1998 MITSUBISHI MONTERO ball joint

AXLE RATIO SPECIFICATIONS








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Application Ratio
Montero ..................................................... 4.27:1
Montero Sport .................................................. (1)
( 1) - On vehicles equipped with wide fender, ratio is 4.64:1. On
vehicles with narrow fender, ratio is 4.27:1.









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LUBRICATION
CAPACITY
DIFFERENTIAL FLUID CAPACITY








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Application Specification
Montero & Montero Sport ............................ 2.4 Pts. (1.1L)\









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FLUID TYPE
All models use fluid type SAE 80W-90/API GL-5.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
AXLE SHAFTS R & I
Removal
1) Raise and support vehicle. Remove wheels and undercover.
Ensure hub is in free-wheeling position. Place transfer case in 2H
position. Remove drive hub cover, snap ring and shim from axle shaft.
See Fig. 3 . Remove brake calipers and support aside.
2) Disconnect tie rod assembly. Support lower control arm
with jack. Separate ball joints from knuckle. Remove knuckle and front
hub assembly. Using flat-blade pry bar, carefully remove left axle
shaft from differential carrier. DO NOT damage oil seal. On right axle
shaft, remove axle shaft-to-inner shaft flange retaining bolts. Remove
right axle shaft.
CAUTION: Replace circlips on BJ/DOJ splined shaft end.
Installation
1) Install right axle shaft on inner shaft flange. Install
new circlip on DOJ side of left axle shaft. Carefully install left
axle shaft into differential. DO NOT damage oil seal.
2) Reinstall knuckle with front hub assembly. To complete
installation, reverse removal procedure. Install shim and snap ring.
Check axle end play. See Fig. 4. End play should be .016-.028" (.4-.7
mm). If end play is not within specification, install correct shim.

Removal
1) Raise and support vehicle. Drain gear oil. Support
differential carrier. Remove axle shafts and inner shaft. See
AXLE SHAFTS R & I and
INNER SHAFT & BEARING . Place alignment mark on drive shaft and pinion
companion flange for reassembly reference.
2) Remove drive shaft. Remove differential mounting brackets
at differential and frame. See Fig. 1. Disconnect front crossmember
from frame. Remove differential carrier assembly and front
crossmember. Remove differential carrier from front crossmember.
Installation
To install, reverse removal procedure. Align marks on drive
shaft and pinion companion flange.
INNER SHAFT & BEARING
Removal
Remove right axle shaft. See AXLE SHAFTS R & I. Using slide
hammer, remove inner shaft from differential carrier. See Fig. 1. If
dust seal replacement is required, pry dust seal from housing tube
assembly using a screwdriver. To remove bearing, bend outer area of
dust cover inward on inner shaft. Press shaft out of bearing. Remove
dust cover from shaft.
Inspection
Inspect inner shaft for damaged splines or threads. Inspect
bearing for roughness or damage.
Installation
1) Install housing tube. Using Seal Installer (MB990955) and\
Handle (C-4171), install NEW dust seal in housing tube. Dust seal must\
be even with housing tube. Coat seal lip with grease.
2) Using a pipe with O.D. of 2.00" (75.0 mm), wall thickness\
of .16" (4.0 mm) and overall length of 2.00" (50.0 mm), install dust\
cover on shaft. Coat inside of dust cover with grease. Press bearing
on shaft. Install new circlip on inner shaft. Carefully drive inner
shaft into differential. DO NOT damage oil seal. To complete
installation, reverse removal procedure.
OVERHAUL
AXLE SHAFTS & BEARINGS
NOTE: References to BJ and DOJ refer to Birfield Joint and Double
Offset Joint, respectively.
Disassembly
1) Remove boot bands. Remove circlip from DOJ outer race.
Separate axle shaft from DOJ outer race. Remove balls from DOJ cage.
Remove DOJ cage from DOJ inner race in direction of BJ. See Fig. 2.
2) Remove snap ring from axle shaft shaft. Remove DOJ inner
race from shaft. Remove circlip from shaft. Wrap tape around splines
of shaft to prevent boot damage during removal. Remove DOJ boot. Note
size of boot. Remove dust cover from shaft. Move boot protector toward
BJ side of shaft and remove. Remove BJ boot.
CAUTION: Axle shaft and BJ are serviced as a unit. DO NOT attempt to
disassemble BJ and axle shaft.
Reassembly
1) Coat shaft with light coat of grease. Wrap splines with

tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Pack proper amount of grease in BJ and BJ boot. See
CV JOINT GREASE CAPACITY table. Boot bands must be installed so lever
is pulled toward rear of vehicle when band is tightened.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage. Apply
proper amount of grease to outer DOJ race. See
CV JOINT GREASE CAPACITY table. Install shaft into DOJ outer race.
Install circlip.
4) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between center line of boot
bands. Distance should be 3.03-3.27" (76.9-83.0 mm). This distance is
necessary to control air in DOJ boot. Tighten boot bands. Install boot
protector and band. Install dust cover on shaft.
CV JOINT GREASE CAPACITY









