Mitsubishi Outlander (2003+). Manual — part 236

DRIVE SHAFT ASSEMBLY

REAR AXLE <4WD>

27B-15

DISASSEMBLY SERVICE POINTS

<<A>> TJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION

Do not disassemble the spider assembly.
1. Wipe off grease from the TJ case and spider

assembly.

2. If there is water or foreign material in the wiped

grease, be sure to clean the spider assembly.

<<B>> TJ BOOT/BJ BOOT REMOVAL

1. Wipe off grease from the shaft spline part.
2. Wrap plastic tape around the spline part on the TJ

side of the drive shaft so that TJ and BJ boots are
not damaged when they are removed.

REASSEMBLY SERVICE POINTS

>>A<< BJ BOOT/TJ BOOT INSTALLATION
Wrap plastic tape around the spline part on the TJ
side of the drive shaft, and then install BJ and TJ
boots.

>>B<< SPIDER ASSEMBLY/TJ CASE
INSTALLATION

CAUTION

•

The drive shaft 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

2. Install the spider assembly to the shaft from the

direction of the spline chamfered side.

3. After applying the specified grease to the TJ case,

insert the driveshaft and apply grease one more
time.

Specified grease: Repair kit grease
Used amount: 110

±

10 g

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

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

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

Standard value (A): 80

±

3 mm

ACX02368AB

Plastic tape

AC102654AC

Chamfered
side

AC102656 AC

AC102657

A

AC

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-16

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL AND INSTALLATION

M1272002000254

Pre-removal Operation

•

Main Muffler and Centre Exhaust Pipe Removal (Refer to

GROUP 15, Exhaust Pipe and Muffler

P.15-13

).

•

Differential Gear Oil Draining

•

Drive Shaft Removal (Refer to

P.27B-10

).

Post-installation Operation

•

Drive Shaft Installation (Refer to

P.27B-10

).

•

Differential Gear Oil Filling (Refer to

P.27B-7

).

•

Main Muffler and Centre Exhaust Pipe Installation (Refer

to GROUP 15, Exhaust Pipe and Muffler

P.15-13

).

•

Rear Wheel Alignment Check and Adjustment (Refer to

GROUP 34, On-vehicle Service

−

Rear Wheel Alignment

Check and Adjustment

P.34-7

).

AC304071

90 ± 10 N·m

N

3

90 ± 10 N·m

4

44 ± 9 N·m

2

9

13

7

5

70 ± 10 N·m

90 ± 10 N·m

32 ± 2 N·m

1

AC

49 ± 9 N·m

64 ± 4 N·m

N

N

N

12

11

10

8

6

Removal steps

<<A>> >>B<<

1. Propeller shaft connection
2. Self-locking nut
3. Dynamic damper
4. Differential support arm connecting

bolt

5. Self-locking nut
6. Rear differential support weiht

7. Differential support arm

>>A<<

8. Breather hose assembly
9. Differential mount bracket bolt
10. Lower stopper
11. Upper stopper
12. Differential mount bracket
13. Differential carrier assembly

Removal steps (Continued)

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-17

REMOVAL SERVICE POINTS

<<A>> PROPELLER SHAFT DISCONNECTION

1. Make mating marks on the differential companion

flange and the propeller shaft assembly.

2. Suspend the removed propeller shaft from the

body with a wire to prevent bending.

INSTALLATION SERVICE POINTS

>>A<< BREATHER HOSE ASSEMBLY
INSTALLATION

CAUTION

Be careful not to apply grease, water or soapy
water to the hose inlet.

Fully insert the breather hose into the vent plug.
Install the breather hose pad as shown in the
illustration.

>>B<< PROPELLER SHAFT INSTALLATION
Align the mating marks of differential companion
flange and propeller shaft assembly.

DIFFERENTIAL SUPPORT MEMBER
BUSHING REPLACEMENT

M1272001400077

<DIFFERENTIAL MOUNT BRACKET>

1. Use special tool rear suspension bushing arbor

(MB990883) to remove or install the bushing.

2. Press-fit the bushing with its hollow portion facing

in the direction shown.

3. Press-fit the bushing until the bushing outer case

end face is flush with the differential mount
bracket.

AC300150AC

Marking

Marking

Differential
companion flange

Propeller shaft
assembly

AC211428AD

Vent plug

Drive shaft

Pad

Breather hose assembly

Differential case

AC107255

MB990883

Differential
mount bracket

Bushing

Iron piece

Hollow
portion

AB

DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE <4WD>

27B-18

<DIFFERENTIAL SUPPORT ARM>

1. Use special tool mont bushing arbor (MB990984)

to remove or install the bushing.

2. Press-fit the bushing with its marks facing in the

direction shown.

3. Press-fit the bushing until the bushing outer case

end face is flush with the differential support arm.

AC107256

MB990984

Differential
support arm

Bushing

Iron piece

LH side

RH side

45˚

Bushing

Marks

AB

Bushing

Marks