Mitsubishi Outlander (2003+). Manual - part 228

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-17

<<B>> SELF-LOCKING NUT (TIE ROD END 
CONNECTION) REMOVAL

CAUTION

•

Do not remove the nut from ball joint. Loosen 
it and use special tool to avoid possible 
damage to ball joint threads.

•

Hang special tool with cord to prevent it from 
falling. 

1. Install special tool ball joint remover (MB991897) 

as shown in the figure.

2. Turn the bolt and knob as necessary to make the 

jaws of special tool parallel, tighten the bolt by 
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make 
sure the knob is in the position shown in the 
figure.

3. Tighten the bolt with a wrench to disconnect the 

tie rod end.

<<C>> DRIVE SHAFT/DRIVE SHAFT AND INNER 
SHAFT ASSEMBLY <2WD-RH> REMOVAL

1. Use the following special tools to push out the 

drive shaft or the drive shaft and inner shaft 
assembly from the hub.

•

Puller shaft (MB990242)

•

Puller bar (MB990244)

•

Puller body (MB991354)

•

End yoke holder (MB990767)

2. Remove the drive shaft from the hub by pulling 

the bottom of the brake disc towards you.

CAUTION

•

Do not pull on the drive shaft; doing so will 
damage the PTJ; be sure to use the pry bar.

•

When pulling the drive shaft out from the 
transmission, be careful that the spline part of 
the drive shaft does not damage the oil seal.

AC208247AD

Cord

Bolt

MB991897

Nut

Ball joint

AC106821

Knob

Parallel

Bolt

Correct

Wrong

AD

AC102550

MB990244
(Three)

MB991354

MB990242

MB990767

AC

AC102551AC

Drive shaft

AC100141

Transmission

PTJ assembly

Pry bar

AF

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-18

3. Insert a pry bar between the transmission case 

and the drive shaft, and then pry and remove the 
drive shaft from the transmission.

4. If the inner shaft is hard to remove from the 

transmission, strike the bracket assembly lightly 
with a plastic hammer and remove the inner shaft. 

5. Use special tool plug (MB991460) to prevent the 

entry of foreign material into the transmission 
case.

CAUTION

Do not apply pressure to the wheel bearing by 
the vehicle weight to avoid possible damage 
when the drive shaft is removed. If, however, 
vehicle weight must be applied to the bearing in 
moving the vehicle, temporarily secure the wheel 
bearing by using the following special tools. 

•

Spacer (MB991000)

•

Front hub remover and installer (MB991017)

<<D>> OUTPUT SHAFT <4WD> REMOVAL

CAUTION

When pulling the output shaft out from the 
transmission, be careful that the spline part of 
the output shaft does not damage the oil seal.

Use special tool sliding hammer (MB991721) to 
remove the output shaft.

INSTALLATION SERVICE POINTS

>>A<< OUTPUT SHAFT <4WD>/DRIVE 
SHAFT/DRIVE SHAFT AND INNER SHAFT 
ASSEMBLY <2WD-RH> INSTALLATION

CAUTION

When installing the output shaft, the drive shaft 
or the drive shaft and inner shaft assembly, be 
careful that the spline part of the output shaft, the 
drive shaft or the drive shaft and inner shaft 
assembly do not damage the oil seal.

>>B<< SELF-LOCKING NUT INSTALLATION

Tighten the self-locking nut so that the protruding 
length of the stabilizer link protruding part meets its 
standard value (A).

Standard value (A): 9.4 

±

 0.4 mm

AC102553 AC

Bracket assembly

AC102554

MB991460

AC

AC102555 AC

MB991017

MB991000

AC102556

MB991721

Output shaft

AC

AC107031

AC107031

AB

A

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-19

>>C<< WASHER/DRIVE SHAFT NUT 
INSTALLATION

1. Be sure to install the drive shaft washer in the 

specified direction.

CAUTION

Before securely tightening the drive shaft nuts, 
make sure there is no load on the wheel 
bearings. Otherwise the wheel bearing will be 
damaged.
2. Using special tool end yoke holder (MB990767), 

tighten the drive shaft nut to the specified torque.

Tightening torque: 245 

±

 29 N

⋅

m 

AC102465AD

MB990767

Washer

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-20

DISASSEMBLY AND REASSEMBLY

M1261003700531

CAUTION

•

Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly 
and reassembly.

•

Never disassemble the BJ assembly except when replacing the BJ boot.

AC101959

2

1

15

14

13

4

12

8

11

10

9

7

12

4

12

4

16

17

6

5

6

3

9

10

8

12

9

10

11

8

12

12

13

15

1

2

12

4

13

14

15

1

2

12

13

1

2

20

19

N

N

N

N

N

<2WD-RH>

<2WD-LH>

<4WD>

18

20

21

19

16

21

N

N

Grease
for PTJ

Grease
for BJ

BJ boot repair kit

PTJ boot repair kit

PTJ repair kit

Bracket assembly repair kit

Bearing dust seal repair kit

AD

N

Disassembly steps

>>G<<

1.

PTJ boot band (large)

>>G<<

2.

PTJ boot band (small)

3.

PTJ case and inner shaft assembly 
<2WD-RH>

<<A>>

>>F<<

4.

PTJ case

<<B>>

>>E<<

5.

Inner shaft <2WD-RH>

6.

Dust cover <2WD-RH>

7.

Bracket assembly <2WD-RH>

>>D<<

8.

Dust sear outer <2WD-RH>

>>D<<

9.

Dust seal inner <2WD-RH>

<<C>>

>>C<<

10. Centre bearing <2WD-RH>
11. Centre bearing bracket <2WD-RH>
12. Circlip
13. Snap ring

<<A>>

>>B<<

14. Spider assembly

<<D>>

>>A<<

15. PTJ boot

>>A<<

16. Damper band

>>A<<

17. Dynamic damper

Disassembly steps (Continued)