Mitsubishi Montero (2004+). Manual - part 470

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-19

<<B>> 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.

INSTALLATION SERVICE POINTS

.

>>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.

.

>>B<< DRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.

CAUTION

Do not apply pressure to wheel bearing by the vehicle 
weight to avoid possible damage to wheel bearing before 
tightening drive shaft nut fully.
2. Tighten the drive shaft nut to the torque specification  with 

special tool MB990767.

3. If the pin hole does not align with another, tighten the drive 

shaft nut [less than 284 N

⋅m (209 ft-lb)] and find the nearest 

hole then bend the split pin to fit in.

ACX01086 AB

WOODEN 
BLOCK

ACX01086 AB

WOODEN 
BLOCK

ACX01087AB

MB990767

WASHER

255 ± 29 N·m
188 ± 21 ft-lb

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-20

DISASSEMBLY AND ASSEMBLY

M1271003500099

CAUTION

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

ACX01092 AC

10

13

12

11

2

9

1

6

8

5

7

3

4

10

12

7

3

1

2

11

13

3

7

1

2

2

9

1

6

8

5

7

3

4

2

9

1

7

3

BJ BOOT REPAIR KIT

BJ REPAIR KIT

DOJ REPAIR KIT

DOJ BOOT REPAIR KIT

N

N

N

N

DISASSEMBLY STEPS

1. DOJ BOOT BAND (LARGE)
2. DOJ BOOT BAND (SMALL)
3. CIRCLIP
4. DOJ OUTER RACE

<<A>>

5. BALLS

<<B>>

6. DOJ CAGE
7. SNAP RING
8. DOJ INNER RACE

<<C>>

9. DOJ BOOT
10. BJ BOOT BAND (LARGE)
11. BJ BOOT BAND (SMALL)

<<C>>

12. BJ BOOT
13. BJ ASSEMBLY

ASSEMBLY STEPS

13. BJ ASSEMBLY

>>A<<

12. BJ BOOT
11. BJ BOOT BAND (SMALL)
10. BJ BOOT BAND (LARGE)

>>A<<

9. DOJ BOOT

>>B<<

6. DOJ CAGE

>>B<<

8. DOJ INNER RACE
7. SNAP RING
5. BALLS

>>C<<

4. DOJ OUTER RACE
3. CIRCLIP

>>D<<

2. DOJ BOOT BAND (SMALL)

>>D<<

1. DOJ BOOT BAND (LARGE)

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-21

Required Special Tool:
MB990939: Brass Bar

LUIBRICATION POINTS

CAUTION

Do not mix old and new or different types of grease, as a special grease is used in the joint.

ACX01093 AD

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

USED AMOUNT:  <BJ> 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)] 

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

   

<DOJ> 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)]

DOJ

BJ

DRIVE SHAFT ASSEMBLY

TSB Revision

REAR AXLE

27-22

DISASSEMBLY SERVICE POINTS

.

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

.

<<B>> DOJ CAGE REMOVAL
Remove the DOJ cage from the DOJ inner race in the direction 
of the BJ.

.

<<C>> DOJ BOOT/BJ BOOT REMOVAL
Wrap plastic tape around the spline part on the DOJ side of the 
drive shaft so that DOJ boot/BJ boot are not damaged when 
they are removed.

ASSEMBLY SERVICE POINTS

.

>>A<< BJ BOOT/DOJ BOOT INSTALLATION
1. Wrap the tape around the spline of the shaft, then install BJ 

boot and DOJ boot in order.

ACX01094

ACX01095

ACX02368AB

PLASTIC TAPE