Mitsubishi Montero (2004+). Manual - part 456

 

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Mitsubishi Montero (2004+). Manual - part 456

 

 

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-29

 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.

UJ BOOT (RESIN BOOT) REPLACEMENT

M1261005900058

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 (0.11 inch) 

<If it is smaller than 2.9 mm (0.11 inch)> loosen the 

adjusting bolt.

<If it is larger than 2.9 mm (0.11 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

26-30

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 (0.09 − 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 operation 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 (0.09 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 (4.9 oz) (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

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-31

12.Install the UJ boot band (large) to the UJ boot.
13.Use special tool MB991561 to crimp the UJ boot band 

(large) in the same way as in step 6.

14.Check that the crimping amount (B) of the UJ boot band is 

at the standard value and that the crimping amount (C) of 
the UJ boot band is at the limited value.

Standard value (B): 2.4 

− 2.8 mm (0.09 − 0.11 inch)

Limited value (C): 9.5 mm (0.37 inch)

<If the crimping amount is larger than 2.8 mm (0.11 

inch)> 
Readjust the value of (W) in step 11 according 
to the following formula, and then repeat the 
operation in step 13. 
W = 5.8 mm (0.23 inch) 

− B 

Example: If B = 2.9 mm (0.11 inch), then W = 2.9 
mm (0.11 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 11 according to the following for-
mula, and then repeat the operations in steps 12 
and 13 using a new UJ boot band. 
W = 5.8 mm (0.23 inch) 

− B 

Example: If B = 2.3 mm (0.09 inch) then W = 3.5 
mm (0.14 inch).

15.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 12 to 14 using a new UJ boot band.

AC000425

ACX00997AB

B

C

INNER SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-32

INNER SHAFT ASSEMBLY

REMOVAL AND INSTALLATION

M1261004000104

Required Special Tools:

• MB990211: Sliding Hammer

• MB990906: Driveshaft Attachment

Pre-removal and Post-installation Operation
• Removal and Installation of Under Cover.

• Removal and Installation of Skid Plate (Refer to GROUP 

51, Front Bumper 

P.51-3

).

• Drive Shaft <RH> Removal and Installation (Refer to 

P.26-24

).

ACX00998AC

69 

± 9 N

·

m *

51 

± 7 ft-lb *

69 

± 9 N

·

m *

51 

± 7 ft-lb *

89 

± 9 N

·

m

65 

± 7 ft-lb

25 

± 5 N

·

m

22 

± 4 ft-lb

90 

± 10 N

·

m

67 

± 7 ft-lb

12 

± 2 N

·

m

107 

± 17 in-lb

12 

± 2 N

·

m

107 

± 17 in-lb

1

3

10

5

8

2

4

7

6

9

17 

± 3 N

·

m

13 

± 2 ft-lb

 

  REMOVAL 

STEPS

 <<A>> >>B<< 

1. INNER 

SHAFT

 

 

2. CLIP

 

 

3.

COLLAR

4. PIN

 

 

5. ACTUATOR 

ASSEMBLY

 

 

6. VACUUM 

TANK 

ASSEMBLY

 

 

7. 

FREE WHEEL ENGAGE SWITCH 
ASSEMBLY

 <<B>>   >>A<< 

•

LOOSENING AND TIGHTENING 
OF DIFFERENTIAL MOUNTING 
INSULATOR BOLT

 

 

•

SUPPORT THE DIFFERENTIAL 
WITH A TRANSMISSION JACK.

 

 

8. DIFFERENTIAL 

MOUNTING 

BRACKET <RH>

 

 

9. BREATHER 

PIPE

 

 

10. HOUSING 

TUBE

 

 

 

REMOVAL STEPS (Continued)

 

 

 

 

 

 

 

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