Mitsubishi Outlander GS45X. Manual - part 1515

 

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Mitsubishi Outlander GS45X. Manual - part 1515

 

 

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE <AWD>

27B-9

INSPECTION PROCEDURE 3: 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 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 
6.

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 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.

AC703480 AB

8 mm
(0.3 in)

Upper 
limit

Lower 
limit

Gear oil

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE <AWD>

27B-10

INSPECTION PROCEDURE 4: 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.

INSPECTION PROCEDURE 5: 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 6: 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.

REAR AXLE DIAGNOSIS

TSB Revision

REAR AXLE <AWD>

27B-11

INSPECTION PROCEDURE 7: 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 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 
3.

NO :  Go to Step 2.

STEP 2. Check for excessive gear backlash (Refer to 

P.27B-39

).

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 :  Start over at Step 1.

INSPECTION PROCEDURE 8: Oil Leakage <DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the cover installation.
Q: Is the cover installed correctly?

YES : Go to Step 2.
NO :  Repair. Then go to Step 4.

STEP 2. Check the oil seal for wear or damage.
Q: Is the oil seal worn or damaged?

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

AC703480 AB

8 mm
(0.3 in)

Upper 
limit

Lower 
limit

Gear oil

SPECIAL TOOLS

TSB Revision

REAR AXLE <AWD>

27B-12

STEP 3. 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 : 
Refill Hypoid gear oil API classification GL-5 or 

higher, SAE80.  Then go to Step 4 .

NO :  Go to Step 4.

STEP 4. Retest the system.
Q: Is there oil leakage?

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

SPECIAL TOOLS

M1271000600978

AC703480 AB

8 mm
(0.3 in)

Upper 
limit

Lower 
limit

Gear oil

Tool

Tool number and 
name

Supersession

Application

MB991115
Oil seal installer

MB991115-01

Oil seal press-fitting (used in 
combination with MB990938)

MB990767
Front hub and flange 
yoke holder

MB990767-01

Hub fixing

MB991618
Hub bolt remover

General service tool

Hub bolt removal

MB990241 
Axle shaft puller

A: MB990242

Puller shaft

B: MB990244

Puller bar

MB990241-01 or 
General service tool

• Driveshaft removal

• Rear hub assembly removal

MB991354
Puller body

General service tool

B990767

MB991618

MB990241AD

B

A

MB991354

 

 

 

 

 

 

 

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