Mitsubishi Montero (2004+). Manual — part 456

DRIVE SHAFT ASSEMBLY

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FRONT AXLE

26-29

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.

UJ BOOT (RESIN BOOT) REPLACEMENT

M1261005900058

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 (0.11 inch)

<If it is smaller than 2.9 mm (0.11 inch)> loosen the

adjusting bolt.

<If it is larger than 2.9 mm (0.11 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

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FRONT AXLE

26-30

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 (0.09 − 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 operation 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 (0.09 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 (4.9 oz) (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

DRIVE SHAFT ASSEMBLY

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FRONT AXLE

26-31

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 (0.09 − 0.11 inch)

Limited value (C): 9.5 mm (0.37 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
operation 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 (0.09 inch) then W = 3.5
mm (0.14 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

26-32

INNER SHAFT ASSEMBLY

REMOVAL AND INSTALLATION

M1261004000104

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.26-24

).

ACX00998AC

69

± 9 N

·

m *

51

± 7 ft-lb *

69

± 9 N

·

m *

51

± 7 ft-lb *

89

± 9 N

·

m

65

± 7 ft-lb

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

17

± 3 N

·

m

13

± 2 ft-lb

REMOVAL

STEPS

<<A>> >>B<<

1. INNER

SHAFT

2. CLIP

3.

COLLAR

4. PIN

5. ACTUATOR

ASSEMBLY

6. VACUUM

TANK

ASSEMBLY

7.

FREE WHEEL 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)