Mitsubishi Outlander manuals

Mitsubishi Outlander: Driveshaft Assembly

REMOVAL AND INSTALLATION

CAUTION

Pre-removal operation

Post-installation operation

<FWD>

Mitsubishi Outlander. Front Axle

Removal steps

  1. Cotter pin
  2. Driveshaft nut
  3. Washer
  4. Front wheel speed sensor
  5. Front wheel speed sensor harness bracket
  6. Brake hose bracket
  7. Stabilizer link connection
  8. Self-locking nut (lower arm ball joint connection)
  9. Self-locking nut (tie-rod end connection)
  10. Driveshaft assembly
  11. Driveshaft
  12. Circlip

<AWD>

Mitsubishi Outlander. Front Axle

Removal steps

  1. Cotter pin
  2. Driveshaft nut
  3. Washer
  4. Front wheel speed sensor
  5. Front wheel speed sensor harness bracket
  6. Brake hose bracket
  7. Stabilizer link connection
  8. Self-locking nut (lower arm ball joint connection)
  9. Self-locking nut (tie-rod end connection)
  10. Driveshaft assembly
  11. Driveshaft
  12. Circlip
  13. Heat protector <3.0L engine without S-AWC>

Required Special Tools:

REMOVAL SERVICE POINTS

DRIVESHAFT NUT REMOVAL

CAUTION Do not apply the vehicle weight on the wheel bearing with the driveshaft nut loosened. Otherwise, the wheel bearing may be broken.

Use special tool MB990767 to counter the hub as shown in the figure to remove the driveshaft nut.

Mitsubishi Outlander. Front Axle

STABILIZER LINK DISCONNECTION

Use a hexagon wrench to remove the stabilizer link and strut connection nut as shown in the figure.

Mitsubishi Outlander. Front Axle

SELF-LOCKING NUT (TIE-ROD END CONNECTION) REMOVAL

CAUTION

1. Install special tool MB991897 or MB992011, as shown in the figure.

Mitsubishi Outlander. Front Axle

2. Turn the bolt and knob to make the special tool jaws parallel, then hand-tighten the bolt. After tightening, check that the jaws are still parallel.

NOTE: To adjust the special tool jaws to be parallel, set the orientation of the knob as shown in the figure.

3. Unscrew the bolt to disconnect the ball joint.

Mitsubishi Outlander. Front Axle

DRIVESHAFT ASSEMBLY REMOVAL

CAUTION

Mitsubishi Outlander. Front Axle

1. If the driveshaft is seized with the hub, use special tools MB990242 and MB990244, MB990767 and MB991354 to push the driveshaft assembly out from the hub.

Mitsubishi Outlander. Front Axle

2. While pulling the lower side of the brake disk toward you, remove the driveshaft assembly from the hub.

Mitsubishi Outlander. Front Axle

CAUTION

3. For driveshafts other than FWD-RH driveshafts, insert a lever between the transaxle case or transfer and driveshaft assembly, and then pull the driveshaft assembly out from the transaxle.

Mitsubishi Outlander. Front Axle

CAUTION

Do not apply the vehicle weight to the wheel bearing with the driveshaft assembly removed. If, however, the vehicle weight shall be applied to the bearing (in order to move the vehicle), tighten the following special tools MB991000 and MB991017 to the specified torque 144 − 176 N*m (107 − 129 ft-lb).

Mitsubishi Outlander. Front Axle

INSTALLATION SERVICE POINTS

DRIVESHAFT ASSEMBLY INSTALLATION

CAUTION

Mitsubishi Outlander. Front Axle

STABILIZER LINK CONNECTION

Use a hexagon wrench to install the stabilizer link and strut connection nut as shown in the figure.

Mitsubishi Outlander. Front Axle

WASHER/DRIVESHAFT NUT INSTALLATION

CAUTION Do not apply the vehicle weight on the front wheel hub assembly before fully tightening the driveshaft nut. Otherwise, the wheel bearing may be broken.

1. Incorporate the driveshaft assembly washer as shown in the illustration.

2. Use special tool MB990767 to tighten the driveshaft nuts. At this time, tighten the nuts within the specified torque range considering the final tightening.

