Mitsubishi Montero Sport (2004+). Manual - part 412

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-29

Lubrication Points

DISASSEMBLY SERVICE POINTS

.

<<A>> BALL REMOVAL
Remove the balls from the DOJ cage.

.

AC004716 AD

GREASE:
REPAIR KIT GREASE: 120g (4.2 oz)

NOTE
THE GREASE IN THE REPAIR KIT SHOULD
BE DIVIDED IN HALF FOR USE,
RESPECTIVELY, AT THE JOINT AND INSIDE
THE BOOT.

GREASE:
REPAIR KIT GREASE: 140 g (4.9 oz)

NOTE
THE GREASE IN THE REPAIR KIT SHOULD BE DIVIDED IN
HALF FOR USE, RESPECTIVELY, AT THE JOINT AND
INSIDE THE BOOT.

GREASE: REPAIR KIT GREASE

DO NOT MIX OLD AND NEW OR DIFFERENT TYPES OF GREASE, AS A SPECIAL GREASE IS USED IN THE
JOINT.

!  CAUTION

ACX01094 AB

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-30

<<B>> DOJ CAGE REMOVAL
Remove the DOJ cage from the DOJ inner race in the direction 
shown in the illustration.

.

<<C>> DOJ BOOT REMOVAL
Wrap plastic tape around the spline part on the DOJ side of the 
driveshaft so that DOJ boot is not damaged when removed.

ASSEMBLY SERVICE POINTS

.

>>A<< DOJ INNER RACE/SNAP RING/DOJ CAGE/BALLS 
INSTALLATION
Install the cage, balls and inner race to the driveshaft, and fit 
the snap ring securely to the groove in the driveshaft.

.

ACX01095AB

AC000437AB

PLASTIC TAPE

AC004718 AB

BALL

SHAFT

INNER RACE

CAGE

SNAP RING

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-31

>>B<< DOJ OUTER RACE INSTALLATION

CAUTION

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

specified grease.

Specified grease: Repair kit grease 140 g (4.9 oz)

CAUTION

Do not secure the boot band (large).
2. Install the circlip onto the DOJ outer race. Place the DOJ 

boot over the DOJ outer race, and then use a boot band 
(small) to secure the boot.

.

>>C<< 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): 92 

− 98 mm (3.6 − 3.9 inches) 

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

release the air pressure inside the boot.

CAUTION

Be sure that the installation direction of the boot bands is 
correct.
3. Secure the boot band (large) on DOJ boot.

BJ BOOT (RESIN BOOT) REPLACEMENT

M1261005200231

1. Remove the boot bands (large and small).

NOTE:  The BJ boot bands cannot be re-used.

2. Remove the BJ boot.

ACX02369

ACX02370

BOOT BAND (LARGE)

BOOT BAND (SMALL)

A

AB

AC004719 AB

BOOT BAND

DIRECTION OF
DRIVESHAFT
ROTATION WHEN
VEHICLE IS MOVING
FORWARD

ACX00982 AB

DRIVE SHAFT ASSEMBLY

TSB Revision

FRONT AXLE

26-32

3. 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 larger than 2.9 mm (0.11 inch)> Tighten the 

adjusting bolt. 

<If it is smaller than 2.9 mm (0.11 inch)> Loosen 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.

4. Place the BJ boot band (small) against the projection at the 

edge of the boot, and then secure it so that there is a 
clearance left as shown by (A) in the illustration.

CAUTION

• Secure the drive shaft in an upright position and clamp 

the part of the BJ boot band to be crimped securely in 
the jaws of the special tool MB991561.

• Crimp the BJ boot band until the special tool touches 

the stopper.

5. Use the special tool MB991561 to crimp the BJ boot band 

(small).

ACX00993AB

STOPPER

ADJUSTING BOLT

(W)

MB991561

AC001175

BJ BOOT

A

BJ BOOT BAND
(SMALL)

PROJECTION

AB

ACX00995AB

MB991561