REMOVAL & INSTALLATION
See Figures 1 and 2
- Raise and support the vehicle with jackstands.
- Remove the transfer case oil fill plug from the back of the transfer case. Set a pan or similar container under the drain plug of the transfer case. Remove the drain plug and drain the transfer case.
- Matchmark the front flange of the front driveshaft and the flange on the front differential with white paint, a yellow grease pencil or by a similar method. This will permit the shaft to be reinstalled in the same position for balance purposes.
- Remove the nuts and bolts from the companion flange, and lower the front of the driveshaft. Slide the rear of the shaft out of the transfer case. Cover the opening left at the front of the transfer case with a clean rag or similar means so dirt will be kept out. Have a pan or similar container at hand to catch any transmission fluid which may leak out of the flange.
- Apply SAE 80 hypoid gear oil (API GL-4) to the inner and outer surface of the sleeve yoke where it will enter the transmission or center bearing.
- Slide the driveshaft end into the transfer hole, making sure not to damage the oil seal lip of the transfer case.
- Align the marks on the yoke and companion flange; line up the bolt holes.
- Install the nuts and bolts with the lockwashers on the back (nut) side of the flange. Tighten the bolts to 36-43 ft. lbs. (49-58 Nm).
- Install the drain plug of the transfer to 22-25 ft. lbs. (29-34 Nm). Fill the transfer case with transfer case fluid, then install the fill hole plug to 22-25 ft. lbs. (29-34 Nm).
- Lower the vehicle back to the ground.
UNIVERSAL JOINT REPLACEMENT
See Figures 3, 4, 5, 6 and 7
To perform this operation, you'll need Mitsubishi Tool MB990840-01 (or an equivalent large C-clamp) and a small collar designed to fit against the yoke and accept the pressed out bearing cups.
- Scribe mating marks on the yokes of each joint that is to be disassembled. Joints must be assembled in the same position to maintain driveshaft balance.
- Remove the snaprings from all four positions of the joint. Situate the collar against one side of the yoke so it is perfectly lined up with the hole in the yoke and will accept the bearing cup from that side. Place the flat bottom of the C-clamp under the collar and then screw the upper portion downward against the top of that same yoke cross-shaft.
- Turn the C-clamp screw handle to press the cross-shaft out. Remove the bearing cups and bearings from that cross-shaft. It's best to turn the unit so the closed end of the cup is at the bottom for retention of the needle bearings when you do this.
- Repeat this step for the other cross-shaft. You can then separate the two yokes of the joint and remove the cross-shaft assembly.
- Apply multipurpose grease (SAE J310a NLGI grade #2 EP) to the journal outer diameters, ends, and reservoirs on all four arms of the cross-shaft. Apply grease also to the lips of the dust seals in the ends of the bearing cups and to the needles. All parts should be thoroughly coated, but excess grease may make the unit hard to assemble.
- Place a bearing cup, open end inward, on opposite sides of one of the forks. Place the C-clamp around the cups without the collar. Center the cross-shaft assembly so the bearing cups will be assembled around two of the journals as they are pressed into the yoke. Turn the C-clamp until the bearing cups are pressed in with room for a snapring on either side. Line up the mating mark for the two yokes and then repeat the procedure for the other cross-shaft and yoke.
- Install the snapring on one side with snapring pliers. Install the collar over the side of the yoke onto which you've installed the snapring. Then install the C-clamp with the bottom against the collar and the lower end of the screw over the top of the upper bearing cup.
- Turn the clamp to seat the outside of the cup against the snapring on one side. Install a snapring on the other side. Measure the clearance between the outside surface of the second snapring and the outer wall of the groove which retains the snapring in the yoke. If the clearance is more than 0.0024 in. (0.06mm), replace both snaprings with new ones.