Mitsubishi Outlander (2003+). Manual - part 230

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-25

2. Apply repair kit grease to the inner shaft spline, 

then press fit it into the PTJ case.
NOTE: When press-fitting the inner shaft into the 
PTJ case, apply a thin coat of repair kit grease to 
the dust seal outer lip part and the outside edge of 
the PTJ axial part.

>>F<< PTJ CASE INSTALLATION

CAUTION

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

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

Specified grease: Repair kit grease

Amount to use <2WD>: 215 

±

  10 g

Amount to use <4WD>: 150 

±

 10 g

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

>>G<< 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):

<2WD>: 90 

±

 3 mm

<4WD>: 85 

±

 3 mm

INSPECTION

M1261003800129

•

Check the drive shaft 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 drive shaft 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 dynamic damper for damage or 
cracking.

•

Check the boots for deterioration, damage or 
cracking.

•

Check the centre bearing for seizure, 
discolouration or roughness of rolling surface.

•

Check the dust cover for damage or 
deterioration.

AC101699

PTJ case

Inner shaft

AD

AC102656 AC

AC102657

A

AC

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-26

BJ BOOT (RESIN BOOT) REPLACEMENT

M1261005200338

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

NOTE: The boot bands cannot be re-used.

2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and 

assemble the boot band and BJ boot.

4. Align the centre groove on the BJ boot small end 

with the shaft groove.

5. Turn the adjusting bolt on special tool boot band 

crimping tool (MB991561) so that the size of the 
opening (W) is at the standard value.

Standard value (W): 2.9 mm

•

<If it is larger than 2.9 mm> Tighten the 
adjusting bolt.

•

<If it is smaller than 2.9 mm> Loosen the 
adjusting bolt.

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

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

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

even clearance at either end (A and B).

CAUTION

•

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

•

Crimp the boot band until special tool 
touches the stopper.

7. Use the special tool to crimp the boot band 

(small).

8. Check that the crimping amount (C) of the boot 

band is at the standard value.

Standard value (C): 2.4 

−

 2.8 mm

<If the crimping amount is larger than 2.8 mm 

>

Readjust the value of (W) in step 5 according to 

the following formula, and then repeat the 
operation in step 7.

AC102658

AC102659

AC102660

W

MB991561

Stopper

Adjusting bolt

AC

AC102661AC

Boot

A

Boot band
(small)

B

Projection

AC102663 AC

MB991561

AC102662

C

AD

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-27

W = 5.5 mm 

−

 C

Example: If C = 2.9 mm, then W = 2.6 mm.

<If the crimping amount is smaller than 2.4 

mm >

Remove the BJ 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 BJ boot band.

W = 5.5 mm 

−

 C

Example: If C = 2.3 mm, then W = 3.2 mm.

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 drive shaft 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 <2WD>: 120 

±

 10 g

Amount to use <4WD>: 85 

±

 10 g

11.Align the centre groove on the BJ boot big end 

with the BJ 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): 2.9 mm

13.Position the BJ boot band (large) so that there is 

even clearance at either end (D and E).

14.Use the special tool to crimp the BJ 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

<If the crimping amount is larger than 2.8 mm 

>

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 

−

 F

Example: If F = 2.9 mm, then W = 2.9 mm.

<If the crimping amount is smaller than 2.4 

mm >

Remove the BJ 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 BJ boot band.

W = 5.8 mm 

−

 F

Example: If F = 2.3 mm, then W = 3.5 mm.

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.

AC102664 AC

AC102665 AC

Boot

Projection

Boot band
(large)

D

E

AC102666

F

AD

NOTES