Mitsubishi Montero (2002-2004). Manual — part 229

PROPELLER SHAFT

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PROPELLER SHAFT

25-7

CAUTION

Be careful not to bend the joint portion when removing the
propeller shaft, because this will damage the joint boot.
4. Remove the front propeller shaft assembly after placing a

rag around the joint boot portion.

5. Cover the transfer case opening to prevent foreign material

from entering.

.

<<B>> REAR PROPELLER SHAFT ASSEMBLY REMOVAL

CAUTION

When working with the CFRP propeller shaft assembly,
wrap the shaft with rubber sheet to prevent damage.
1. Check that the rear propeller shaft assembly is wrapped with

the rubber sheet.

2. Make mating marks on the differential companion flange and

the outer race of ball joint assembly.

CAUTION

• Do not bend the joint portion when removing the pro-

peller shaft because this will damage the joint boot.

• Do not drop the air breather at the end portion of pro-

peller shaft differential side into the propeller shaft ball
joint.

• Do not drop, shock, or scratch the propeller shaft.
• If the propeller shaft is dropped on the ground, replace

it with new one. If the dropped rear propeller shaft is
reinstalled, the rear propeller shaft may be broken.

3. Remove the rear propeller shaft assembly after placing a rag

around the joint boot portion.

4. Cover the transfer case opening to prevent foreign material

from entering.

ACX00641AB

PROPELLER
SHAFT

JOINT BOOT

RAG

JOINT
ASSEMBLY (BJ)

ACX00638 AB

RUBBER SHEET OR
PROPELLER SHAFT PROTECTOR

ACX00919AB

AIR BREATHER

ACX00641AB

PROPELLER
SHAFT

JOINT BOOT

RAG

JOINT
ASSEMBLY (BJ)

PROPELLER SHAFT

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PROPELLER SHAFT

25-8

INSTALLATION SERVICE POINTS

.

>>A<< REAR PROPELLER SHAFT ASSEMBLY INSTALLA-
TION
1. Check that the rear propeller shaft assembly is wrapped with

the rubber sheet.

CAUTION

• Work with the CFRP tube of the propeller shaft assem-

bly under the condition that the tube is wrapped with
rubber sheet to prevent scratch on the outer surface.
Do not drop, shock or scratch the rear propeller shaft.

• Remove oil and grease from the threads of the mount-

ing bolts and nuts before tightening, or they will loosen.

• If the propeller shaft is dropped on the ground, replace

it with new one. If the dropped rear propeller shaft is
reinstalled, the rear propeller shaft may be broken.

• Do not drop the air breather at the end portion of pro-

peller shaft differential side into the propeller shaft ball
joint.

• Do not damage the oil seal lips on the transfer case.

2. If reusing the propeller shaft, align the mating marks of

differential companion flange and outer race of ball joint
assembly to install.

ACX00638 AB

RUBBER SHEET OR
PROPELLER SHAFT PROTECTOR

ACX00919AB

AIR BREATHER

ACX00642AB

OIL SEAL

PROPELLER SHAFT

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PROPELLER SHAFT

25-9

3. When installing a new rear propeller shaft assembly, align

the mark on the propeller shaft tube with the mark at the side
of the differential companion flange.

.

>>B<< FRONT PROPELLER SHAFT ASSEMBLY
INSTALLATION

CAUTION

• Do not damage the oil seal lips on the transfer case.
• Remove oil and grease from the threads of the mount-

ing bolts and nuts before tightening, or they will loosen.

If reusing the propeller shaft, align the mating mark to install.

INSPECTION

M1251001100048

FRONT PROPELLER SHAFT RUNOUT

Limit: 0.5 mm (0.02 inch)

REAR PROPELLER SHAFT

1. Check whether there is any damage such as crack or peel at

the seal portion shown in the illustration. If it is found,
replace the propeller shaft with new one.

AC000179 AB

PPROPELLER
SHAFT ASSEMBLY

DIFFERENTIAL
COMPANION FLANGE

MARKING

MARKING

ACX00642AB

OIL SEAL

ACX00643AB

ACX00639AB

SEAL

SEAL

CFRP TUBE

PROPELLER SHAFT

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PROPELLER SHAFT

25-10

2. Check the condition of the tube. If crack, chip or deformation

is found, replace the propeller shaft with new one. When
flaw is found, confirm whether there is any failure by using a
dye penetrant. If a failure is found, replace the propeller
shaft.

3. Measure the clearance (A) between the tube and the shaft

at the end portion of the tube.

Standard value (A): 0.2

− 0.5 mm (0.008 − 0.020 inch)

4. If the standard value is not met, replace the rear propeller

shaft.

DISASSEMBLY AND ASSEMBLY

M1251001200131

REAR PROPELLER SHAFT

CAUTION

The CFRP rear propeller shaft cannot be separated.

FRONT PROPELLER SHAFT

AC001585

AB

CFRP TUBE

ACX00920AB

A

A

AC203529

3

4

1

2

3

4

5

6

1

2

3

4

AB

UNIVERSAL JOINT REPAIR KIT