Post by silversport on Oct 31, 2005 20:17:31 GMT -5
I have a Montero Sport XLS 2002 4WD which I think has a front differential leak. I think it is from the Drain Plug or the Cover Seal, probably the Cover Seal. Curious, how difficult is it to change the Cover seal. Any special tools required? Also, manual states 90W oil and about 1.22 Quarts for the Front Differential. Can anyone direct me to a url that had detail for inspecting and changing the front differential seals? And, does anyone know what causes cover seals to leak? Meaning, could there be some damage.
I use the vehicle only for commuting, never ever off road and always in AWL. Never in 4WHi or 4WLow. I do engage 4 Wheel drive once a month just to engage the differential, but only for a few minutes and only in a straight line. I bought the vehicle with 4WD for the 2 times a year when I travel in snow.
Double check and make sure that the leak isn't coming from the front differential Freewheel engagement switch. They have been known to leak through the BODY of the switch- not the gasket. If it's leaking- you'll have to replace the actual switch. IF it's coming from the actual diff cover- it's as simple are removing a few bolts, cleaning off the pan and diff, applying a quality FIPG- and reinstalling. Throw in a new drain bolt washer and your good to go. Good luck!
Post by silversport on Nov 1, 2005 15:59:09 GMT -5
Hi, thanks for the input. I've located the price for the engagement switch for 41 dollars. But I can't find where it resides? I've got the ALLDATA diagrams, but I can't find it. Where does it reside? Is it on top of the differential? Or on top of the differential cover? All I can see is the vent plug and vacuum hose connection on the front cover? How hard is it to get to? do I need to drop the front end to change it? Please advise and thank you.
Your initial post is misleading. You list your vehicle as a Montero Sport XLS 2002 4WD, then you go on to mention that you're always in AWD. If you have a 4wd Sport, you will have a freewheel switch in the front differential. If you have an A4WD Sport- i don't believe they have such a switch. Which is it?
Post by silversport on Nov 2, 2005 10:45:27 GMT -5
Hi Joel, thank you very much for the reply. You are correct, it is an Awd. Sorry for the confusion, this is my first AWD and i'm not used to writing AWD, sorry about that. This is a 2002 Sport AWD. On the floorboard there is a shifter to select AWD, 4WH or 4WL. I've also noticed that the 4WH dash light blinks but never turns solid, indicating that the 4WH is not completely engageing properly. It does engage into 4WL properly. I'm glad you pointed out the AWD, because I was looking under the car forever trying to find the switch. Knowing this information, do you have any ideas of what the possibilites are for the differential oil leak is coming from? Thank you in advance for your help. /silversport
Yeah, it you take a closer look, the "A" in AWD is also a "4" written in a different shade... hence A4WD. Most people don't notice that design ;D It should be fairly obvious as there aren't many places it could be leaking from aside from the differential and associated fill and drain plugs. There may be a breather tube/vent on top of the differential. Good Luck
Post by silversport on Nov 3, 2005 11:37:50 GMT -5
Thanks for the response. Hey, I opened the check plug on the front differential. The Sport was on level ground and the plug is about 2/3 the way up on the cover, i.e. not the drain plug. When I opened it I was expecting oil to be level with the plug; however, oil began rushing out of the check plug. I was wondering if the last service overfilled the front differential and the oil is coming out of the vent tube? Should oil be pouring out of the check plug? what do you think?
No, the gear lube should not be pouring out of the hole like that.
I will fill my differnetials up and when the lube starts to come out of the hole very slowly, I know its full and stop. I then plug the hole back up.
It is MAYBE a 45 minute job if you've never cracked open the cover on the front differential. Its about 10 or so bolts.
You'll need a socket set and ratchet. hammer and a fairly sharp flat head screw driver.
Kinda stick the flat head screw driver in and wiggle it a bit as you lightly tap on the differential cover.
The differential cover is either held on by a gasket or permatex silicone.
Scrape all the gasket material off after you get the cover off and then apply a bead all the way around, being sure to circle each bolt hole with the permatex silicone gasket maker. Let the silicone set up for about 5~10 minutes. Then secure the differential cover back, but only LOOSELY. Let the silicone set up for another 5 minutes. Then tighten it down to specifications. Not sure what the specs are for tightening it, but I get it snug, but not to the point that it is "bubba tight."
I usually go grab a beer at this point, well, it will usually be the 2nd beer and drink it. Then I fill 'er up with the gear lube.
I use Royal Pruple 85-140. It protects as well as the 90 weight and actually a bit better for harsher conditions.
'01 XLS 4WD, 2" OME, 255/85R15 BFG M/T km, ARB Air Compressor (dual lockers to come), Kargomaster Roof Rack
Not trying to hijack your post, however my 98 MS is doing the same thing as yours. As someone stated it could be the freewheel clutch switch. Does any where the best price on this part could be found. Is there a mistsu dealer that's know for giving fair prices or a discount to montero sport online members?