Mitsubishi L200. Manual — part 380
DRIVESHAFT ASSEMBLY <4WD>
FRONT AXLE
26-25
1. Be sure to install the driveshaft washer in the
specified direction.
2. Using special tool front hub and flange yoke
holder (MB990767), tighten the driveshaft nut. At
this time, tighten the driveshaft nut to the specified
torque in expectation of final tightening.
Tightening torque: 190
− 210 N⋅m
3. If the pin hole do not align with the pins, tighten
the driveshaft nut (less than 210 N
⋅m) and find the
nearest hole then bend the split pin to fit it.
DISASSEMBLY AND REASSEMBLY
M1261003701147
CAUTION
Never disassemble the BJ assembly except when replacing the BJ boot.
AC500631
AC501569 AC
BJ boot repair kit
BJ repair kit
DOJ repair kit
DOJ boot repair kit
3
1
2
13
12
4
9
7
10
1
4
5
3
6
2
N
N
N
(LH)
(RH)
11
3
1
2
4
8
7
4
3
6
10
2
1
(LH)
(RH)
5
10
2
3
1
8
9
6
8
10
11
12
13
10
6
6
N
N
N
N
N
Disassembly steps
1. DOJ boot band (large)
2. DOJ boot band (small)
3. Circlip
4. DOJ outer race
5. Dust cover
6. Snap ring
<<
A
>>
7. DOJ assembly
<<
B
>>
8. DOJ boot
9. BJ assembly
10. Circlip
11. BJ boot band (small)
12. BJ boot band (large)
13. BJ boot
Reassembly steps
10. Circlip
9. BJ assembly
>>
A
<< 7. DOJ assembly
>>
A
<< 6. Snap ring
>>
B
<< 4. DOJ outer race
5. Dust cover
3. Circlip
Disassembly steps (Continued)
DRIVESHAFT ASSEMBLY <4WD>
FRONT AXLE
26-26
NOTE:
.
•
DOJ: Double Offset Joint
•
BJ: Birfield Joint
LUBRICATION POINTS
AC500631
AC501588
Grease:
Repair kit grease: 120 ± 10 g
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: 125 ± 10 g (joint: 80 g, boot: 45 g)
Note
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
Do not mix old and new or different types of grease, as a special grease is used in the joint.
Grease: Repair kit grease
AB
CAUTION
DISASSEMBLY SERVICE POINTS
<<A>> DOJ ASSEMBLY REMOVAL
ACX01094 AB
1. Remove the balls from the DOJ cage.
ACX01095AB
>>
C
<< 8. DOJ boot
>>
C
<< 2. DOJ boot band (small)
>>
C
<< 1. DOJ boot band (large)
Reassembly
steps
(Continued)
DRIVESHAFT ASSEMBLY <4WD>
FRONT AXLE
26-27
2. Remove the DOJ cage from the DOJ inner race in
the direction shown in the illustration.
<<B>> DOJ BOOT REMOVAL
AC000437AB
Plastic tape
Wrap plastic tape around the spline part on the DOJ
side of the driveshaft so that DOJ boot is not dam-
aged when removed.
REASSEMBLY SERVICE POINTS
>>A<< DOJ ASSEMBLY/SNAP RING INSTALLA-
TION
AC004718 AB
Ball
Driveshaft
Inner race
Cage
Snap ring
Install each part of the DOJ assembly (ball, cage and
inner race) to the driveshaft, and fit the snap ring
securely to the groove in the driveshaft.
>>B<< DOJ OUTER RACE INSTALLATION
CAUTION
The driveshaft joint use special grease. Do not
mix old and new or different types of grease.
ACX02369
1. Fill the inside of the DOJ outer race and DOJ boot
with the specified grease.
Specified grease: Repair kit grease 125
± 10
g
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
ACX02370
Boot band (small)
A
AB
Boot band (large)
1. Position the DOJ outer race so that the distance
between the boot bands is at the standard value.
Standard value (A): 85
± 3 mm
2. Remove part of the DOJ boot from the DOJ outer
race to release the air pressure inside the boot.
AC004719 AB
Direction of driveshaft
rotation when vehicle
is moving forward.
Boot band
CAUTION
Be sure that the installation direction of the boot
bands is correct.
3. Secure the boot band (large) on DOJ boot.
INSPECTION
M1261003800271
• Check the driveshaft for damage, bending or cor-
rosion.
• Check the driveshaft spline part for wear or dam-
age.
• Check the boots for deterioration, damage or
cracking.
• Check the dust cover for damage or deteriora-
tion.
DRIVESHAFT ASSEMBLY <4WD>
FRONT AXLE
26-28
BJ BOOT (RESIN BOOT) REPLACEMENT
M1261005200662
ACX00982 AB
1. Remove the boot bands (large and small).
NOTE: The BJ boot bands cannot be re-used.
2. Remove the BJ boot.
ACX00993AB
(W)
MB991561
Stopper
Adjusting bolt
3. Turn the adjusting bolt on special tool boot band
clipping tool (MB991561) so that the size of the
opening (W) is at the standard value.
Standard value (W): 2.9 mm
<If it is larger than 2.9 mm> Tighten the adjust-
ing bolt.
<If it is smaller than 2.9 mm> Loosen the
adjusting bolt.
NOTE: The value of W will change by approxi-
mately 0.7 mm for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned
more than once.
AC001175
BJ boot
A
BJ boot band
(small)
Projection
AB
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.
•
AC606919AC
MB991561
Crimp the BJ boot band until the special tool
touches the stopper.
5. Use the special tool to crimp the BJ boot band
(small).
AC606920
AE
B
ACX00993AB
(W)
MB991561
Stopper
Adjusting bolt
6. Check that crimping amount (B) of the BJ boot
band is at the standard value.
Standard value (B): 2.4
− 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 3 according to
the following formula, and then repeat the
operation in step 5.
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