Mitsubishi Montero Sport (2004+). Manual - part 411

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-25

DRIVE SHAFT ASSEMBLY

REMOVAL AND INSTALLATION

M1261003500485

Required Special Tool:

• MB991897: Ball Joint Remover

Pre-removal Operation
• Under Cover Removal (Refer to GROUP 42, Under cover 

P.42-207

.)

• Gear Oil Draining (Refer to 

P.26-14

.)

 Post-installation Operation
• Press the dust cover with a finger to check whether the 

dust cover is cracked or damaged.

• Gear Oil Supplying (Refer to 

P.26-14

.)

• Under Cover Installation (Refer to GROUP 42, Under 

cover 

P.42-207

.)

• Wheel Alignment Check and Adjustment (Refer to 

GROUP 33A, On-vehicle Service 

P.33A-3

.)

AC004699 AB

FRONT HUB SHIM
SET

118 - 177 N·m
87 - 131 ft-lb

59 - 88 N·m
44 - 65 ft-lb

88 N·m
65 ft-lb

88 - 103 N·m
65 - 76 ft-lb

12 N·m
106 in-lb

44 N·m
32 ft-lb

49 - 59 N·m
36 - 43 ft-lb

RIGHT-SIDE DRIVESHAFT

LEFT-SIDE DRIVESHAFT

13

12

10

6

7

9

12

8

5

3

11

3

4

5

1

2

N

N

N

SEALANT: 3M™ AAD PART
NO.8672, 8679, 8678, 8661,
8663 OR EQUIVALENT 

 

  

REMOVAL 

STEPS

<<A>>  

1. CALIPER 

ASSEMBLY

2. FRONT 

SPEED 

SENSOR 

<VEHICLES WITH ABS> (REFER TO 
GROUP 35B, WHEEL SPEED 
SENSOR

P.35C-77

.)

3. HUB CAP

 

>>C<<

•

DRIVESHAFT END PLAY 
ADJUSTMENT

 

 

4. SNAP 

RING

 

 

5. SHIM
6.  STABILIZER BAR CONNECTION

 

 

7.  SHOCK ABSORBER LOWER 

MOUNTING BOLT

<<B>>

8. TIE ROD END CONNECTION

<<B>>

9. LOWER ARM BALL JOINT 

CONNECTION

<<B>>

10. UPPER ARM BALL JOINT 

CONNECTION

<<C>> >>B<<

11. KNUCKLE AND FRONT HUB 

ASSEMBLY

<<D>> >>A<<

12. DRIVESHAFT ASSEMBLY
13. CIRCLIP

 

  

REMOVAL 

STEPS 

(Continued)

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-26

REMOVAL SERVICE POINTS

.

<<A>> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire to prevent it 
from falling off.

.

<<B>> TIE ROD END /LOWER ARM BALL JOINT /UPPER 
ARM BALL JOINT DISCONNECTION

CAUTION

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

use the special tool to avoid possible damage to ball 
joint threads.

• Hang the special tool with a cord to prevent from fall-

ing. 

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 tie rod end.

.

<<C>> KNUCKLE AND FRONT HUB ASSEMBLY REMOVAL
1. Press down the lower arm and remove the upper knuckle 

towards you.
NOTE: Pull the DOJ side of the driveshaft assembly out 
slightly from the front differential carrier.

2. Slightly back off driveshaft from the knuckle. Remove the 

lower knuckle holding nut from the lower arm ball joint.

3. Disconnect the knuckle and lower ball joint.

CAUTION

Do not damage the knuckle oil seals with the driveshaft 
spline.
4. Remove the knuckle and front hub assembly from the 

driveshaft assembly.

.

AC106820 AB

CORD

BOLT

MB991897

NUT

BALL JOINT

AC106821

KNOB

PARALLEL

BOLT

CORRECT

WRONG

AC

AC004701 AB

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-27

<<D>> DRIVESHAFT (LEFT SIDE) REMOVAL

CAUTION

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

INSTALLATION SERVICE POINTS

.

>>A<< DRIVE SHAFT (LEFT SIDE) INSTALLATION

CAUTION

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

.

>>B<< KNUCKLE AND FRONT HUB ASSEMBLY 
INSTALLATION

CAUTION

Do not damage the knuckle oil seal with the drive shaft 
splines. 
1. Insert the knuckle and front hub assembly to the driveshaft.
2. Assemble knuckle and lower ball joint and temporarily 

tighten slotted nut.

3. Press up the lower arm and lock upper ball joint onto the 

upper arm.

4. Tighten the lower ball joint mounting nuts to the specified 

torque.

Tightening torque: 118 

− 177 N⋅m (87 − 131 ft-lb)

.

>>C<< DRIVESHAFT END PLAY ADJUSTMENT
1. Push the driveshaft in by hand toward the knuckle until they 

touch.

2. Measure the clearance between the drive flange and the 

spacer with a feeler gauge as shown in the illustration.

Standard value: 0.4 

− 0.7 mm (0.02 − 0.03 inch)

3. If the amount of play is not within the standard value, adjust 

by selecting a shim that will bring the play to the standard 
value.
NOTE: The shims available range from 0.3 mm (0.01 inch) 
thick to 0.6 mm (0.02 inch) thick in steps of 0.1 mm (0.004 
inch), and from 0.9 mm (0.04 inch) thick to 1.8 mm (0.07 
inch) thick in steps of 0.3 mm (0.01 inch).

AC004702 AB

AC004703AB

AC004633 AB

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-28

DISASSEMBLY AND ASSEMBLY

M1261003700229

CAUTION

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

NOTE: 

.

•

DOJ: Double Offset Joint

•

BJ: Birfield Joint

Required Special Tool:

• MB991561: Boot Band Crimping Tool

AC004715 AB

BOOT REPAIR KIT (BJ)

BJ REPAIR KIT

DOJ REPAIR KIT

BOOT REPAIR KIT (DOJ)

10

2

3

1

8

12

12

4

8

9

7

4

3

6

10

2

1

(LH)

(RH)

11

12

3

8

1

2

3

12

8

1

2

13

14

15

12

4

8

9

7

10

1

4

5

3

6

2

N

N

N

(LH)

(RH)

11

 

  

DISASSEMBLY 

STEPS

 

 

1.  DOJ BOOT BAND (LARGE)

 

 

2.  DOJ BOOT BAND (SMALL)

 

 

3. CIRCLIP

 

 

4. DOJ 

OUTER 

RACE

5. DUST COVER

<<A>>

6. BALLS

<<B>>

7. DOJ CAGE

 

 

8. SNAP 

RING

9. DOJ INNER RACE

<<C>>

10. DOJ BOOT
11. BJ ASSEMBLY
12. CIRCLIP
13. BJ BOOT BAND (SMALL)
14. BJ BOOT BAND (LARGE)
15. BJ BOOT

 

  

ASSEMBLY 

STEPS

 

 

12. CIRCLIP

 

 

11. BJ ASSEMBLY

 

 >>A<<

9. DOJ 

ASSEMBLY

 

 >>A<<

8. SNAP 

RING

 

 >>A<<

7. DOJ 

CAGE

 

 >>A<<

6. BALLS

 

 >>B<<

4. DOJ 

OUTER 

RACE

 

 

5. DUST 

COVER

 

 

3. CIRCLIP

 

 >>C<<

10. DOJ BOOT

 

 >>C<<

2.  DOJ BOOT BAND (SMALL)

 

 >>C<<

1.  DOJ BOOT BAND (LARGE)