Tightening torque: 144 − 176 N*m (107 − 129 ft-lb)

3. If the pin holes do not align with the pins, tighten the driveshaft nut [less than 200 N*m(147 ft-lb) ] and find the nearest hole then bend the cotter pin to fit it.

Mitsubishi Outlander. Front Axle

DISASSEMBLY AND ASSEMBLY <2.4L ENGINE- FWD>

CAUTION As for the EBJ assembly, only the EBJ boot can be replaceable, and other parts cannot be disassembled.

Mitsubishi Outlander. Front Axle

Mitsubishi Outlander. Front Axle

Disassembly steps

  1. PTJ boot band (large)
  2. PTJ boot band (small)
  3. Circlip
  4. PTJ case/Inner shaft assembly
  5. Dust cover <LH>
  6. PTJ case <LH>
  7. Circlip
  8. Snap ring
  9. Spider assembly
  10. PTJ boot
  11. EBJ assembly
  12. EBJ boot band (small)
  13. EBJ boot band (large)
  14. EBJ boot

Required Special Tools:

LUBRICATION POINTS

Mitsubishi Outlander. Front Axle

DISASSEMBLY SERVICE POINTS

PTJ CASE/INNER SHAFT ASSEMBLY REMOVAL

CAUTION When removing the PTJ case and inner shaft assembly, be careful not to drop off the roller part of spider assembly, because it easily departs from the spider assembly.

PTJ BOOT REMOVAL

1. Wipe off grease from the shaft spline.

2. When reusing the PTJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

ASSEMBLY SERVICE POINTS

EBJ BOOT INSTALLATION

Wrap plastic tape around the shaft spline, and then install the EBJ boot.

PTJ BOOT INSTALLATION

Wrap plastic tape around the shaft spline, and then install the PTJ boot.

SPIDER ASSEMBLY INSTALLATION

CAUTION

1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.

Specified grease: Repair kit grease

2. Install the spider assembly to the shaft from the direction of the spline chamfered side.

Mitsubishi Outlander. Front Axle

PTJ CASE/INNER SHAFT ASSEMBLY INSTALLATION

CAUTION The driveshaft joint uses special grease. Do not mix old and new or different types of grease.

After applying the specified grease to the PTJ case, insert the driveshaft and apply grease again.

Specified grease: Repair kit grease
Amount to use: 210 +- 10 g (7.4 +- 0.3 ounce) <LH>, 225 +- 10 g (7.9 +- 0.3 ounce) <RH>

NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

Mitsubishi Outlander. Front Axle

PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION

Set the PTJ boot bands at the specified distance in order to adjust the amount of air inside the PTJ boot, and then tighten the PTJ boot band (small), PTJ boot band (large) securely.

Standard value (A): 85 +- 3 mm (3.35 +- 0.12 inches)

Mitsubishi Outlander. Front Axle

DISASSEMBLY AND ASSEMBLY <3.0L ENGINE- FWD>

CAUTION As for the EBJ assembly, only the EBJ boot can be replaceable, and other parts cannot be disassembled.

Mitsubishi Outlander. Front Axle

Disassembly steps

  1. PTJ boot band (large)
  2. PTJ boot band (small)
  3. Circlip
  4. PTJ case and inner shaft assembly <RH>
  5. Dust cover <LH>
  6. PTJ case <LH>
  7. Circlip
  8. Snap ring
  9. Spider assembly
  10. PTJ boot
  11. EBJ assembly
  12. EBJ boot band (small)
  13. EBJ boot band (large)
  14. EBJ boot

Required Special Tools:

LUBRICATION POINTS

Mitsubishi Outlander. Front Axle

DISASSEMBLY SERVICE POINTS

PTJ CASE/INNER SHAFT ASSEMBLY REMOVAL

CAUTION When removing the PTJ case and inner shaft assembly, be careful not to drop off the roller part of spider assembly, because it easily departs from the spider assembly.

PTJ BOOT REMOVAL

1. Wipe off grease from the shaft spline.

2. When reusing the PTJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

ASSEMBLY SERVICE POINTS

EBJ BOOT INSTALLATION

Wrap plastic tape around the shaft spline, and then install the EBJ boot.

