25-1

GROUP 25
PROPELLER SHAFT
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 25-2
PROPELLER SHAFT DIAGNOSIS . . 25-2
INTRODUCTION TO PROPELLER
SHAFT DIAGNOSIS . . . . . . . . . . . . . . . . . . 25-2
PROPELLER SHAFT DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . . . 25-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 25-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 25-3
SPECIAL TOOL. . . . . . . . . . . . . . . . . 25-4
PROPELLER SHAFT . . . . . . . . . . . . . 25-4
REMOVAL AND INSTALLATION . . . . . . . . 25-4
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 25-6
DISASSEMBLY AND ASSEMBLY . . . . . . . 25-7
SPECIFICATIONS . . . . . . . . . . . . . . . 25-12
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 25-12
GENERAL SPECIFICATIONS . . . . . . . . . . 25-13
SERVICE SPECIFICATION . . . . . . . . . . . . 25-13
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 25-13
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . 25-13
GENERAL DESCRIPTION
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PROPELLER SHAFT
25-2
GENERAL DESCRIPTION
M1251000100142
3 way split 4-joint type propeller shaft with center
bearing, with the following features is utilized:
The No.3 joint incorporates LJ, which is light and
compact.
An insulator is located at the center bearing to
vehicle body joint, reducing vibration.
For environmental protection, a lead-free grease
is used on LJ and center bearing.
LJ: Lobro Joint
CONSTRUCTION DIAGRAM
AC211158
CENTER BEARING
SLEEVE YOKE
No.1 JOINT
FRONT
PROPELLER SHAFT
No.2 JOINT
CENTER
PROPELLER
SHAFT
REAR
PROPELLER SHAFT
No.4 JOINT
No.3 JOINT(LJ)
AB
INSULATOR
INSULATOR
PROPELLER SHAFT DIAGNOSIS
INTRODUCTION TO PROPELLER SHAFT DIAGNOSIS
M1251001800111
If an abnormal noise is heard from the propeller shaft
while driving, some parts of the propeller shaft may
be worn or damaged, or some mounting bolts may
be loose.
PROPELLER SHAFT DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1251001900129
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted all of the possible ways to find a pro-
peller shaft fault.
1. Gather information from the customer.
2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1251002000107
SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE
Noise at start 1
P.25-3
Noise and vibration at high speed 2
P.25-3
PROPELLER SHAFT DIAGNOSIS
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PROPELLER SHAFT
25-3
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Noise at Start
DIAGNOSIS
STEP 1. Check if the propeller shaft and
differential companion flange connecting nuts
and the center bearing mounting nuts are loose.
Connecting nuts tightening torque: 32 2 N m (24
1 ft-lb)
Mounting nuts tightening torque: 30 4 N m (22 3
ft-lb)
Q: Are the connecting nuts and mounting nuts
tightened to the specified torque?
YES : Go to Step 2.
NO : Tighten the connecting nuts and mounting
nuts to the specified torque. Then go to Step
3.
STEP 2. Check the sleeve yoke's spline of front
propeller shaft for wear.
Q: Is wear apparent?
YES : Replace the propeller shaft. Then go to Step
3.
NO : Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Recheck from Step 1.
INSPECTION PROCEDURE 2: Noise and Vibration at High Speed
DIAGNOSIS
STEP 1. Check the propeller shaft run-out.
(1) Remove the propeller shaft. (Refer to P.25-4.)
ACX00643
(2) Measure the propeller shaft runout.
Limit: 0.5 mm (0.02 inch)
Q: Is the measured value within the limit?
YES : Go to Step 2.
NO : Replace the propeller shaft. Then go to Step 2.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Recheck from Step1.
