SUBJECT:

ABNORMAL NOISE/VIBRATION FROM THE REAR
DIFFERENTIAL ASSEMBLY

No:

TSB-25-27-001

DATE:

April 2025

MODEL:

Outlander

CIRCULATE TO:

[ ] GENERAL MANAGER

[ X ] PARTS MANAGER

[ X ] TECHNICIAN

[ X ] SERVICE ADVISOR

[ X ] SERVICE MANAGER

[ X ] WARRANTY PROCESSOR

[ X ] SALES MANAGER

PURPOSE

An abnormal noise and/or vibration may occur in the Rear Differential Assembly. The hole where
the breather pipe is inserted on the rear differential carrier is off-spec and the o-ring on the
breather pipe can become damaged when inserting the breather pipe into the rear differential
carrier, which could allow water to enter the coupling. If water enters the coupling, transferred
torque could fluctuate and abnormal noise and vibration can occur when driving.
Upon customer complaint and confirmation of an abnormal noise/vibration occurring, please
follow the work procedure below to replace the Coupling Unit, and Right Rear Differential
Breather Pipe.

AFFECTED VEHICLES

2022-2024 Outlander (VIN cut off JA4J4VA86RZ077680 / June 18, 2024)

WORK PROCEDURE

Please refer to the following work procedure and the Service Manual for additional parts and
directions required to complete the repair.
Please note: To avoid damage from occurring on the insertion hole during cleaning, sand the
metal tip down on the nylon brush.

Copyright 2025, Mitsubishi Motors North America, Inc.
The information contained in this bulletin is subject to change. For the latest version of this document, go to the
Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).

4/23/2025

1 of 4

(5427/TSL2407027)

WORK PROCEDURE (continued)
1. Remove the fuel tank, rear driveshaft and remove the rear differential.
Please note: Do not remove the breather hose from the suspension member; leave it on the
body side.

2. Clean around the coupling to prevent contaminants from entering coupling before removing
the old breather pipe. To avoid damage from occurring on the insertion hole during cleaning,
sand the metal tip down on the nylon brush.
3. Remove the old breather pipe from differential carrier.
4. Clean insertion hole with nylon brush and parts cleaner in a way not to damage the insertion
hole of differential carrier breather.
Nylon brush

o-ring
position

Insertion hole
Before cleaning
※Clean the area above the red line
(o-ring position) so that the o-ring is
not damaged when installing the
breather pipe.

After cleaning
※Be careful not to damage the
o-ring position as this may
result in water intrusion.

5. Install the new breather pipe:
a. Apply coupling oil to the insertion hole of differential carrier breather so that the o-ring can
be smoothly inserted.
b. Fill the container cap of the bottle with coupling oil, dip the breather pipe with o-ring in the
container to apply coupling oil all around the o-ring.

4/23/2025

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(5427/TSL2407027)

WORK PROCEDURE (continued)
c. Insert the o-ring carefully to avoid damaging o-ring.
Please note: Do not force o-ring in. Tapping breather pipe lightly once makes the
breather pipe stand upright.
d. Fix the breather pipe by tightening the bolt (8 Nm).
6. Remove coupling and drain the old coupling oil inside the tank cover from hole (red circle shown
below):

7. Remove coupling oil tank cover.
Please note: Remove the original gasket sealant completely in advance with a spatula.
8. Clean inside of coupling oil tank.
Please note: The space at the back of the breather should also be cleaned.

9. Dry the inside of coupling oil tank with compressed air.
Please note: Do not leave moisture and contamination in coupling oil tank.
10. Install new coupling.
Please note: Apply coupling oil around the o-ring of coupling and carefully insert coupling to
the differential carrier.

o-ring

4/23/2025

3 of 4

(5427/TSL2407027)

WORK PROCEDURE (continued)
11. Apply gasket sealant to coupling oil tank cover and install it.
Please note: Follow the Service Manual for details.
12. Allow 1 hour for gasket sealant to dry/become solid.
13. Fill with new coupling oil.
14. Install Rear Axle Differential , right rear Axle Drive Shaft, and Fuel Tank. At this time,
assemble the Breather Hose to the Breather Pipe (new).
15. Fill with new Differential oil.
16. Program AWD control unit.
17. Bleed air.

PARTS INFORMATION
PART NAME
COUPLING UNIT, RR DIFF
PIPE, RR DIFF BREATHER
GASKET SEALANT
BORGWARNER LSC TRANSMISSION
FLUID 12-301: 0.6l
DIFFERENTIAL GEAR OIL
(SAE 75W-80): 0.5l
PARTS CLEANER
NYLON BRUSH

PART NO. QUANTITY
REMARKS
3570A087
1
Primary failed part
3501A863
1
Or equivalent
TB1215
1
Also referred to as Coupling Oil
MZ321133
MZ321131
Also referred to as Differential Oil
-

-

To clean hole of breather pipe

WARRANTY
This bulletin is supplied as technical information only and is not an authorization to repair. If
an affected vehicle is reported with the described condition, diagnose the condition, repair as
described in this bulletin and submit a normal warranty claim using the information below.
Labor
Operation
Code
276121SX

4/23/2025

Operation

Cause
Code A

Nature
Code B

Nature
Code C

Quantity

Labor
Time

Replacement

130

31

L

1

6.5H

4 of 4

Primary
Failed Part
Number
3570A087

(5427/TSL2407027)