Mitsubishi Montero, Sport 1998-06

Halfshafts

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Removal & Installation





Click image to see an enlarged view

Fig. Front halfshaft 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 under cover. Remove the skid plate.
  6.  
  7. Disconnect the shock absorber and stabilizer bar lower link.
  8.  
  9. Remove the front brake caliper and position it to the side.
  10.  
  11. Disconnect the knuckle and tie rod end connection.
  12.  
  13. Remove the dust cap, cotter pin, locknut and washer.
  14.  
  15. Disconnect the brake hose and VSS clamp bracket.
  16.  
  17. Remove the wheel speed sensor.
  18.  
  19. Remove the upper control arm ball joint connection.
  20.  
  21. Remove the halfshaft retaining bolts.
    NOTE
    When pulling the halfshaft out from the differential carrier, be careful that the spline part of the halfshaft does not damage the oil seal.

  22.  
  23. On the left side halfshaft, remove the circlip.
  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  



Click image to see an enlarged view

Fig. Front halfshaft and related components-Montero Sport

  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 under cover. Remove the skid plate. Drain the gear oil.
  6.  
  7. Remove the caliper assembly and position it to the side.
  8.  
  9. If equipped with ABS, remove the front speed sensor.
  10.  
  11. Remove the dust cap, snapring and shim.
  12.  
  13. Disconnect the stabilizer bar connection.
  14.  
  15. Remove the lower shock absorber mounting bolt.
  16.  
  17. Using the proper tools, disconnect the tie rod end connection.
  18.  
  19. Using the proper tools, disconnect the lower arm ball joint connection.
  20.  
  21. Using the proper tools, disconnect the upper arm ball joint connection.
  22.  
  23. Press down on the lower control arm and remove the upper knuckle towards you.
    NOTE
    Pull the DOJ side of the halfshaft assembly out slightly from the front differential carrier.

  24.  
  25. Slightly back off the halfshaft from the knuckle. Remove the lower knuckle retaining nut from the lower arm ball joint.
  26.  
  27. Disconnect the knuckle and lower ball joint.
    NOTE
    Do not damage the knuckle oil seals with the driveshaft spline.

  28.  
  29. Remove the knuckle and front hub assembly from the halfshaft assembly.
  30.  
  31. Remove the halfshaft assembly and circlip.
    NOTE
    On the left side, when pulling the halfshaft out from the differential carrier, be careful that the spline part of the halfshaft does not damage the oil seal.

  32.  

To install:

  1. Insert the knuckle and front hub assembly to the halfshaft. Assemble the knuckle and lower ball joint and temporarily tighten the slotted nut.
  2.  
  3. Press up the lower arm and lock the upper ball joint onto the upper arm.
  4.  
  5. Tighten the lower ball joint mounting nuts to 87-131 ft. lbs.
  6.  
  7. Push the halfshaft in by hand toward the knuckle until they touch.
  8.  
  9. Measure the clearance between the drive flange and the spacer, specification should be 0.02-0.03 inch.
  10.  
  11. If the end play is not within specification, adjust by selecting a shim that will bring the end play within specification.
    NOTE
    Shims are available from 0.01 inch thick to 0.02 inch thick, in increments of 0.004 inches, and from 0.04 inch to 0.07 inch thick in increments of 0.01 inches.

  12.  
  13. Continue the installation in the reverse order of the removal procedure.
  14.  
  15. Be sure to correct and adjust the gear oil level, as necessary.
  16.  

 
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