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    Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

    CV-Joints

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    OVERHAUL



    See Figures 1 through 6

    Before an overhaul is possible, remove the front drive axles-refer to the removal procedures described earlier.

    The front axle shafts of Montero and 4WD Pick-ups have the serviceable joints (TJ or DOJ) at the outside and the BJ or RJ at the inner end.

    The drive axle assembly is a flexible unit consisting of an inner and outer constant velocity (CV) joint joined by the axle shaft. Some cars may have a center bearing or carrier but the inner and outer joint remain. The inner joint, because of its design, is completely flexible and allows the joint to flex left/right, up/down and compress/extend while the joint is turning. This range of motion is necessary to allow the car to accelerate during all possible positions of the car's front wheels.

    Because of the inner joints' flexibility, care must be taken not to over-extend the joint during repairs or handling. When either end of the shaft is disconnected from the car, support the shaft with wire to prevent joint damage.

    CV-joints are protected by rubber boots or seals, designed to keep the high temperature grease in and the road grime and water out. The most common cause of joint failure is a ripped boot which allows the lubricant to leave the joint, thus causing heavy wear, noise and ultimate failure. The boots are constantly exposed to road hazards and should be inspected frequently. Any time a boot is found to be damaged or slit, it should be replaced immediately.

    This is another very good example of maintenance being cheaper than repair.

    A replacement boot kit is generally under $35 while a new joint can range above $150.



    Click image to see an enlarged view

    Fig. Fig. 1: Right driveshaft disassembly and reassembly components



    Click image to see an enlarged view

    Fig. Fig. 2: Left driveshaft disassembly and reassembly components



    Click image to see an enlarged view

    Fig. Fig. 3: Wrap vinyl tape around the spline part of the DOJ side of the driveshaft so that the DOJ boots are not damaged when removed



    Click image to see an enlarged view

    Fig. Fig. 4: Install the BJ and DOJ boots and bands in the order as shown in the illustration



    Click image to see an enlarged view

    Fig. Fig. 5: The internal components of the DOJ joint



    Click image to see an enlarged view

    Fig. Fig. 6: Apply 1.9 oz. (55 gr) of Repair kit grease to the DOJ outer race, insert the driveshaft into the race, then apply the same amount of grease on top of the race

    Mitsubishi uses no fewer than 4 types of CV-joint on its cars; they appear in various combinations on various driveshafts. The types of joints and their abbreviations are:



    Tripod joint (TJ)-commonly found as an inboard joint, the three sided spider inside can be replaced on the bench.
     
    Rzepppa joint (RJ)-named for its inventor, it almost always shows up as an outer joint. The joint is not replaceable under most conditions but comes installed on a new axle.
     
    Double Offset joint (DOJ)-identified by its ball-in-cage arrangement, this highly flexible inner joint can be dismantled and rebuilt.
     
    Birfield joint (BJ)-outer joint with good reliability. Cannot be disassembled from the axle. A new joint will include a new shaft.
     

    This section will use these abbreviations for each joint. Additionally, any reference to an outer or outboard joint indicates the joint at or near the wheel/hub/knuckle assembly. Not surprisingly, inner or inboard refers to the joint at or closest to the transaxle.


    WARNING
    Bands and snaprings are not reusable. Parts are not interchangeable. Each band and boot for each model and type of joint has an identifying code on it. Obtain this code and shop for exact replacements. A few cents saved on the wrong part may cost you a second repair when the boot doesn't seal correctly.The grease that comes in the repair kit should be used throughout the joint. Do not substitute other lubricants; they will not withstand the heat and pressure within the joint.

    Tripod Joint
    1. Remove the driveshaft from the car, following directions outlined earlier.
    2.  
    3. Remove the large band holding the boot to the joint and the smaller band holding the boot to the shaft. Slide the boot off the joint and down the shaft, out of the way.
    4.  
    5. Gently pull the TJ case off the joint.
    6.  
    7. Remove the small snapring on the end of the shaft and remove the spider assembly. Clean the spider assembly thoroughly but do not disassemble it.
    8.  
    9. Wrap several turns of vinyl or electrician's tape around the splines on the driveshaft. Slide the boot off the shaft.
    10.  
    11. Clean and examine the parts carefully. All traces of the old grease should be removed and the parts should be totally dry before reinstallation.
    12.  

