Mitsubishi Montero (2002-2004). Manual - part 221

KNUCKLE

TSB Revision

REAR AXLE

27-17

REMOVAL SERVICE POINT

.

<<A>> KNUCKLE AND TOE-CONTROL ARM/UPPER ARM 
DISCONNECTION

CAUTION

• Do not remove the nut from ball joint. Loosen it and use 

special tool MB991897 to avoid possible damage to ball 
joint threads.

• Hang special tool MB991897 with cord to prevent it 

from falling. 

1. Install special tool MB991897 as shown in the figure.

2. Turn the bolt and knob as necessary to make the jaws of 

special tool MB991897 parallel, tighten the bolt by hand and 
confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make sure the 
knob is in the position shown in the figure.

3. Tighten the bolt with a wrench to disconnect the knuckle and 

toe-control arm, upper arm.

AC106820 AB

CORD

BOLT

MB991897

NUT

BALL JOINT

AC106821

KNOB

PARALLEL

BOLT

GOOD

BAD

AB

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-18

DRIVE SHAFT ASSEMBLY

REMOVAL AND INSTALLATION

M1271003300073

Required Special Tool:
MB990767: End Yoke Holder

REMOVAL SERVICE POINTS

.

<<A>> DRIVE SHAFT NUT REMOVAL

CAUTION

Do not apply pressure to wheel bearing by the vehicle 
weight to avoid possible damage to wheel bearing before 
tightening drive shaft nut fully.

.

ACX01091AB

255 

± 

29 N·m

188 

±

 21 ft-lb

152 

± 

25 N·m

113 

±

 18 ft-lb

113 

± 

14 N·m

84 

±

 10 ft-lb

3

5

4

2

1

N

REMOVAL STEPS

1. CAP

<<A>> >>B<<

2. DRIVE SHAFT NUT
3. COMPANION SHAFT AND DRIVE 

SHAFT CONNECTION

<<B>> >>A<<

4. KNUCKLE AND LOWER ARM 

CONNECTION

5. REAR DRIVE SHAFT ASSEMBLY

ACX00972

MB990767

AC

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-19

<<B>> KNUCKLE AND LOWER ARM DISCONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to remove the lower arm mounting 
bolt by compressing the coil spring.

INSTALLATION SERVICE POINTS

.

>>A<< KNUCKLE AND LOWER ARM CONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to install the lower arm mounting 
bolt by compressing the coil spring.

.

>>B<< DRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.

CAUTION

Do not apply pressure to wheel bearing by the vehicle 
weight to avoid possible damage to wheel bearing before 
tightening drive shaft nut fully.
2. Tighten the drive shaft nut to the torque specification with 

special tool MB990767.

3. If the pin hole does not align with another, tighten the drive 

shaft nut [less than 284 N

⋅m (209 ft-lb)] and find the nearest 

hole then bend the split pin to fit in.

ACX01086 AB

WOODEN 
BLOCK

ACX01086 AB

WOODEN 
BLOCK

ACX01087AB

MB990767

WASHER

255 ± 29 N·m
188 ± 21 ft-lb

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-20

DISASSEMBLY AND ASSEMBLY

M1271003500099

CAUTION

Never disassemble the BJ assembly except when replacing the BJ boot.

Required Special Tool:
MB990939: Brass Bar

ACX01092 AC

10

13

12

11

2

9

1

6

8

5

7

3

4

10

12

7

3

1

2

11

13

3

7

1

2

2

9

1

6

8

5

7

3

4

2

9

1

7

3

BJ BOOT REPAIR KIT

BJ REPAIR KIT

DOJ REPAIR KIT

DOJ BOOT REPAIR KIT

N

N

N

N

DISASSEMBLY STEPS

1. DOJ BOOT BAND (LARGE)
2. DOJ BOOT BAND (SMALL)
3. CIRCLIP
4. DOJ OUTER RACE

<<A>>

5. BALLS

<<B>>

6. DOJ CAGE
7. SNAP RING
8. DOJ INNER RACE

<<C>>

9. DOJ BOOT
10. BJ BOOT BAND (LARGE)
11. BJ BOOT BAND (SMALL)

<<C>>

12. BJ BOOT
13. BJ ASSEMBLY

ASSEMBLY STEPS

13. BJ ASSEMBLY

>>A<<

12. BJ BOOT
11. BJ BOOT BAND (SMALL)
10. BJ BOOT BAND (LARGE)

>>A<<

9. DOJ BOOT

>>B<<

6. DOJ CAGE

>>B<<

8. DOJ INNER RACE
7. SNAP RING
5. BALLS

>>C<<

4. DOJ OUTER RACE
3. CIRCLIP

>>D<<

2. DOJ BOOT BAND (SMALL)

>>D<<

1. DOJ BOOT BAND (LARGE)