Mitsubishi Outlander GS45X. Manual — part 1509

DRIVESHAFT ASSEMBLY

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FRONT AXLE

26-39

<<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.

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

CAUTION

• 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

2. Install the spider assembly to the shaft from the direction of

the spline chamfered side.

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.

.

AC703329AB

Chamfered side

AC703336AB

DRIVESHAFT ASSEMBLY

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FRONT AXLE

26-40

>>C<< 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>

INSPECTION

M1261003800323

• 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 corro-

sion.

• 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

M1261007500238

Required Special Tool:

• MB991561:Boot Band Crimping 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.

AC703337 AB

A

AC505563 AB

DRIVESHAFT ASSEMBLY

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FRONT AXLE

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

shaft groove.

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.

6. Position the EBJ boot band (small) so that there is even

clearance at either end (A and B).

CAUTION

• 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).

AC703341AB

AC703342 AB

W

MB991561

Stopper

Adjusting bolt

AC703343 AB

Boot

A

Boot band
(small)

B

Projection

AC606919

MB991561

AD

DRIVESHAFT ASSEMBLY

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FRONT AXLE

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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)

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.

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)

AC606920

C

AF

AC703346 AB