Mitsubishi Montero, Sport 1998-06

Inner Shaft Assembly

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Removal & Installation





Click image to see an enlarged view

Fig. Front inner shaft assembly 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. Remove the right side halfshaft.
  8.  
  9. Loosen the differential mounting insulator bolts.
  10.  
  11. Remove the inner shaft. Remove the circlip.
    NOTE
    When pulling the inner shaft from the front differential carrier with tools MB9909906 and MB990211, be careful that the spline part of the inner shaft does not damage the oil seal.

  12.  
  13. Remove the collar, pin and actuator assembly.
  14.  
  15. Remove the vacuum tank assembly.
  16.  
  17. Remove the free wheel engage switch assembly.
  18.  
  19. Properly support the differential assembly, using a floor jack.
  20.  
  21. Remove the right side differential mounting bracket.
  22.  
  23. Remove the breather pipe. Remove the housing tube.
  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. When installing the differential mounting insulator bolts lower the vehicle to the ground after temporarily tightening the bolts to prevent the bushing from twisting. Then fully tighten the bolts in the unladen condition to 44-58 ft. lbs. and in the proper sequence.

    Click image to see an enlarged view

    Fig. Front differential mounting insulator bolt torque sequence-Montero

  4.  



Click image to see an enlarged view

Fig. Front inner shaft assembly 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. Drain the gear oil.
  6.  
  7. Remove the brake caliper and position it to the side, using wire.
  8.  
  9. Remove the knuckle and hub assembly.
  10.  
  11. Remove the halfshaft assembly.
  12.  
  13. Remove the inner shaft. Remove the circlip.
    NOTE
    When pulling the inner shaft from the front differential carrier with tools MB9909906 and MB990211, be careful that the spline part of the inner shaft does not damage the oil seal.

  14.  
  15. Remove the circlip, pin and spacer.
  16.  
  17. Properly support the differential assembly using a floor jack.
  18.  
  19. Remove the differential mounting cushion. Remove the right side differential mounting bracket.
  20.  
  21. Remove the breather hose. Remove the breather pipe. Remove the heat protector.
  22.  
  23. Remove the housing tube assembly.
  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. When installing the inner shaft, drive it into position using tools MB990906 and MB990211.
    NOTE
    Be careful not to damage the lip of the dust seal and/or the oil seal.

  4.  
  5. Fill the front differential with the proper grade and type gear oil.
  6.  

 
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