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FYI: Gen III rear axle problem, and with very low miles still ***UPDATE*** #1060179 05/29/13 08:25 PM
Joined: Jun 2003
Posts: 7,353
MontyMcV Offline OP
Trail Leader
More and informational post here, not looking for answers. Here's the saga by bullet points on the 03:

1. We are now up to a whopping 34k miles.
2. Noticed some spotting on the drive, and then see tell tale signs on the rear diff housing. Made a mental not to crawl under some day when I have time and it isn't raining.
3. With the holiday travels last weekend it started to make a horrific whine.
4. Finally crawlwed underneath to find the DS axle had backed out from the housing. Seems as if something failed with the cir-clip that must be on the diff end.
5. Checked the gear lube and it was way low. Refilled and took for a drive and still sounds like hell.
6. With the 14k miles when we bought it, I did what I seldom do and bought a bumper-to-bumper extended warranty good for 8yrs/85k miles. And so we limped home.
7. Took it to the stealer who just called to say it likely needs a new diff.

This is going to cost over a grand I expect, which means half the cost of warranty is effectively paid back.

The biggest thing though is what the hell happened that the axle floated out to begin with? e.g. Did the cir-clip break? Will report back when there is more to share...

Last edited by MontyMcV; 05/31/13 03:13 PM.

Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
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Re: FYI: Gen III rear axle problem, and with very low miles still [Re: MontyMcV] #1060180 05/29/13 08:58 PM
Joined: Jan 2000
Posts: 16,226
off-roader Offline
Web Wheeler
*****
I wonder if the previous owner mis-used it somehow? <img src="/forums/images/graemlins/confused.gif" alt="" />


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Re: FYI: Gen III rear axle problem, and with very low miles still [Re: off-roader] #1060181 05/30/13 04:16 PM
Joined: Jun 2003
Posts: 7,353
MontyMcV Offline OP
Trail Leader
I'd say unlikely. It belonged to a Mist dealership owner and was kept at his summer house. It only had one tiny chip on the inner lip of one wheel well. The rest of the truck was mint.

Waiting for the warratny company rep to inspect for final approval on repairs. They should have the diff opened by tomorrow at the latest.


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: FYI: Gen III rear axle problem, and with very low miles still [Re: MontyMcV] #1060182 05/30/13 11:01 PM
Joined: Aug 2005
Posts: 826
icysyrup Offline
Rock Warrior
pajero club in oz i think had a whole thread on this if i remember right....cir-clips failed and had the axles back out just like you had happen. Cant remember what solution was, been a while since I lurked on that board.


03 Montero XLS, OME 2"suspension lift,Full skid plates, Extended Diff/transfer breathers. 34 LTB's, Winch w/syn rope, Locked front/rear.
Re: FYI: Gen III rear axle problem, and with very low miles still [Re: icysyrup] #1060183 05/31/13 02:08 AM
Joined: Jun 2003
Posts: 7,353
MontyMcV Offline OP
Trail Leader
Interesting. Do you recall if it was the Outerlimits board, or the Victoria Pajero one? I would like to track down what they have as the third party warranty company is sending signals that they may not cover it.

They are reserving final decision until it is opened up. They say if it was run dry then they might come back with "it needed service that I didn't do." My view is that I did't know anything was wrong until it started with the howling, at which point the damage was underway, IMO.


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: FYI: Gen III rear axle problem, and with very low miles still [Re: MontyMcV] #1060184 05/31/13 05:49 AM
Joined: Sep 2004
Posts: 4,479
StockRaider Offline
Roll Me Over
***
sounds like something caused the axle to back out, and then the diff leaked its fluid out and ran dry, no signs of leaking prior? Insurance companies are magicians at not paying for $hit... Good luck man!


Richard E
1989 Montero - Stock-ish
1989 V6 Auto Raider - 5.3 Vortech Swap.
1987 Mitsubishi Starion 2.6t, soon to be 3.5
1983 Honda XL600R
Re: FYI: Gen III rear axle problem, and with very low miles still ***UPDATE*** [Re: StockRaider] #1060185 05/31/13 03:13 PM
Joined: Jun 2003
Posts: 7,353
MontyMcV Offline OP
Trail Leader
Update
I found a good number of threads on this from down under. Then looking at ASA there is a new part number for the rear stub shafts.

Seems the new part has a bigger groove for the circlip and then a bigger clip to match. I called the dealer to infomr himn of this and to say that regardless of how it pans out with the warranty company, I want to get the new shafts.

Given them history of the problem, I am not quite as worried about the situation. Stinks for the warranty company, but that's their business. They can take it up with MM if they don't like having to fix faulty parts of theirs.


NOTE TO GEN III OWNERS, ESPECIALLY THOSE WHO WHEEL:
The factory chage to the new part seems to be some time in 2005. If you have an older year, consider making the change. The stub shafts should be easy to swap. Four bolts to the half shafts, swing them out of the way, and yank out the stubs. (Drain the diff first of course.) Online pricing is $75-80 per shaft.


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: FYI: Gen III rear axle problem, and with very low miles still ***UPDATE*** [Re: MontyMcV] #1060186 05/31/13 09:49 PM
Joined: Jun 2003
Posts: 7,353
MontyMcV Offline OP
Trail Leader
Note, not all stealers are bad... <img src="/forums/images/graemlins/kewl.gif" alt="" />

Just got a call. He said after talking with me this morning, he knew that the warranty company won't cover it just because some people on the web say there is a problem. So he drilled into Mitsu tech info and came up with some references that he passed along to the company, including how there is a superceded part. Also, he pitched it to them as the circlip/stub shaft failed, taking the diff with it. Meaning, they should cover the stub shaft as the failed part, and the diff as collateral damage. Sounded like the warranty co was not feeling they had a position to argue as they told the dealer they had to crunch numbers to see if the diff gets rebuilt, or if they put a whole new unit in.

Gonna be a long weekend with the fingers crossed... <img src="/forums/images/graemlins/scared.gif" alt="" />


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: FYI: Gen III rear axle problem, and with very low miles still ***UPDATE*** [Re: MontyMcV] #1060187 06/01/13 12:01 AM
Joined: Aug 2005
Posts: 826
icysyrup Offline
Rock Warrior
Glad to hear you are "hopefully" getting it fixed. Sorry I didnt reply sooner...forgot to check notify about thread posts...lol....anyhow....hope they stand up and fix it right for you.


03 Montero XLS, OME 2"suspension lift,Full skid plates, Extended Diff/transfer breathers. 34 LTB's, Winch w/syn rope, Locked front/rear.
Re: FYI: Gen III rear axle problem, and with very low miles still ***UPDATE*** [Re: icysyrup] #1060188 06/03/13 02:02 AM
Joined: Jan 2000
Posts: 7,304
PajEvo Offline
Trail Leader
*****
This is helpful info... Thanks for sharing. I intend to make use of this thread in 2014... <img src="/forums/images/graemlins/wink.gif" alt="" />

Was there a recall in other markets, according to your research? Sounds like the crank bolt all over again, eh?

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