Mitsubishi Outlander XL. Manual - part 551

INSPECTION PROCEDURE 2: Constant Noise <DIFFERENTIAL>

M12701000910USA0000010000

DIAGNOSIS

STEP 1. Check the oil level.

ZC5000770000

8 mm 
(0.3 in)

Upper
limit

Lower
limit

Gear oil

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):
SAE90, 85W-90, 80W-90, From -34 to -23°C(-30 to -10°F):
SAE80W, 80W-90, Below -34°C(-30°F): SAE75W. 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-26).

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.

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.

REAR AXLE<AWD>

27B-7

REAR AXLE DIAGNOSIS

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 3: Gear Noise while Driving <DIFFERENTIAL>

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DIAGNOSIS

STEP 1. Check the oil level.

ZC5000770000

8 mm 
(0.3 in)

Upper
limit

Lower
limit

Gear oil

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):
SAE90, 85W-90, 80W-90, From -34 to -23°C(-30 to -10°F):
SAE80W, 80W-90, Below -34°C(-30°F): SAE75W. 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.

27B-8

REAR AXLE<AWD>

REAR AXLE DIAGNOSIS

STEP 6. 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 Coasting <DIFFERENTIAL>

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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>

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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>

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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.

REAR AXLE<AWD>

27B-9

REAR AXLE DIAGNOSIS

NO:

 Start over at Step 1.

INSPECTION PROCEDURE 7: Heat <DIFFERENTIAL>

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DIAGNOSIS

STEP 1. Check the oil level.

ZC5000770000

8 mm 
(0.3 in)

Upper
limit

Lower
limit

Gear oil

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):
SAE90, 85W-90, 80W-90, From -34 to -23°C(-30 to -10°F):
SAE80W, 80W-90, Below -34°C(-30°F): SAE75W. Then go to
Step 3.

NO:

 Go to Step 2.

STEP 2. Check for excessive gear backlash (Refer to P.
27B-33).

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>

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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.

27B-10

REAR AXLE<AWD>

REAR AXLE DIAGNOSIS