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Application ( 1) Ozs. (g)
BJ Boot & Joint
Montero ................................................ 4.6 (130)\
Montero Sport .......................................... 4.2 (120)\
DOJ Boot & Joint
Montero ................................................ 3.5 (100)\
Montero Sport .......................................... 4.9 (140)\
( 1) - Apply 1/2 of the amount of grease specified to joint, the other
half to inside of CV boot.









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DIFFERENTIAL ASSEMBLY
Disassembly
1) Remove differential carrier from vehicle. See
DIFFERENTIAL CARRIER ASSEMBLY under REMOVAL & INSTALLATION. Remove
cover. Mark bearing caps for reassembly reference. Remove bearing
caps. Remove differential case assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components
must be installed in original location.
2) Using bearing puller, remove differential case side
bearings. Loosen ring gear retaining bolts in diagonal sequence.
Remove ring gear. Remove drive pinion shaft lock pin from ring gear
side. Remove pinion shaft and pinion gears. Remove side gears and
thrust spacers.
Drive Pinion Removal
Remove pinion flange nut. Scribe alignment mark on pinion
companion flange and drive pinion. Remove flange. Using soft-faced
hammer, drive out pinion. Remove rear bearing and oil seal from
carrier. Remove rear adjusting shim from pinion. See Fig. 1. Press
front bearing from pinion. Remove front adjusting shim and spacer from
pinion.
Cleaning & Inspection
Use cleaning solvent to rinse gears and components. Check
bearings for wear or discoloration. Check gear carrier for cracks or
damage. Check pinion, side gear and flange splines for excessive wear.

Brake Caliper Bolt ......................................... 65 (88)\
Carrier-To-Housing Tube Bolt
Montero ...................................................... (1)
Montero Sport ...................................... 58-72 (79-98)\
Differential
Cover Bolt ............................................... 14 (19)\
Drain Plug
Montero .......................................... 43-51 (58-69)\
Montero Sport .............................................. ( 1)
Fill Plug
Montero ................................................ 39 (53)\
Montero Sport .......................................... 36 (49)\
Drive Shaft Flange Bolt .............................. 36-43 (49-58)\
Front Crossmember Bolt .............................. 72-87 (98-118)\
Hub Cover Bolt ....................................... 13-25 (18-34)\
Knuckle-To-Ball Joint Nut
Upper
Montero ................................................ 54 (73)\
Montero Sport .................................... 44-65 (60-88)\
Lower
Montero .............................................. 108 (146)\
Montero Sport ............. .................. 87-130 (118-176)\
Mounting Bracket-To-Frame Bolt ...................... 58-80 (79-108)\
Mounting Bracket-To-Housing Tube Bolt ................ 58-72 (79-98)\
Pinion Flange Nut
Montero
A/T .................................................. 137 (186)\
M/T .................................................. 159 (216)\
Montero Sport .......................................... 159 (216)\
Right Drive Axle-To-Inner Shaft Bolt ................. 36-43 (49-58)\
Ring Gear-To-Case Bolt ............................... 58-65 (79-88)\
Side Bearing Cap Bolt ................................ 40-47 (54-64)\
Tie Rod-To-Knuckle Nut
Montero .................................................. 33 (45)\
Montero Sport ............................................ 32 (43)\
Wheel Lug Nuts
Montero ........................................... 72-87 (98-118)\
Montero Sport
Aluminum Wheel .................................. 73-86 (99-117)\
Steel Wheel ................................... 87-101 (118-137)\
INCH Lbs. (N.m)
Undercover-To-Frame Bolts (Montero) .............. 84-108 (9.5-12.2\
)
( 1) - Information is not available from manufacturer.









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not leaking ............ 2 . Suggest replacement of CV boot.
Cage broken ............. A ... Require repair or replacement
of CV joint.
Housing damaged to the
extent that it no longer
performs its intended
function ............... A ........... (1) Require repair or
replacement of CV joint.
Housing worn to the extent
that it no longer performs
its intended function .. A ........... ( 1) Require repair or
replacement of CV joint.
Holes elongated ......... A ............ Require replacement.
Internal parts binding .. A .. Require repair or replacement.
Internal parts worn ..... A .. Require repair or replacement.
Lubricant missing ....... C ... Require cleaning, inspection,
and repacking of CV joint.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Housing assembly may appear blue in color from normal
manufacturing process of heat-treating the housing.









