Mitsubishi Outlander XL. Manual - part 546

LUBRICATION POINTS

ZC5019330000

Grease: Repair kit grease
amount used: 
 <LH> 245 ± 10 g (8.6  ± 0.3 oz)
 <RH> 255 ± 10 g (9.0 ± 0.3 oz) 

The drive shaft joint uses special
grease. do not mix old and new or 
different types of grease.

CAUTIO N

The drive shaft joint uses special
grease. do not mix old and new or
different types of grease.

CAUTIO N

Grease: Repair kit grease
amount used:  140 ± 10 g 
(4.9 ± 0.3 oz) 

DISASSEMBLY SERVICE POINT

<<A>> PTJ CASE/SPIDER ASSEMBLY REMOVAL

Do not disassemble 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.

 

<<B>> 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.

FRONT AXLE

26-31

DRIVESHAFT ASSEMBLY

ASSEMBLY SERVICE POINT

>>A<< PTJ BOOT INSTALLATION
Apply a tape to the shaft spline area. Then incorporate the PTJ
boot band (small) and PTJ boot.

 

>>B<< SPIDER ASSEMBLY/PTJ CASE INSTALLATION

｠

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

｠

If the spider assembly has been cleaned, take special care
to apply the specified grease.

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

ZC5019120000

Chamfered side

2.

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

ZC501930000

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:
245 ± 10 g (8.6 ± 0.3 ounce) LH
255 ± 10 g (9.0 ± 0.3 ounce) RH

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.

 

26-32

FRONT AXLE

DRIVESHAFT ASSEMBLY

>>C<< PTJ BOOT BAND (SMALL)/PTJ BOOT BAND
(LARGE) INSTALLATION

ZC5019140000

A

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):

95 ± 3 mm (3.74 ± 0.12 inches)

INSPECTION

M12601000038USA0000010000

｠

Check the driveshaft for damage, bending or corrosion.

｠

Check the inner shaft for damage, bending or corrosion.

｠

Check the output shaft for damage, bending or corrosion.

｠

Check the driveshaft spline part for wear or damage.

｠

Check the inner shaft spline part for wear or damage.

｠

Check the output shaft spline part for wear or damage.

｠

Check  the  spider  assembly  for  roller  rotation,  wear  or
corrosion.

｠

Check the groove inside PTJ case for wear or corrosion.

｠

Check the boots for deterioration, damage or cracking.

｠

Check  the  center  bearing  for  seizure,  discoloration  or
roughness of rolling surface.

｠

Check the dust cover for damage or deterioration.

EBJ BOOT REPLACEMENT

M12601000075USA0000010000

Required Special Tool:

MB991561:Boot Band Crimping Tool

ZC5019550000

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.

FRONT AXLE

26-33

DRIVESHAFT ASSEMBLY

ZC5019560000

4.

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

ZC5019570000

W

MB991561

Stopper

Adjusting bolt

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)

｠

If it is larger than 2.9 mm (0.11 inch)
Tighten the adjusting bolt.

｠

If it is smaller than 2.9 mm (0.11 inch)
Loosen the adjusting bolt.

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.

ZC5019580000

Boot

A

Boot band
(small)

B

Projection

6.

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

 

ZC5019590000

MB991561

｠

Secure  the  driveshaft  in  an  upright  position  and  clamp
part of the boot band to be crimped securely in the jaws
of the special tool MB991561.

｠

Crimp the boot band until special tool MB991561 touches
the stopper.

7.

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

26-34

FRONT AXLE

DRIVESHAFT ASSEMBLY