Here's a general overview of the process. This is NOT a comprehensive guide and specifics may vary slightly depending on the exact model and modifications. Always consult a repair manual specific to your vehicle year and model for precise instructions and torque specifications:
Tools You'll Likely Need:
* Jack and jack stands: Securely support the vehicle.
* Wheel chocks: Essential for safety.
* Socket set and wrenches: Various sizes, including metric.
* Torque wrench: Crucial for proper tightening.
* Penetrating oil: To loosen rusted or seized bolts.
* Hammer and punch: May be needed to break loose stubborn components.
* Driveshaft support: To prevent damage to the driveshaft during removal and installation. This is very important.
* Transmission jack (highly recommended): Helps support the transmission and facilitates easier removal and installation of the driveshaft.
* Shop rags and gloves: For cleanliness and protection.
* Repair manual specific to your 2002 Mitsubishi Montero Sport: This is absolutely essential.
General Steps (Consult your repair manual for specifics):
1. Safety First: Disconnect the negative battery terminal. Secure the vehicle on jack stands, engage the parking brake, and use wheel chocks.
2. Component Removal:
* Remove the front wheels: This will give you better access.
* Disconnect the CV axles: This usually involves removing cotter pins, castle nuts, and separating the axles from the hubs and transmission. This step often requires special tools.
* Remove the driveshaft: This may require disconnecting the driveshaft from the transfer case and the differential. You'll likely need to support the transmission to avoid dropping it. Pay close attention to how the driveshaft is oriented and any shims or spacers present. Photographing everything before disassembly is highly recommended.
* Inspect the differential and transfer case for damage or leaks. If found, address these issues before installing the new driveshaft.
3. Installation of the New Driveshaft:
* Install the new driveshaft: Reverse the removal process. Ensure the driveshaft is properly seated and aligned.
* Reconnect the CV axles and other components: Tighten everything according to the torque specifications in your repair manual. Pay careful attention to proper alignment.
4. Final Steps:
* Lower the vehicle: Carefully lower the vehicle from the jack stands.
* Test drive: Perform a test drive to ensure proper operation and check for vibrations. If there are vibrations, a driveshaft alignment issue may be present.
Important Considerations:
* Alignment: Proper alignment is critical to avoid vibrations and premature wear. Misalignment can lead to damage to the transmission and other components.
* Torque Specifications: Always use a torque wrench and adhere to the manufacturer's specified torque values.
* Balance: New driveshafts usually come pre-balanced, but it's a good idea to have it checked and balanced professionally to avoid vibrations.
* Parts: Ensure you're using the correct replacement driveshaft for your specific vehicle.
Again, this is a simplified overview. This repair requires mechanical skills and specialized tools. If you are unsure about any step, consult a professional mechanic. Attempting this repair without proper knowledge and tools could result in damage to your vehicle or personal injury.
