Mitsubishi Montero (2002-2004). Manual — part 222

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-21

LUIBRICATION POINTS

CAUTION

Do not mix old and new or different types of grease, as a special grease is used in the joint.

DISASSEMBLY SERVICE POINTS

.

<<A>> BALLS REMOVAL
Remove the balls from the DOJ cage.

.

ACX01093AD

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

USED AMOUNT: <BJ> 245

±

10 g (8.7

±

0.3 oz)

[INSIDE JOINT: 135

±

5 g (4.8

±

0.1 oz), INSIDE BOOT: 110

±

5 g (3.9

±

0.2 oz)]

NOTE
THE GREASE IN THE REPAIR KIT SHOULD BE DIVIDED IN HALF FOR USE,
RESPECTIVELY, AT THE JOINT AND INSIDE THE BOOT.

<DOJ> 295

±

10 g (10.5

±

0.3 oz)

[INSIDE JOINT: 185

±

5 g (6.5

±

0.2 oz), INSIDE BOOT: 110

±

5 g (3.9

±

0.2 oz)]

DOJ

BJ

ACX01094

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-22

<<B>> DOJ CAGE REMOVAL
Remove the DOJ cage from the DOJ inner race in the direction
of the BJ.

.

<<C>> DOJ BOOT/BJ BOOT REMOVAL
Wrap plastic tape around the spline part on the DOJ side of the
drive shaft so that DOJ boot/BJ boot are not damaged when
they are removed.

ASSEMBLY SERVICE POINTS

.

>>A<< BJ BOOT/DOJ BOOT INSTALLATION
1. Wrap the tape around the spline of the shaft, then install BJ

boot and DOJ boot in order.

CAUTION

Do not mix old and new or different types of grease, as a
special grease is used in the joint.
2. Fill the inside of BJ and BJ boot with specified grease.

NOTE: The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.

Specified grease: Repair kit grease
Used amount: 245

± 10 g (8.7 ± 0.3 oz) [inside joint: 135

± 5 g (4.8 ± 0.1 oz), inside boot: 110 ± 5 g (3.9 ± 0.2 oz)]

CAUTION

In order to fill the specified amount of air inside the BJ
boot, keep the bent angle of the drive shaft to O

° during

the operation.
3. Tighten the boot band.

.

>>B<< DOJ CAGE/DOJ INNER RACE INSTALLATION
1. Install DOJ cage to the drive shaft and put it aside to BJ

assembly side.

2. Align the mating mark of DOJ inner race with that of the

shaft.

ACX01095

ACX02368AB

PLASTIC TAPE

ACX01096

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-23

3. Tap the inner race with even force to press-fit into the bump

of the shaft with special tool MB990939.

.

>>C<< DOJ OUTER RACE INSTALLATION

CAUTION

The drive shaft joint use special grease. Do not mix old
and new or different types of grease.
Fill the inside of the DOJ outer race and DOJ boot with the
specified grease.

Specified grease: Repair kit grease
Used amount: 295

± 10 g (10.5 ± 0.3 oz) [inside joint:

185

± 5 g (6.5 ± 0.2 oz), inside boot: 110 ± 5 g (3.9 ± 0.2

oz)]

.

>>D<< 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): 110

± 3 mm (4.3 ± 0.1 inches)

2. Remove part of the DOJ boot from the DOJ outer race to

release the air pressure inside the boot.

ACX01097AB

MB990939

MATING MARK

ACX02369

ACX02370

BOOT BAND (LARGE)

BOOT BAND (SMALL)

A

AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-24

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL AND INSTALLATION

M1272002000124

CAUTION

Since a carbon fiber fortified plastic tube is used in the rear propeller shaft, make sure to refer to
GROUP 25 for removal procedure.

Pre-removal and Post-installation Operation
Differential Gear Oil Draining and Refilling (Refer to

P.27-

12

.)

AC205391AB

152 ±

25 N·m

113 ±

18 ft-lb

1

4

6

7

3

1

2

3

6

5

8

3

113 ±

14 N·m

84 ±

10 ft-lb

113 ±

14 N·m

84 ±

10 ft-lb

152 ±

25 N·m

113 ±

18 ft-lb

83 ±

12 N·m

61 ±

9 ft-lb

46 ±

8 N·m

34 ±

6 ft-lb

46 ±

8 N·m

34 ±

6 ft-lb

N

N

REMOVAL STEPS

• PROPELLER SHAFT (REFER TO

GROUP 25

P.25-5

.)

1. DRIVE SHAFT CONNECTION

<<A>> >>A<<

2. KNUCKLE AND LOWER ARM

CONNECTION

3. COMPANION SHAFT
4. TOE CONTROL TOWER BAR
5. BREATHER HOSE CONNECTION

<<B>>

6. DIFFERENTIAL CARRIER

ASSEMBLY

• FUEL TANK (REFER TO GROUP

13B

P.13B-11

.)

7. REAR DIFFERENTIAL MOUNT

MEMBER

8. DYNAMIC DAMPER

REMOVAL STEPS (Continued)