Mitsubishi Montero Sport (2004+). Manual - part 763

SHOCK ABSORBER ASSEMBLY AND UPPER ARM

TSB Revision

FRONT SUSPENSION

33A-7

REMOVAL SERVICE POINTS

.

<<A>> REAR ANCHOR ARM ADJUSTING NUT LOOSEN-
ING

CAUTION

When the rear anchor arm adjusting nut is loosened, use a 
jack to support the lower arm of the side to be loosened.
Loosen the anchor arm bolt of the torsion bar all the way.

.

<<B>> UPPER ARM BALL JOINT DISCONNECTION

CAUTION

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

special tool MB991897 to avoid possible damage to ball 
joint threads.

• Hang special tool MB991897 with cord to prevent it 

from falling. 

1. Install the 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 upper 

arm ball joint.

.

<<C>> SHIMS REMOVAL
NOTE: The camber and caster adjustment shims should be 
kept for use during assembly.

AC004998 AB

AC106820 AB

CORD

BOLT

MB991897

NUT

BALL JOINT

AC106821

KNOB

PARALLEL

BOLT

GOOD

BAD

AB

SHOCK ABSORBER ASSEMBLY AND UPPER ARM

TSB Revision

FRONT SUSPENSION

33A-8

INSTALLATION SERVICE POINTS

.

>>A<< UPPER ARM INSTALLATION 
Install the upper arm so that the "OUT" mark on the upper arm 
shaft is facing toward the outside of the vehicle. 

.

>>B<< REBOUND STOPPER INSTALLATION
Install the rebound stopper so that its arrow faces inside of the 
vehicle.

.

>>C<< BUMP STOPPER AND BUMP STOPPER BRACKET 
CLEARANCE ADJUSTMENT
1. With the vehicle in an unladen condition, dimension A from 

the bump stopper to the bump stopper bracket should be 18 
− 20 mm (0.71 − 0.79 inch).
NOTE: Dimension A will be 18 mm (0.71 inch) (B = 50 mm 
[2.0 inches]) when the bump stopper is a new part. When 
the bump stopper is worn and becomes less than 50 mm 
(2.0 inches), dimension A will increase by the decreased 
amount.

2. If dimension A is not 18 

− 20 mm (0.71 − 0.79 inch), adjust 

the rear anchor arm adjusting nut.

.

>>D<< SHOCK ABSORBER INSTALLATION
Install the shock absorber so that the distance (A) shown in the 
illustration is at the standard value.

Standard value (A): 1 

− 2 mm (0.04 − 0.08 inch)

AC004999 AB

MARK

AC005000 AB

INSIDE OF VEHICLE

AC005001AB

A

B

BUMP STOPPER
BRACKET

BUMP STOPPER

AC005002 AB

A

SHOCK ABSORBER ASSEMBLY AND UPPER ARM

TSB Revision

FRONT SUSPENSION

33A-9

INSPECTION

M1332002600077

.

UPPER ARM BALL JOINT BREAKAWAY TORQUE CHECK
1. After shaking the upper arm ball joint assembly stud several 

times, install the nut to the stud and use the special tool 
MB990326 to measure the breakaway torque of the upper 
arm ball joint assembly.

Standard value: 0.8 

− 3.4 N⋅m (7.1 − 30.1 in-lb)

2. When the measured value exceeds the standard value, 

replace the upper arm ball joint.

3. When the measured value is lower than the standard value, 

check that the ball joint turns smoothly without excessive 
play. If not, it is possible to use that upper arm ball joint.

.

UPPER ARM BALL JOINT DUST COVER CHECK
1. Press the dust cover with a finger to check whether the dust 

cover is cracked or damaged.

2. If dust cover is cracked or damaged, replace the upper arm 

ball joint. Cracked or damaged dust cover may cause 
damage to the ball joint. In addition, if the dust cover is 
damaged during service work, replace the dust cover. 

BALL JOINT DUST COVER REPLACEMENT

M1332008000158

Only when dust cover is damaged accidentally during service 
work, replace the dust cover as follows:
1. Apply multipurpose grease to the interior of the dust cover 

and the upper arm ball joint.

2. Secure the dust cover to the upper arm ball joint with ring.
3. Press the dust cover with a finger to check whether the dust 

cover is cracked or damaged.

AC005003 AB

TORQUE
WRENCH

MB990326

AC005007AB

LOWER ARM AND TORSION BAR

TSB Revision

FRONT SUSPENSION

33A-10

LOWER ARM AND TORSION BAR

REMOVAL AND INSTALLATION

M1332010700057

CAUTION

*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on 
the ground in an unladen condition.

Pre-removal Operation
• Under Cover and Skid Plate Removal (Refer to GROUP 

42, Under Cover 

P.42-207

.)

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

dust cover is cracked or damaged.

• Front Wheel Alignment Check and Adjustment (Refer to 

P.33A-3

.)

• Under Cover and Skid Plate Installation (Refer to GROUP 

42, Under Cover 

P.42-207

.)

AC005008 AD

ADHESIVES: 3M™ AAD PART NO.
8730 OR EQUIVALENT

ANCHOR
BOLT

44 N·m
32 ft-lb

4.9 N·m
43.4 in-lb

106 N·m
78 ft-lb

62 N·m
46 ft-lb

81 N·m
60 ft-lb

25 N·m
18 ft-lb

137 - 157 N·m*
101 - 116 ft-lb*

118 - 177 N·m*
87 - 131 ft-lb*

137 - 157 N·m*
101 - 116 ft-lb*

88 - 103 N·m*
65 - 76 ft-lb*

7 5

7

3

2

4

3

4

7

6

5

1

14

15

6

7

11

12

14

8

10

13

9

14

REMOVAL STEPS

>>B<<

• BUMP STOPPER AND BUMP 

STOPPER BRACKET CLEARANCE 
ADJUSTMENT

1. HEAT PROTECTOR (RIGHT SIDE 

ONLY)

2. ANCHOR ARM ASSEMBLY 

ADJUSTING NUT

>>A<<

3. REAR ANCHOR ARM ASSEMBLY
4. ANCHOR COLLAR

>>A<<

5. TORSION BAR
6. HEAT COVER (RIGHT SIDE ONLY)

REMOVAL STEPS (Continued)