Outlander GS45X. Manual - part 1514

SERVICE SPECIFICATIONS

TSB Revision

REAR AXLE <AWD>

27B-5

SERVICE SPECIFICATIONS

M1271000301215

LUBRICANTS

M1271000400606

SEALANT AND ADHESIVE

M1271000500539

COMPONENT IDENTIFICATION

M1271003800142

DRIVE PINION SPACER

Item

Standard value

Limit

Rear axle total backlash mm (in)

−

5 (0.2)

Wheel bearing end play mm (in)

−

0.05 (0.002)

Hub rotation starting torque  N

⋅m(ft-lb)

−

1.4 (1.03)

Electronic control coupling stud bolt length  mm (in)

22.3 

− 25.1 (0.88 − 

0.99)

−

Final drive gear backlash  mm (in)

0.08 

− 0.15 (0.003 − 

0.006)

−

Drive gear runout on backside  mm (in)

−

0.05 (0.002)

Differential gear backlash  mm (in)

0 

− 0.076 (0 − 0.0030) 0.2 (0.01)

Drive pinion rotation torque  N

⋅m (in-lb) When replaced with 

new one
(coated with rust 
inhibitor oil) 

0.7 

− 1.2 (6.20 − 

10.62)

−

ETJ boot assembly dimension  mm (in)

75 

± 3 (2.95 ± 0.12)

−

Item

Specified lubricant

Quantity

Rear differential gear 
oil

Hypoid gear oil API classification GL-5, SAE 80

Approx. 0.5 dm

3

 (0.53 qt)

ETJ joint

Repair kit grease

75 

± 10 g (2.6 ± 0.3 oz)

Item

Specified sealant and adhesive

Vent plug

3M

™ AAD Part No.8672, 8679, 8678, 8661, 8663 or 

equivalent

Differential cover assembly
Differential carrier and electronic control coupling 
mounting part
Drive gear and differential case mounting part

3M

™ AAD Part No. 8730, 8731 or equivalent

Height of drive pinion spacer mm (in)
24.3 (0.96)
23.6 (0.93)

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE <AWD>

27B-6

REAR AXLE DIAGNOSIS

INTRODUCTION

M1271004100287

Noise from the driveshaft or differential may be 
caused by defects in the components.

TROUBLESHOOTING STRATEGY

M1271004200314

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

M1271004300355

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise during Wheel Rotation <DRIVESHAFT>

DIAGNOSIS

STEP 1. Check the wheel bearing end play.
(1) Remove the caliper assembly, and suspend the caliper 

assembly with a wire and remove the brake disc.

(2) Fit the dial gauge as shown in the diagram and move the 

hub in the axial direction to measure the play.

Limit: 0.05 mm (0.002 inch)

Q: Is the wheel bearing end play within the limit?

YES : Go to step 2.
NO :  Replace the part, then go to Step 4.

Symptom

Inspection 
procedure

Reference page

Driveshaft

Noise during wheel rotation

1

P.27B-6

Differential 

Constant noise

2

P.27B-7

Gear noise while driving

3

P.27B-9

Gear noise while coasting

4

P.27B-10

Bearing noise while driving or coasting

5

P.27B-10

Noise while turning

6

P.27B-10

Heat

7

P.27B-11

Oil leakage

8

P.27B-11

AC703428 AB

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE <AWD>

27B-7

STEP 2. Check if the driveshaft is bent.
Q: Is the driveshaft bent?

YES : Replace the part. Then go to Step 3.
NO :  Go to Step 4.

STEP3. Check the driveshaft assembly for wear or 
damage.
Q: Is the driveshaft assembly worn or damaged?

YES : Replace the driveshaft assembly. Then go to Step 4.
NO :  There is no action to be taken.

STEP 4. Retest the system.
Q: Is the abnormal noise eliminated?

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

INSPECTION PROCEDURE 2: 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 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, SAE80.  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 

P.27B-33

).

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 loose, worn or damaged?

YES : Adjust or replace the part. Then go to Step 9.
NO :  Go to Step 4.

AC703480 AB

8 mm
(0.3 in)

Upper 
limit

Lower 
limit

Gear oil

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE <AWD>

27B-8

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.

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 spacer or pinion shaft for 
wear. 
Q: Is the side gear spacer 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 strained 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.