Mitsubishi Montero (2002-2004). Manual - part 418

ON-VEHICLE SERVICE

TSB Revision

FRONT SUSPENSION

33A-7

NOTE: Solid lines show caster, broken lines show camber.

UPPER ARM BALL JOINT END PLAY CHECK

M1332011400026

1. Raise the vehicle.
2. Move the upper arm up and down with your hands to check 

for an excessive play in the axial direction of the ball joint. If 
there is an excessive play, replace the upper arm ball joint 
assembly.

BALL JOINT DUST COVER CHECK

M1332008600224

1. Press the dust cover with your finger to check that there are 

no cracks or damage in the dust cover.

2. If the dust cover is cracked or damaged, replace the upper 

arm ball joint assembly, lower arm ball joint assembly or 
stabilizer link.
NOTE: If the dust cover is cracked or damaged, it is possible 
that there may also be damage to the ball joint.

ACX02270 AB

(STANDARD VALUE)

(STANDARD VALUE)

"A"DIRECTION

"A"DIRECTION

GRADUATION AT THE 
REAR ADJUSTING CAM

GRADUATION AT THE 
FRONT ADJUSTING CAM

UPPER ARM ASSEMBLY

TSB Revision

FRONT SUSPENSION

33A-8

UPPER ARM ASSEMBLY

REMOVAL AND INSTALLATION

M1332004300050

CAUTION

*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on 
the ground in an unladen condition.

Required Special Tool:

• MB991897: Ball Joint Remover

Post-installation Operation
• Check the dust cover for cracks or damage by pushing it 

with your finger. 

• Wheel Alignment Check and Adjustment (Refer to 

P.33A-

5

.)

ACX00714 AB

7

5

6

7

1

3

2

4

147 

± 

10 N

·

m *

109 

± 

7 ft-lb *

30 

± 

4 N

·

m

22 

± 

3 ft-lb

74 

± 

14 N

·

m

55 

± 

10 ft-lb

147 

± 

10 N

·

m *

109 

± 

7 ft-lb *

REMOVAL STEPS

1. FRONT WHEEL SPEED SENSOR 

BRACKET MOUNTING BOLT

2. CLIP
3. BRAKE HOSE

<<A>>

4. UPPER ARM BALL JOINT AND 

KNUCKLE CONNECTION

5. UPPER ARM ASSEMBLY AND 

FRONT FRAME CONNECTION

6. UPPER ARM ASSEMBLY
7. UPPER ARM BALL JOINT 

ASSEMBLY

REMOVAL STEPS (Continued)

UPPER ARM ASSEMBLY

TSB Revision

FRONT SUSPENSION

33A-9

REMOVAL SERVICE POINT

.

<<A>> UPPER ARM BALL JOINT AND KNUCKLE DISCON-
NECTION

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 a 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 ball joint.

INSPECTION

M1332004400057

• Check the bushing for wear and deterioration.

• Check the upper arm for bend or breakage.

• Check all bolts for condition and straightness.

.

UPPER ARM BALL JOINT TURNING TORQUE CHECK

Required Special Tool:

• MB990326: Preload Socket

1. After shaking the ball joint stud several times, install the nut 

to the stud and use special tool MB990326 to measure the 
turning torque of the ball joint.

Standard value: 0.4 

− 2.5 N⋅m (4 − 22 in-lb)

2. If the measured value exceeds the standard value, replace 

the upper arm ball joint assembly.

3. If the measured value is lower than the standard value, 

check that the upper arm ball joint turns smoothly without 
excessive play. If so, it is possible to use that ball joint.

.

AC106820 AB

CORD

BOLT

MB991897

NUT

BALL JOINT

AC106821

KNOB

PARALLEL

BOLT

GOOD

BAD

AB

ACX00716

MB990326

AB

UPPER ARM ASSEMBLY

TSB Revision

FRONT SUSPENSION

33A-10

UPPER ARM BALL JOINT DUST COVER CHECK
1. Press the dust cover with your finger to check that there are 

no cracks or damage in the dust cover.

2. If the dust cover is cracked or damaged, replace the upper 

arm ball joint assembly.
NOTE: If the dust cover is cracked or damaged, it is possible 
that there may also be damage to the ball joint. If it is dam-
aged during service work, replace the dust cover.

BALL JOINT DUST COVER REPLACEMENT

M1332008000136

CAUTION

Do not apply grease to the place (tapered section) where 
the threaded section of the ball joint connects with the 
knuckle. Wipe the grease off if it is applied to this area. To 
prevent the grease from being applied to the ball joint con-
nection (taper) with knuckle, do not compress the dust 
cover before installation.
Only when the dust cover is damaged accidentally during ser-
vice work, replace the dust cover as follows:
1. Remove the clip ring, and then remove the dust cover.
2. Apply multipurpose grease to the inside of the dust cover as 

shown.

3. Apply multipurpose grease to the shown parts inside the 

dust cover and the ball joint stud.

4. Wrap plastic tape around the upper arm ball joint stud, and 

then install the dust cover to the upper arm ball joint.

5. Secure the dust cover in place with the clip ring.
6. Press the dust cover with your finger to check that there are 

no cracks or damage in the dust cover.

ACX00717 AB

28 mm
(1.1 in)
OR MORE

CLIP RING

DUST 
COVER

TAPERED 
SECTION