Mitsubishi Montero Sport (2004+). Manual — part 412
DRIVE SHAFT ASSEMBLY
TSB Revision
FRONT AXLE
26-29
Lubrication Points
DISASSEMBLY SERVICE POINTS
.
<<A>> BALL REMOVAL
Remove the balls from the DOJ cage.
.
AC004716 AD
GREASE:
REPAIR KIT GREASE: 120g (4.2 oz)
NOTE
THE GREASE IN THE REPAIR KIT SHOULD
BE DIVIDED IN HALF FOR USE,
RESPECTIVELY, AT THE JOINT AND INSIDE
THE BOOT.
GREASE:
REPAIR KIT GREASE: 140 g (4.9 oz)
NOTE
THE GREASE IN THE REPAIR KIT SHOULD BE DIVIDED IN
HALF FOR USE, RESPECTIVELY, AT THE JOINT AND
INSIDE THE BOOT.
GREASE: REPAIR KIT GREASE
DO NOT MIX OLD AND NEW OR DIFFERENT TYPES OF GREASE, AS A SPECIAL GREASE IS USED IN THE
JOINT.
! CAUTION
ACX01094 AB
DRIVE SHAFT ASSEMBLY
TSB Revision
FRONT AXLE
26-30
<<B>> DOJ CAGE REMOVAL
Remove the DOJ cage from the DOJ inner race in the direction
shown in the illustration.
.
<<C>> DOJ BOOT REMOVAL
Wrap plastic tape around the spline part on the DOJ side of the
driveshaft so that DOJ boot is not damaged when removed.
ASSEMBLY SERVICE POINTS
.
>>A<< DOJ INNER RACE/SNAP RING/DOJ CAGE/BALLS
INSTALLATION
Install the cage, balls and inner race to the driveshaft, and fit
the snap ring securely to the groove in the driveshaft.
.
ACX01095AB
AC000437AB
PLASTIC TAPE
AC004718 AB
BALL
SHAFT
INNER RACE
CAGE
SNAP RING
DRIVE SHAFT ASSEMBLY
TSB Revision
FRONT AXLE
26-31
>>B<< DOJ OUTER RACE INSTALLATION
CAUTION
The driveshaft joint use special grease. Do not mix old and
new or different types of grease.
1. Fill the inside of the DOJ outer race and DOJ boot with the
specified grease.
Specified grease: Repair kit grease 140 g (4.9 oz)
CAUTION
Do not secure the boot band (large).
2. Install the circlip onto the DOJ outer race. Place the DOJ
boot over the DOJ outer race, and then use a boot band
(small) to secure the boot.
.
>>C<< DOJ BOOT/DOJ BOOT BAND INSTALLATION
1. Position the DOJ outer race so that the distance between
the boot bands is at the standard value.
Standard value (A): 92
− 98 mm (3.6 − 3.9 inches)
2. Remove part of the DOJ boot from the DOJ outer race to
release the air pressure inside the boot.
CAUTION
Be sure that the installation direction of the boot bands is
correct.
3. Secure the boot band (large) on DOJ boot.
BJ BOOT (RESIN BOOT) REPLACEMENT
M1261005200231
1. Remove the boot bands (large and small).
NOTE: The BJ boot bands cannot be re-used.
2. Remove the BJ boot.
ACX02369
ACX02370
BOOT BAND (LARGE)
BOOT BAND (SMALL)
A
AB
AC004719 AB
BOOT BAND
DIRECTION OF
DRIVESHAFT
ROTATION WHEN
VEHICLE IS MOVING
FORWARD
ACX00982 AB
DRIVE SHAFT ASSEMBLY
TSB Revision
FRONT AXLE
26-32
3. Turn the adjusting bolt on special tool MB991561 so that the
size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
<If it is larger than 2.9 mm (0.11 inch)> Tighten the
adjusting bolt.
<If it is smaller than 2.9 mm (0.11 inch)> Loosen the
adjusting bolt.
NOTE: The value of W will change by approximately 0.7 mm
(0.03 inch) for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned more than
once.
4. Place the BJ boot band (small) against the projection at the
edge of the boot, and then secure it so that there is a
clearance left as shown by (A) in the illustration.
CAUTION
• Secure the drive shaft in an upright position and clamp
the part of the BJ boot band to be crimped securely in
the jaws of the special tool MB991561.
• Crimp the BJ boot band until the special tool touches
the stopper.
5. Use the special tool MB991561 to crimp the BJ boot band
(small).
ACX00993AB
STOPPER
ADJUSTING BOLT
(W)
MB991561
AC001175
BJ BOOT
A
BJ BOOT BAND
(SMALL)
PROJECTION
AB
ACX00995AB
MB991561
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