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.