PTJ BOOT INSTALLATION

Wrap plastic tape around the shaft spline, and then install the PTJ boot.

SPIDER ASSEMBLY INSTALLATION

CAUTION

1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.

Specified grease: Repair kit grease 2. Install the spider assembly to the shaft from the direction of the spline chamfered side.

Mitsubishi Outlander. Front Axle

PTJ CASE AND INNER SHAFT ASSEMBLY INSTALLATION

CAUTION The driveshaft joint use special grease. Do not mix old and new or different types of grease.

After applying the specified grease the PTJ case, insert the driveshaft and apply grease one more time.

Specified grease: Repair kit grease
Amount to use:
245 +- 10 g (8.6 +- 0.3 ounce) <LH>
255 +- 10 g (9.0 +- 0.3 ounce) <RH>

NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

Mitsubishi Outlander. Front Axle

PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION

Set the PTJ boot bands at the specified distance in order to adjust the amount of air inside the PTJ boot, and then tighten the PTJ boot band (small), PTJ boot band (large) securely.

Standard value (A):
95 +- 3 mm (3.74 +- 0.12 inches)

Mitsubishi Outlander. Front Axle

DISASSEMBLY AND ASSEMBLY <AWD>

CAUTION

Mitsubishi Outlander. Front Axle

Disassembly steps

  1. Circlip
  2. PTJ boot band (large)
  3. PTJ boot band (small)
  4. Circlip
  5. PTJ case
  6. Snap ring
  7. Spider assembly
  8. PTJ boot
  9. EBJ boot band (large)
  10. EBJ boot band (small)
  11. EBJ boot
  12. EBJ assembly

LUBRICATION POINTS

Mitsubishi Outlander. Front Axle

DISASSEMBLY SERVICE POINT

PTJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION

When removing the PTJ case, be careful not to drop off the roller part of spider assembly, because it easily departs from the spider assembly.

1. Wipe off grease from the spider assembly and the inside of the PTJ case.

2. Always clean the spider assembly when the grease contains water or foreign material.

PTJ BOOT REMOVAL

1. Wipe off the grease on the shaft spline.

2. When reusing the TJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

ASSEMBLY SERVICE POINT

PTJ BOOT INSTALLATION

Apply a tape to the shaft spline area. Then incorporate the PTJ boot band (small) and PTJ boot.

SPIDER ASSEMBLY/PTJ CASE INSTALLATION

CAUTION

1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.

Specified grease: Repair kit grease

2. Install the spider assembly to the shaft from the direction of the spline chamfered side.

Mitsubishi Outlander. Front Axle

3. After applying the specified grease to the PTJ case, insert the driveshaft and apply grease one more time.

Specified grease: Repair kit grease
Amount to use:
210 +- 10 g (7.4 +- 0.3 ounce) <2.4L Engine-LH>
200 +- 10 g (7.0 +- 0.3 ounce) <2.4L Engine-RH>
245 +- 10 g (8.6 +- 0.3 ounce) <3.0L Engine-LH>
255 +- 10 g (9.0 +- 0.3 ounce) <3.0L Engine-RH>
250 +- 10 g (8.8 +- 0.3 ounce) <3.0L Engine-RH with S-AWC>

NOTE: When using the repair kit grease, fill the half of the grease into the joint and the other half into the boot as a guideline, and consume the grease completely.

Mitsubishi Outlander. Front Axle

PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION

Adjust the distance (A shown in the illustration) between the boot bands to the standard value to adjust the air volume inside the PTJ boot to the specified value, then be sure to tighten the PTJ boot band (large) and PTJ boot band (small).

Standard value (A):
85 +- 3 mm (3.35 +- 0.12 inches) <2.4L Engine>
95 +- 3 mm (3.74 +- 0.12 inches) <3.0L Engine>

Mitsubishi Outlander. Front Axle

INSPECTION

EBJ BOOT REPLACEMENT

Required Special Tool:

1. Remove the boot bands (large and small).

NOTE: The boot bands cannot be re-used.

