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