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DIP STICK TUBES
DIP STICK TUBE INSPECTION








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Condition Code Procedure
Broken .................. A .. Require repair or replacement.
Checkball missing ....... C .. Suggest repair or replacement.
Cracked ................. A .. Require repair or replacement.
Hold down bracket
broken ................. A .. Require repair or replacement.
Hold down bracket
missing ................ C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.









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DIP STICKS (FLUID LEVEL INDICATORS)
DIP STICK (FLUID LEVEL INDICATOR) INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Compressed .............. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Modified ................ A ............ Require replacement.
Stretched ............... A .. Require repair or replacement.









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DOWEL PINS, GUIDES AND PILOT HOLES
DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION








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Scored .................. B ............ Require replacement.
Spring rate less than
specifications ......... B ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
Worn beyond
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.









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PRESSURE SWITCHES
See SWITCHES.
RACES
See BEARINGS AND RACES .
RUBBER JOINTS (METALASTIC)
These joints may be found on half and/or drive shafts. They
are usually found on European vehicles featuring a three-lug drive
flange. They may be equipped with a centering ball or pin.
RUBBER JOINT (METALASTIC) INSPECTION









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Condition Code Procedure
Drive flange bent ....... A ............. Require repair or
replacement.
Drive flange damaged,
affecting performance .. A ............ Require replacement.
Rubber drive joint
cracked ................ 2 ............ Suggest replacement.
Rubber drive joint
damaged, affecting
performance ............ A ............ Require replacement.
Rubber drive joint split
between mounting holes . A ............ Require replacement.
Rubber drive joint torn at
mounting holes ......... A ............ Require replacement.
Rubber drive joint weather-
cracked ................ .. ........ No service suggested or
required.









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SCREENS
See FILTERS AND SCREENS .
SEALS
SEAL INSPECTION








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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary. Check vent. A plugged

Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bearing cap distorted ... B ............ Require replacement.
Binding ................. A ............ Require replacement.
Cross (trunion) worn,
affecting performance .. A ............ Require replacement.
Double cardon centering
ball damaged ........... A ............ Require replacement.
Double cardon centering
ball worn, affecting
performance ............ A ............ Require replacement.
Double cardon centering
spring broken .......... A ............ Require replacement.
Double cardon centering
spring missing ......... C ............ Require replacement.
Double cardon centering
spring weak ............ A ............ Require replacement.
End cap seal cracked .... 2 ............ Suggest replacement.
End cap seal missing .... C .... Require replacement of seal.
Grease fitting broken ... A ...... (1) Require replacement of
grease fitting.
Grease fitting missing .. C ...... ( 2) Require replacement of
grease fitting.
Rust-colored powder around
end cap seals .......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - A broken grease fitting does not require replacement
of the U-Joint.
( 2) - A missing grease fitting does not require replacement
of the U-Joint.









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VACUUM CONTROLS
See ACTUATORS (VACUUM) .
VACUUM HOSES
See HOSES, LINES AND TUBES .
VACUUM MOTORS
See ACTUATORS (VACUUM) .
VACUUM-OPERATED SWITCHES
See SWITCHES.
VEHICLE SPEED SENSORS
See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .
VENTS

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Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

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 Oil Filter  0.32 Qts. (0.3L) 

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 Oil Cooler  0.32 Qts. (0.3L) 
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1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
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30,000 MILE (48,000 KM) NORMAL SERVICE
30,000 MILE (48,000 KM) NORMAL SERVICE
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VERIFY 
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Last Major Service Was Performed 
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SERVICE 
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 Ball Joints With Grease Nipple (
6) 
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 Propeller Shaft Joints (
6) 
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INSPECT 
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 Fuel Hoses (
3) 
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 Drive Belt (For Generator, Water Pump, Power Steering Pump) 
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 Manual Transmission Oil 
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 Transfer Oil 
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 Disc Brake Pads (
4) 
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 Brake Hoses (
4) 
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 Ball Joint & Steering Linkage Seals (
3) 
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 Drive Shaft Boots (
4) 
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 Exhaust System (
3) 
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REPLACE 
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1) 
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 Engine Oil Filter (
2) 
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 Engine Coolant 
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 Automatic Transmission Fluid 
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 Air Cleaner Filter 
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(
1) - Change once a year or every 7,500 miles (12,000 KM). 

(
2) - If mileage is less than 7,500 miles (12,000 KM) each year, 

replace the oil filter at every oil change.