Mitsubishi Pajero: Front Axle Birfield Joint Wear and Clicking Under Load

The front half-shafts on Super Select 4WD Pajeros use Birfield constant-velocity joints (a sealed ball-and-groove design integral to the shaft) that wear over high mileage, particularly after repeated use in 4WD with steering lock applied. Worn Birfield joints produce a rhythmic clicking or knocking when the wheels are turned and the vehicle is under power. The joints cannot be repacked — the entire front shaft assembly or inner axle must be replaced once the joint is worn beyond specification.

• Rhythmic clicking or knocking from the front axle area during slow tight turns in 4WD
• Noise increases when turning under power and decreases or disappears when coasting
• Vibration through the steering wheel at low speed in 4WD mode
• Grease or oil residue on inner faces of front wheels or around axle shaft seals
• Clunking sound when transitioning between acceleration and deceleration in 4WD

In a safe open area, engage 4H and perform slow tight-radius turns in both directions while on slight throttle. A clicking or clunking noise that changes with steering angle and throttle load indicates Birfield wear. Also check the front differential housing for oil seepage around the axle shaft seals, which indicates the seals are failing and allowing grease to escape the Birfield area.

Parts involved: CV joint and boot.

$700 to $2,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

• “Have the front axle shafts or Birfield joints ever been replaced, and at what mileage?”
• “Is there any clicking or knocking noise when turning in 4WD, especially at slow speed?”
• “Has the front differential oil been changed and are there any signs of oil seepage around the front axle area?”

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.