Mitsubishi Outlander GS45X. Manual - part 1509

DRIVESHAFT ASSEMBLY

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<<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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>>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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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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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