2. Remove the EBJ boot.

3. Wrap a plastic tape around the shaft spline, and assemble the boot band and EBJ boot.

Mitsubishi Outlander. Front Axle

4. Align the center groove on the EBJ boot small end with the shaft groove.

Mitsubishi Outlander. Front Axle

5. Turn the adjusting bolt on special tool MB991561 so that the size of the opening (W) is at the standard value.

Standard value (W): 2.9 mm (0.11 inch)

NOTE: The value of W will change by approximately 0.7 mm (0.03 inch) for each turn of the adjusting bolt.

NOTE: The adjusting bolt should not be turned more than once.

Mitsubishi Outlander. Front Axle

6. Position the EBJ boot band (small) so that there is even clearance at either end (A and B).

Mitsubishi Outlander. Front Axle

CAUTION

7. Use special tool MB991561 to crimp the boot band (small).

Mitsubishi Outlander. Front Axle

8. Check that the crimping amount (C) of the boot band is at the standard value.

Standard value (C): 2.4 − 2.8 mm (0.10 − 0.11 inch)

If the crimping amount is larger than 2.8 mm (0.11 inch)
Readjust the value of (W) in step 5 according to the following formula, and then repeat the operation in step 7.
W = 5.5 mm (0.22 inch) − C
Example: If C = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch)

If the crimping amount is smaller than 2.4 mm (0.10 inch)
Remove the EBJ boot band, readjust the value of (W) in step 5 according to the following formula, and then repeat the operations in steps 6 and 7 using a new EBJ boot band.
W = 5.5 mm (0.22 inch) − C
Example: If C = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 inch)

Mitsubishi Outlander. Front Axle

9. Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat steps 6 to 8, using a new boot band.

CAUTION The driveshaft joint uses special grease. Do not mix old and new or different types of grease.

10.Fill the inside of the boot with the specified amount of the specified grease.

Specified grease: Repair kit grease
Amount to use: 120 +- 10 g (4.2 +- 0.3 ounces) <2.4L Engine>
Amount to use: 140 +- 10 g (4.9 +- 0.3 ounces) <3.0L Engine>

11.Align the center groove on the EBJ boot big end with the EBJ case groove.

Mitsubishi Outlander. Front Axle

12.Follow the same procedure as in step 5 to adjust the size of the opening (W) on the special tool so that it is at the standard value.

Standard value (W): 3.2 mm (0.13 inch)

13.Position the EBJ boot band (large) so that there is even clearance at either end (D and E).

Mitsubishi Outlander. Front Axle

14.Use special tool MB991561 to crimp the EBJ boot band (large) in the same way as in step 7.

15.Check that the crimping amount (F) of the boot band is at the standard value.

Standard value (F): 2.4 − 2.8 mm (0.10 − 0.11 inch)

If the crimping amount is larger than 2.8 mm (0.11 inch)
Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14.
W = 5.8 mm (0.23 inch) − F
Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch)

If the crimping amount is smaller than 2.4 mm (0.10 inch)
Remove the EBJ boot band, readjust the value of (W) in step 12 according to the following formula, and then repeat the operations in steps 13 and 14 using a new EBJ boot band.
W = 5.8 mm (0.23 inch) − F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm (0.14 inch)

Mitsubishi Outlander. Front Axle

16.Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat steps 13 to 15, using a new boot band.

READ NEXT:

 Brakes and Steering

 Basic Brake

General Information Brake systems with higher reliability and durability have achieved distinguished braking performance. FEATURES IMPROVEMENT OF BRAKING PERFORMANCE In addition to the 10-inch singl

 Basic Brake System Diagnosis

INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster and disc brakes. Malfunctions such as insufficient braking power or the ge

SEE MORE:

 On-vehicle Service

STEERING WHEEL FREE PLAY CHECK 1. With the engine running (hydraulic pressure applied), position the front wheel in the straight ahead direction. 2. Measure the side to side steering wheel play until the front wheels actually start moving while turning the steering wheel slightly in the left and ri

 Engine Control

GENERAL INFORMATION For the accelerator system, the electronic throttle valve control system, disposing of the accelerator cable, is adopted. This system determines the amount of pressure applied to the accelerator pedal using the built-in accelerator pedal position sensor of the accelerator pedal

© 2010-2021 Copyright www.mioutlander.com