Mitsubishi Montero (2002-2004). Manual — part 207

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-25

DISASSEMBLY AND ASSEMBLY

M1261003700326

CAUTION

Never disassemble the UJ assembly except when replacing the UJ boot.

ACX00980 AD

13

12

4 <LH>

3

5

6

7

4 <RH>

2

1

11

3

5 2

1

8

9 10

12 3

5 7

2

1

13

12

4

3 5

6

7

2 1

DOJ

UJ

11

4

12

3

5

2

8

10

11

9

1

UJ BOOT REPAIR KIT

DOJ REPAIR KIT

UJ REPAIR KIT

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

THE DRIVE SHAFT JOINT USES SPECIAL GREASE. DO NOT MIX OLD AND NEW OR DIFFERENT TYPES OF GREASE.

AMOUNT USED: <UJ> 140 g (70

g INSIDE JOINT, 70 g INSIDE BOOT)

<DOJ> 120 g (70

g INSIDE JOINT, 50 g INSIDE BOOT)

12

DOJ BOOT REPAIR KIT

CAUTION

DISASSEMBLY

STEPS

1. DOJ BOOT BAND (SMALL)

2. DOJ BOOT BAND (LARGE)

3. CIRCLIP

4. DOJ

OUTER

RACE

5. SNAP

RING

6. INNER RACE, CAGE AND BALL

ASSEMBLY

<<A>>

7. DOJ

BOOT

8. UJ BOOT BAND (SMALL)

9. UJ BOOT BAND (LARGE)

DISASSEMBLY

STEPS

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-26

NOTE: DOJ: Double Offset Joint, UJ: Under cut Joint

Required Special Tool:

• MB991561: Boot Band Crimping Tool

DISASSEMBLY SERVICE POINT

.

<<A>> DOJ BOOT REMOVAL
Wrap plastic tape around the spline part on the UJ assembly so
that the DOJ boot is not damaged when they are removed.

ASSEMBLY SERVICE POINTS

.

>>A<< DOJ BOOT INSTALLATION
Install boot after wrapping plastic tape around the spline part on
the UJ assembly.

.

>>B<< 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): 80

± 5 mm (3.2 ± 0.1 inch)

2. Remove part of the DOJ outer race to release the air

pressure inside the boot.

INSPECTION

M1261003600125

• Check the boot for damage or deterioration.

• Check the ball joint for operating condition and excessive

looseness.

• Check the splines for wear or damage.

• Check the differential carrier oil seal (LH) for damage.

10. UJ BOOT

11. UJ ASSEMBLY

12. CIRCLIP <LH>

13. CIRCLIP <LH>

ASSEMBLY

STEPS

13. CIRCLIP <LH>

12. CIRCLIP <LH>

11. UJ ASSEMBLY

10. UJ BOOT

9. UJ BOOT BAND (LARGE)

8. UJ BOOT BAND (SMALL)

DISASSEMBLY

STEPS

6. INNER RACE, CAGE AND BALL

ASSEMBLY

5. SNAP

RING

4. DOJ

OUTER

RACE

3. CIRCLIP

>>A<<

7. DOJ

BOOT

>>B<<

2. DOJ BOOT BAND (LARGE)

>>B<<

1. DOJ BOOT BAND (SMALL)

ASSEMBLY

STEPS

(Continued)

AC000437AB

PLASTIC TAPE

ACX00981AB

A

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-27

UJ BOOT (RESIN BOOT) REPLACEMENT

M1261005900047

1. Remove the boot bands (large and small).

NOTE: The BJ boot bands cannot be re-used.

2. Remove the BJ boot.

3. Install the small part on the plastic boot aligning the groove

of the shaft.

4. 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 (0.12 inch)

• If it is smaller than 2.9 mm (0.12 inch), loosen the

adjusting bolt.

• If it is larger than 2.9 mm (0.12 inch), tighten 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.

5. Install the UJ boot band (small) to the UJ boot.

ACX00982 AB

ACX00983AB

ACX00993AB

STOPPER

ADJUSTING BOLT

(W)

MB991561

ACX00994AB

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-28

6. Use special tool MB991561 to crimp the UJ boot band

(small).

CAUTION

• Secure the drive shaft in an upright position and clamp

the part of the UJ boot band to be crimped securely in
the jaws of special tool MB991561.

• Crimp the UJ boot band until the special tool touches

the stopper.

7. Check that crimping amount (A) of the UJ boot band is at the

standard value.

Standard value (A): 2.4

− 2.8 mm (0.10 − 0.11 inch)

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

inch), readjust the value of (W) in step 4 according
to the following formula, and then repeat the opera-
tion in step 6.
W = 5.5 mm (0.22 inch)

− A

Example: If A = 2.9 mm (0.11 inch), then W = 2.6 mm
(0.10 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 4 according to the following
formula, and then repeat the operations in steps 5
and 6 using a new BJ boot band.
W = 5.5 mm (0.22 inch)

− A

Example: If A = 2.3 mm (0.10 inch) then W = 3.2 mm
(0.13 inch).

8. 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 4 to 7 using a new UJ boot band.

9. Fill the inside of the UJ boot with the specified amount of the

specified grease.

Specified grease: Repair kit grease
Amount to use: 140 g (70 g inside joint, 70 g inside
boot)

10.Install the large diameter part on the plastic boot aligning the

groove of the shaft.

11.Follow the same procedure as in step 4 to adjust the size of

the opening (W) on special tool MB991561 so that it is at the
standard value.

Standard value (W): 3.2 mm (0.13 inch)

ACX00995AB

MB991561

ACX00996 AB

A

AC000424