Mitsubishi Montero (2004+). Manual - part 471

 

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Mitsubishi Montero (2004+). Manual - part 471

 

 

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-23

CAUTION

Do not mix old and new or different types of grease, as a 
special grease is used in the joint.
2. Fill the inside of BJ and BJ boot with specified grease.

NOTE: The grease in the repair kit should be divided in half 
for use, respectively, at the joint and inside the boot.

Specified grease: Repair kit grease
Used amount: 245 

± 10 g (8.7 ± 0.3 oz) [inside joint: 135 

± 5 g (4.8 ± 0.1 oz), inside boot: 110 ± 5 g (3.9 ± 0.2 oz)]

CAUTION

In order to fill the specified amount of air inside the BJ 
boot, keep the bent angle of the drive shaft to 0 degree 
angle during the operation.
3. Tighten the boot band.

.

>>B<< DOJ CAGE/DOJ INNER RACE INSTALLATION
1. Install DOJ cage to the drive shaft and put it aside to BJ 

assembly side.

2. Align the mating mark of DOJ inner race with that of the 

shaft.

3. Tap the inner race with even force to press-fit into the bump 

of the shaft with special tool MB990939.

.

>>C<< DOJ OUTER RACE INSTALLATION

CAUTION

The drive shaft joint use special grease. Do not mix old 
and new or different types of grease.
Fill the inside of the DOJ outer race and DOJ boot with the 
specified grease.

Specified grease: Repair kit grease
Used amount: 295 

± 10 g (10.5 ± 0.3 oz) [inside joint: 

185 

± 5 g (6.5 ± 0.2 oz), inside boot: 110 ± 5 g (3.9 ± 0.2 

oz)]

.

ACX01096

ACX01097AB

MB990939

MATING MARK

ACX02369

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-24

>>D<< DOJ BOOT/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): 110 

± 3 mm (4.3 ± 0.1 inches) 

2. Remove part of the DOJ boot from the DOJ outer race to 

release the air pressure inside the boot.

ACX02370

BOOT BAND (LARGE)

BOOT BAND (SMALL)

A

AB

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-25

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL AND INSTALLATION

M1272002000265

CAUTION

Since a carbon fiber fortified plastic tube is used in the rear propeller shaft, make sure to refer to 
GROUP 25 for removal procedure.

Pre-removal and Post-installation Operation
Differential Gear Oil Draining and Refilling (Refer to 

P.27-12

).

AC205391AB

152 ±

 25 N·m

113 ±

 18 ft-lb

1

4

6

7

3

1

2

3

6

5

8

3

113 ±

 14 N·m

84 ±

 10 ft-lb

113 ±

 14 N·m

84 ±

 10 ft-lb

152 ±

 25 N·m

113 ±

 18 ft-lb

83 ±

 12 N·m

61 ±

 9 ft-lb

46 ±

 8 N·m

34 ±

 6 ft-lb

46 ±

 8 N·m

34 ±

 6 ft-lb

N

N

REMOVAL STEPS

• PROPELLER SHAFT (REFER TO 

GROUP 25 

P.25-5

).

1. DRIVE SHAFT AND COMPANION 

SHAFT CONNECTION

<<A>> >>A<<

2. KNUCKLE AND LOWER ARM 

CONNECTION

3. COMPANION SHAFT
4. TOE CONTROL TOWER BAR

5. BREATHER HOSE CONNECTION

<<B>>

6. DIFFERENTIAL CARRIER 

ASSEMBLY

• FUEL TANK (REFER TO GROUP 

13B 

P.13B-8

).

7. REAR DIFFERENTIAL MOUNT 

MEMBER

8. DYNAMIC DAMPER

REMOVAL STEPS (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

TSB Revision

REAR AXLE

27-26

Required Special Tools:

• MB991050: Base(B)

• MB991218: Bearing

• MB991162: Bolt

• MD991816:Bearing Remover and installer base

• MD990955:Oil seal installer

REMOVAL SERVICE POINTS

.

<<A>> 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.

.

<<B>> DIFFERENTIAL CARRIER ASSEMBLY REMOVAL
Support the differential carrier assembly lower part by jacking 
to remove the joint bolt and the differential carrier assembly.

INSTALLATION SERVICE POINT

.

>>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.

REAR SUSPENSION CROSSMEMBER BUSHING 
(FOR REAR DIFFERENTIAL MOUNT) 
REPLACEMENT

1. Remove the rear differential.

ACX01086 AB

WOODEN 
BLOCK

ACX01086 AB

WOODEN 
BLOCK

 

 

 

 

 

 

 

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