Mitsubishi Montero, Sport 1998-06

CV-Joints

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Overhaul





Click image to see an enlarged view

Fig. CV-Joint and related components-Montero

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle safely. Remove the tire and wheel assembly.
  4.  
  5. Remove the halfshaft from the vehicle.
    NOTE
    Never disassemble the UJ assembly except when replacing the UJ boot.

  6.  
  7. Remove the small and large DOJ boot bands.
  8.  
  9. Remove the circlip. Remove the DOJ outer race. Remove the snapring.
  10.  
  11. Remove the inner race, cage and ball assembly.
  12.  
  13. Remove the DOJ boot.
  14.  
  15. Remove the small and large UJ boot bands, boot and assembly.
  16.  
  17. On the left side, remove the circlip. Remove the dust cover.
  18.  

To install:

  1. Assembly is the reverse of the disassembly procedure.
  2.  
  3. When installing the DOJ boot, position the outer race so that the distance between the boot bands is 3.1-3.3 inch. Remove part of the DOJ outer race to release the air pressure inside the boot.
  4.  



Click image to see an enlarged view

Fig. CV-Joint and related components-Montero Sport

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft
     
    Small and larger band
     
    Circlip
     
    Double Offset Joint (DOJ) outer race
     
    Dust cover
     
    Circlip
     
    Balls from the cage
     
    Cage from the inner race. Turn the cage so that the projections of the inner race align with the recesses of the cage.
     
    Snapring from the shaft
     
    DOJ inner race
     
    Slide the boot off
     
    Birfield Joint (BJ) small and larger bands
     
    BJ boot
     
    BJ assembly
     

  4.  

To install:

  1. Check the shaft and splines for damage or wear. Inspect the cage, race and balls for any sign of corrosion, wear, cracking or damage. Clean all the parts thoroughly and air dry them completely before installation. Any remaining cleaning solvent can dissolve the lubricating grease.
  2.  
  3. Tool MB991561 can be used to crimp the bands in place.
  4.  
  5. Install or connect the following:

    BJ assembly
     
    BJ boot, slid the small end of the boot until only one shaft groove can be seen.
     
    BJ small band, crimp the band. Fill the BJ boot with 4.6 oz (130 g) of grease.
     
    BJ larger band, crimp the band
     
    DOJ small band and boot, fill the boot with grease
     
    DOJ cage onto the halfshaft so that the smaller diameter side is installed first.
     
    Circlip
     
    DOJ inner race and new snapring, apply grease to the inner race
     
    Balls into the cage, grease to the ball areas of the cage and race
     
    Outer race, fill the outer race about 1 / 3 full of grease.
     
    Dust cover
     
    Circlip
     
    Large boot band, release the air from the boot then crimp
     
    Halfshaft
     

  6.  

 
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