SPECIAL TOOL
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PROPELLER SHAFT
25-4
SPECIAL TOOL
M1251000600158
TOOL TOOL NUMBER
AND NAME
SUPERSESSION APPLICATION
MD998801
Bearing remover

Removal of the center bearing
assembly
PROPELLER SHAFT
REMOVAL AND INSTALLATION
M1251001000375
AC211529
N
N
32 2 Nm
24 1 ft-lb
30 4 Nm
22 3 ft-lb
4
2
3
3
2
GEAR OIL:
MITSUBISHI LIMITED SLIP DIFFERENTIAL
OIL (LSD) OR EQUIVALENT
30 4 Nm
22 3 ft-lb
2
AD
2
1
1
REMOVAL STEPS
1. SELF LOCKING NUT
2. INSULATOR
3. SPACER
<<A>> >>A<< 4. PROPELLER SHAFT ASSEMBLY
REMOVAL STEPS (Continued)
PROPELLER SHAFT
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PROPELLER SHAFT
25-5
REMOVAL SERVICE POINT
.
<<A>> PROPELLER SHAFT ASSEMBLY
REMOVAL
AC003833AD
MARKING
DIFFERENTIAL
COMPANION
FLANGE
PPROPELLER
SHAFT
ASSEMBLY
1. Make mating marks on the differential companion flange and
the propeller shaft assembly.
CAUTION
Be careful not to bend the joint portion when removing the
propeller shaft because this will damage to the joint boot.
AC101255
REAR PROPELLER
SHAFT
JOINT ASSEMBLY
RAG
JOINT BOOT
AC
2. Insert a rag so as to avoid boot damage, and remove the
propeller shaft assembly in a straight and level manner.
INSTALLATION SERVICE POINT
.
>>A<< PROPELLER SHAFT ASSEMBLY INSTAL-
LATION
CAUTION

AC211569AB
OIL SEAL
TRANSFER
Do not damage the oil seal lips on the transfer case.
Remove oil and grease from the threads of the mount-
ing bolts and nuts before tightening, or they will loosen.
Be careful not to bend the joint portion when removing
the propeller shaft, because this will damage the joint
boot.
AC003833AD
MARKING
DIFFERENTIAL
COMPANION
FLANGE
PPROPELLER
SHAFT
ASSEMBLY
PROPELLER SHAFT
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PROPELLER SHAFT
25-6
1. If reusing the propeller shaft, align the mating marks of
differential companion flange and propeller shaft assembly
to install.
2. When installing a new rear propeller shaft assembly, if there
is no phase alignment mark on the companion flange at the
differential side, assemble while adjusting the hole phases
of propeller shaft flange and differential companion flange.
INSPECTION
M1251001100220
Check the sleeve yoke and flange yoke for wear, damage or
cracks.
Check the propeller shaft for bends, twisting or damage.
Check the universal joint for smooth operation in all direc-
tions.
Check the center bearing for smooth movement.
PROPELLER SHAFT RUNOUT
ACX00643AB
Limit: 0.5 mm (0.02 inch)
PROPELLER SHAFT UNIVERSAL JOINT PLAY
CHECK
AC501206
1. Hold the tube of propeller shaft by one hand, and apply force
by the other hand to the flange yoke or sleeve yoke in
rotative direction, axial direction, and perpendicular direction
for cheking looseness.
2. If looseness is recognized, replace the propeller shaft with a
new one.
