Mitsubishi Montero (2002-2004). Manual — part 208

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-29

12.Install the UJ boot band (large) to the UJ boot.
13.Use special tool MB991561 to crimp the UJ boot band

(large) in the same way as in step 6.

14.Check that the crimping amount (B) of the UJ boot band is

at the standard value and that the crimping amount (C) of
the UJ boot band is at the limited value.

Standard value (B): 2.4

− 2.8 mm (0.10 − 0.11 inch)

Limited value (C): 9.5 mm (0.40 inch)

• If the crimping amount is larger than 2.8 mm (0.11

inch), readjust the value of (W) in step 11 according
to the following formula, and then repeat the opera-
tion in step 13.
W = 5.8 mm (0.23 inch)

− B

Example: If B = 2.9 mm (0.11 inch), then W = 2.9 mm
(0.11 inch).

• If the crimping amount is smaller than 2.4 mm (0.09

inch), remove the UJ boot band, readjust the value
of (W) in step 11 according to the following for-
mula, and then repeat the operations in steps 12
and 13 using a new UJ boot band.
W = 5.8 mm (0.23 inch)

− B

Example: If B = 2.3 mm (0.10 inch) then W = 3.5 mm
(0.15 inch).

15.Check that the UJ boot band is not sticking out past the

place where it has been installed. If the UJ boot band is
sticking out, remove it and then repeat the operations in
steps 12 to 14 using a new UJ boot band.

AC000425

ACX00997AB

B

C

INNER SHAFT ASSEMBLY

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FRONT AXLE

26-30

INNER SHAFT ASSEMBLY

REMOVAL AND INSTALLATION

M1261004000096

Required Special Tools:

• MB990211: Sliding Hammer

• MB990906: Driveshaft Attachment

Pre-removal and Post-installation Operation
• Removal and Installation of Under Cover.

• Removal and Installation of Skid Plate (Refer to GROUP

51 - Front Bumper

P.51-3

.)

• Drive Shaft <RH> Removal and Installation (Refer to

P.26-23

.)

ACX00998AB

69

±

9 N

·

m *

51

±

7 ft-lb *

69

±

9 N

·

m *

51

±

7 ft-lb *

89

±

9 N

·

m

65

±

7 ft-lb

17

±

3 N

·

m

25

±

5 N

·

m

22

±

4 ft-lb

90

±

10 N

·

m

67

±

7 ft-lb

12

±

2 N

·

m

107

±

17 in-lb

12

±

2 N

·

m

107

±

17 in-lb

1

3

10

5

8

2

4

7

6

9

REMOVAL

STEPS

<<A>> >>B<<

1. INNER

SHAFT

2. CLIP

3.

COLLAR

4. PIN

5. ACTUATOR

ASSEMBLY

6. VACUUM

TANK

ASSEMBLY

7.

ENGAGE SWITCH ASSEMBLY

<<B>> >>A<<

•

LOOSENING AND TIGHTENING
OF DIFFERENTIAL MOUNTING
INSULATOR BOLT

•

SUPPORT THE DIFFERENTIAL
WITH A TRANSMISSION JACK.

8. DIFFERENTIAL

MOUNTING

BRACKET <RH>

9. BREATHER

PIPE

10. HOUSING

TUBE

REMOVAL STEPS (Continued)

INNER SHAFT ASSEMBLY

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FRONT AXLE

26-31

REMOVAL SERVICE POINTS

.

<<A>> INNER SHAFT REMOVAL

CAUTION

When pulling the inner shaft out from the front differential
carrier, be careful that the spline part of the inner shaft
does not damage the oil seal.

.

<<B>> LOOSENING DIFFERENTIAL MOUNTING
INSULATOR BOLT
Loosen the bolt shown in the diagram.

INSTALLATION SERVICE POINTS

.

<<A>> DIFFERENTIAL MOUNTING INSULATOR BOLT
TIGHTENING

CAUTION

Place the vehicle on the ground after temporarily tighten-
ing bolts to prevent bushing from twisting, then fully
tighten the bolts in the unladen condition.
Tighten the bolts shown in the diagram to the specified torque
in the order of A, B, C, D or A, C, B, D.

Specified torque: 69

± 9 N⋅m (51 ± 7 ft-lb)

.

>>B<< INNER SHAFT INSTALLATION

CAUTION

Be careful not to damage the lip of the dust seal and oil
seal.

ACX00999AB

MB990906

MB990211

ACX01000 AB

ACX01000AC

C

B

D

A

INNER SHAFT ASSEMBLY

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FRONT AXLE

26-32

DISASSEMBLY AND ASSEMBLY

M1261004200090

Required Special Tools:

• MB990560: Bearing Remover

• MB990938: Bearing and Oil Seal Installer Set

• MB990955: Oil Seal Installer

DISASSEMBLY SERVICE POINT

.

<<A>> BEARING REMOVAL
1. Bend the outside periphery of dust cover inward with a

wooden hammer.

ACX01001AB

5

3

2

1

5

4

3

DISASSEMBLY

STEPS

1. INNER

SHAFT

<<A>> >>C<<

2. BEARING

>>B<<

3.

DUST COVER

4. HOUSING

TUBE

>>A<<

5. DUST

SEAL

ACX01002AB