    To install:
    1. Slide the new boot onto the axle. Use tape to cover the shaft splines.
    2.  
    3. Apply a liberal coating of the special CV-joint grease (comes in the overhaul kit) to the spider assembly and install the assembly on the shaft.
    4.  
    5. Install a new snapring to hold the spider.
    6.  
    7. Use the remainder of the grease inside the joint case and fit the case over the spider.
    8.  
    9. Slide the boot into place and install new boot clamps. Make certain the joint is straight when placing the boot; if the joint is cocked, the boot may not seal correctly.
    10.  
    11. Install a new snapring on the transaxle end of the inner joint.
    12.  
    13. Reinstall the driveshaft.
    14.  

    Double Offset Joint
    1. Remove the driveshaft from the car, following directions outlined earlier.
    2.  
    3. Remove the small band holding the boot to the shaft and the larger band holding the boot to the joint. Slide the boot off the joint and down the shaft, out of the way.
    4.  
    5. Gently pull the DOJ case off the joint. There is a large circular spring clip within the case holding it in place. Carefully work this spring free before disassembly.
    6.  
    7. Make reliable matching marks on the end of the shaft, the inner race and the outer cage. A metal scribe is handy for this marking.
    8.  
    9. Remove the balls from the DOJ cage.
    10.  
    11. Remove the cage from the inner race. Turn the cage so that the projections of the inner race align with the recesses of the cage. Slide the cage toward the center of the shaft, not to the outside.
    12.  
    13. Remove the snapring from the shaft. Mount the shaft in a vise with protected jaws.
    14.  
    15. Use a brass bar and small hammer, tap evenly all around the inner race and remove it from the shaft.
    16.  
    17. Apply several turns of tape over the shaft splines. Remove the cage and boot from the shaft.
    18.  
    19. 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.
    20.  

    To install:
    1. Wrap the splines in tape; install a new boot and slide it down the shaft.
    2.  
    3. Place the cage onto the driveshaft so that the smaller diameter side is installed first.
    4.  
    5. Align the matchmarks of the inner race and the shaft. Use the small hammer and brass bar to tap the race into position until it contacts the rib of the shaft. Install a new snapring.
    6.  
    7. Apply grease liberally to the inner race and the DOJ cage. Align the matchmarks and fit the two together using the same alignment method as during disassembly.
    8.  
    9. Apply grease to the ball areas of the cage and race and insert the balls.
    10.  
    11. Fill the outer race about 1 / 3 full of grease. Install a new large circlip and install the ball and cage assembly. Use the remainder of the grease to fill the back of the joint or the boot.
    12.  
    13. Slide the boot into place over the joint and install new bands. The boot should be neither stretched nor compressed when the bands are applied. The bands should be 3.15 in. (80mm) apart. Too much or too little air within the boot may cause premature boot failure.
    14.  
    15. Install the driveshaft into the car.
    16.  

    BOOT REPLACEMENT



    Inner Joint

    Boot replacement is accomplished by following the appropriate overhaul procedure. The joint components must be removed from the shaft to allow the boot to pass. Even if only the boot is being replaced, the other components should be inspected. Remove as much old grease as possible and reassemble the joint packed with fresh grease.

    Outer Joint
    1. Remove the driveshaft from the car.
    2.  
    3. The outer boot cannot be removed over the outer end of the shaft. You will need 2 repair kits since the inner joint must also be disassembled.
    4.  
    5. Disassemble the inner joint following overhaul procedures listed earlier.
    6.  
    7. If the shaft has a dynamic damper (usually on left shafts), remove its band and slide the damper over the tape-protected splines.
    8.  
    9. Remove the bands holding the boot at the outer joint and slide the boot all the way down the shaft and off.
    10.  
    11. The exposed joint-either RJ or BJ type-should be inspected for signs of wear if possible. Do NOT disassemble this joint.
    12.  
    13. Fit the new boot onto the shaft and into place near the joint.
    14.  
    15. Use about 1 / 2 the grease in the kit to pack the outer joint and the other 1 / 2 to fill the boot.
    16.  
    17. Work the boot into place and apply the new bands. Make sure the joint is not at an angle during the securing of the boot.
    18.  
    19. Install the dynamic damper if one was removed. Use a new band to hold it.
    20.  
    21. Install the new boot for the inner joint and reassemble the joint following the overhaul instructions given earlier. Note that the dynamic damper, if used, must be kept free of grease.
    22.  
    23. Install the driveshaft in the car.
    24.  

     
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