PROPELLER SHAFT
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PROPELLER SHAFT
25-7
DISASSEMBLY AND ASSEMBLY
M1251001200164
AC211583
12
13
14
11
15
14
11
4
1
5
2
34 5 Nm
25 4 ft-lb
3
6
10
34 5 Nm
25 4 ft-lb
9
8
7
N
187 29 Nm
138 21 ft-lb
11 N
14 N
13
15
16 N
10
17
14
16 12 15
AB
187 29 Nm
138 21 ft-lb
12 N
LJ KIT LJ BOOT KIT
N
DISASSEMBLY STEPS
1. BOLT
2. FRONT PROPELLER SHAFT
ASSEMBLY
>>E<< 3. SELF LOCKING NUT
<<A>> >>E<< 4. COMPANION FLANGE
<<B>> >>E<< 5. CENTER BEARING ASSEMBLY
<<C>> 6. BOLT
>>D<< 7. SELF LOCKING NUT
<<A>> >>D<< 8. COMPANION FLANGE
>>D<< 9. CENTER BEARING ASSEMBLY
10. CENTER PROPELLER SHAFT
11. SNAP RING
>>C<< 12. BOOT BAND
<<D>> >>B<< 13. LJ ASSEMBLY
14. RUBBER PACKING
<<E>> >>A<< 15. LJ BOOT
16. WASHER
17. REAR PROPELLER SHAFT
DISASSEMBLY STEPS
PROPELLER SHAFT
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PROPELLER SHAFT
25-8
Required Special Tool:
MD998801: Bearing Remover
LUBRICATION AND ADHESIVE POINTS
AC211584
RUBBER
MOUNT
GREASE: REPAIR KIT GREASE
AMOUNT USED: 75 5 g (2.6 0.1 oz)
TM
ADHESIVE:
3M AAD PART NO. 8730, 8731
OR EQUIVALENT
AB
PROPELLER SHAFT
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PROPELLER SHAFT
25-9
DISASSEMBLY SERVICE POINTS
.
<<A>> COMPANION FLANGE REMOVAL
AC211610AB
MATING
MARKS
Make mating marks on the companion flange and center pro-
peller shaft. Then, remove the companion flange.
.
<<B>> CENTER BEARING ASSEMBLY REMOVAL
AC101273
CENTER BEARING
ASSEMBLY
MD998801
AC
Use special tool MD998801 to remove the center bearing
assembly.
.
<<C>> BOLT REMOVAL
Make mating marks on the rear propeller shaft, LJ assembly
and companion flange. Then, remove the bolt.
.
<<D>> LJ ASSEMBLY REMOVAL
AC101274
LJ ASSEMBLY
LJ BOOT
AB
1. Remove the LJ boot from the LJ assembly.
AC101275 AC
OUTER
RACE
CIRCLIP
BALL
CAGE
INNER
RACE
2. Mark the mating marks in outer race, cage and inner race,
then remove the circlip, outer race and ball.
NOTE: Ensure the proper installation of ball as show.
AC101276
INNER
RACE
PULLER
CAGE
AC
PROPELLER SHAFT
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PROPELLER SHAFT
25-10
3. Using puller (general service tool), remove the inner race
and cage from the center propeller shaft assembly.
4. Wipe grease from the outer race, inner race, cage and ball.
.
<<E>> LJ BOOT REMOVAL
If LJ boot will be reused, tape the spline part of the center pro-
peller shaft in order to remove the boot.
ASSEMBLY SERVICE POINTS
.
>>A<< LJ BOOT INSTALLATION
1. Install the boot band.
2. After taping the spline part of the center propeller shaft,
install the LJ boot.
.
>>B<< LJ ASSEMBLY INSTALLATION
AC101277AC
OUTER
RACE
CIRCLIP
CAGE
INNER
RACE
1. Lubricate the specific grease to ball moving part of the outer
race and inner race.
Specified grease: Repair kit grease
2. Assemble the LJ as follows:.
(1) Align the mating marks and install the outer race, cage,
ball and inner race.
(2) Install the circlip.
AC101278AC
3. Fill the specified grease evenly in LJ assembly.
Specified grease: Repair kit grease
Amount to use: 75 5 g (2.6 0.1 ounces)
AC101279AD
RUBBER
PACKING
LJ ASSEMBLY
PROPELLER SHAFT
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PROPELLER SHAFT
25-11
4. Apply a little of the specified sealant to the surface which
has groove (for packing) of LJ assembly (shown by arrows
in the illustration), fix the rubber packing.
Specified sealant: 3M AAD Part No. 8730, 8731 or
equivalent
5. Install the surface which has groove (for packing) of LJ
assembly to LJ boot side.
