Mitsubishi Montero (2004+). Manual - part 455

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-25

Required Special Tool:

• MB990767: Front Hub and Flange Yoke Holder

REMOVAL SERVICE POINTS

.

<<A>> CASTLE NUT REMOVAL

CAUTION

Do not apply pressure to the wheel bearing by the vehicle 
weight to avoid possible damage when castle nut is loos-
ened. 
Use special tool MB990767 to fix hub and remove the drive 
shaft nut.

.

<<B>> DRIVE SHAFT REMOVAL

CAUTION

When pulling the drive shaft out from the differential car-
rier, be careful that the spline part of the drive shaft does 
not damage the oil seal. 

INSTALLATION SERVICE POINTS

.

>>A<< DRIVE SHAFT INSTALLATION

CAUTION

Do not damage the oil seal of the differential carrier by the 
drive shaft splines. 

.

>>B<< WASHER/CASTLE NUT INSTALLATION
1. Install washer with castle nut with its smaller side facing the 

castle nut.

ACX00972 AB

MB990767

ACX00973AB

WASHER

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-26

2. Tighten castle nut fully, using special tool MB990767.

CAUTION

Do not apply pressure to wheel bearing by the vehicle 
weight to avoid possible damage when castle nut is loos-
ened. 
3. If the pin holes do not match with one another, tighten the 

castle nut to find the mating hole within 30 degree angle and 
then bend the split pin to fit in.

ACX00974

ACX00974 AC

MB990767

200 

± 10 N

·

m

148 

± 7 ft-lb

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-27

DISASSEMBLY AND ASSEMBLY

M1261003700542

CAUTION

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

ACX00980AE

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 (4.9 oz) (70

 g INSIDE JOINT, 70 g INSIDE BOOT)

 <DOJ> 120 g (4.2 oz) (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

 

 

 

DISASSEMBLY STEPS 
(Continued)

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-28

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.

 

 

8.  UJ BOOT BAND (SMALL)

 

 

9.  UJ BOOT BAND (LARGE)

 

10. UJ BOOT

 

 

11. UJ ASSEMBLY

 

 

12. CIRCLIP <LH>

 

 

13. DUST COVER

 

  

ASSEMBLY 

STEPS

 

 

13. DUST COVER

 

 

12. CIRCLIP <LH>

 

 

11. UJ ASSEMBLY

 

 

10. UJ BOOT

 

 

9.  UJ BOOT BAND (LARGE)

 

 

 

DISASSEMBLY STEPS 
(Continued)

 

 

8.  UJ BOOT BAND (SMALL)

 

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