AC101280
SOCKET
WRENCH
AC
6. Align the mating marks of LJ assembly and center propeller
shaft, then install the LJ assembly to center propeller shaft
using socket wrench.
AC101281AD
BOLT
LJ BOOT
7. Aligned the position of bolt holes of LJ boot and LJ
assembly, and install the LJ boot to LJ assembly.
8. Fix the rubber packing of companion flange side, in a similar
manner to step 4.
.
>>C<< BOOT BAND INSTALLATION
CAUTION

AC101282
SALIENT
BOOT BAND MOUNTING
BOOT
AC
Tighten the boot part in opposite direction of convex
part for bleeding the boot.
If there is grease in the convex part, wipe out the
grease in order to bleed the boot.
.
SPECIFICATIONS
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PROPELLER SHAFT
25-12
>>D<< CENTER BEARING
ASSEMBLY/COMPANION FLANGE/SELF
LOCKING NUT INSTALLATION
AC101283 AC
COMPANION
FLANGE
SELF-
LOCKING
NUT
CENTER BEARING
ASSEMBLY
1. Install the center bearing assembly to the center propeller
shaft in the direction shown in the illustration.
2. After aligning the mating marks of the companion flange and
center propeller shaft, install them.
3. Tightening the self locking nut, press fit the center bearing
assembly using companion flange.
.
>>E<< CENTER BEARING
ASSEMBLY/COMPANION FLANGE/SELF
LOCKING NUT INSTALLATION
AC101284
RUBBER
MOUNT
DUST
SEAL
CENTER
YOKE
SELF-
LOCKING
NUT
AC
1. Install the center bearing assembly to the center propeller
shaft in the direction shown in the illustration.
2. After aligning the mating marks of the companion flange and
center propeller shaft, install them.
3. Tightening the self locking nut, press fit the center bearing
assembly using companion flange.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1251001600117
ITEM SPECIFICATION
Center bearing assembly nut 30 4 N m (22 3 ft-lb)
Companion flange to front propeller shaft connecting
nut
34 5 N m (25 4 ft-lb)
Companion flange, LJ assembly, LJ boot and washer
connecting nut
34 5 N m (25 4 ft-lb)
Propeller shaft and differential companion flange
connecting nut
32 2 N m (24 1 ft-lb)
Self locking nut (companion flange to front and center
propeller shaft connection)
187 29 N m (138 21 ft-lb)
SPECIFICATIONS
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PROPELLER SHAFT
25-13
GENERAL SPECIFICATIONS
M1251000200161
ITEM SPECIFICATION
Propeller
shaft
Type 3 way split 4-joint type propeller shaft
Length*
Outside diameter
mm (in)
Front 608.5 x 65 (24.0 x 2.56)
Center 551 x 65 (21.7 x 2.56)
Rear 750.5 x 65 (29.5 x 2.56)
Universal joint Type No.1 Cross type (cauking method)
No.2 Cross type (cauking method)
No.3 Constant velocity type (LJ)
No.4 Cross type (cauking method)
Cross type joint Bearing Non-lubrication type needle roller bearing
Journal diameter mm (in) 18.3 (0.72)
NOTE: *: The propeller shaft length indicates the
length between the center points of each joint.
SERVICE SPECIFICATION
M1251000300168
ITEM LIMIT
Propeller shaft run-out mm (in) 0.5 (0.02)
LUBRICANTS
M1251000400314
ITEM SPECIFIED LUBRICANT QUANTITY
Front propeller shaft sleeve yoke MITSUBISHI Limited Slip Differential Oil
(LSD) or equivalent
As required
LJ assembly Repair kit grease 75 5 g (2.6 0.1 oz)
SEALANT
M1251000500087
ITEM SPECIFIED SEALANT QUANTITY
LJ assembly rubber packing 3M AAD Part No. 8730, 8731 or equivalent As required
NOTES