Mitsubishi Outlander XL. Manual - part 545

ZC5019120000

Chamfered side

2.

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

 

>>B<< CENTER BEARING RH INSTALLATION

ZC5019010000

MB990938

MB990932

Center bearing bracket

Use  special  tools  MB990938  and  MB990932  to  press-fit  the
center bearing into the center bearing bracket.

 

>>C<< DUST SEAL INNER RH /DUST SEAL OUTER RH
INSTALLATION

When applying grease, make sure that it does not adhere to
anything outside the lip.

1.

Apply the specified grease to the rear surface of all dust seals.

Specified grease: Repair kit grease

Amount used:
Dust seal inner: 8 - 12 g (0.3 - 0.4 ounce)
Amount used:
Dust seal outer: 3 - 7 g (0.1 - 0.2 ounce)

ZC5019020000

MB990890

Dust 
seal
inner

2.

Use special tools MB990890, MB990938, and MB990934 to
press the dust seals into the center bearing bracket until they
are flush with each other.

3.

Apply repair kit grease to the lip of each dust seal.

FRONT AXLE

26-27

DRIVESHAFT ASSEMBLY

ZC5019030000

MB990938

MB990934

MB990890

Dust seal
outer

 

>>D<< INNER SHAFT RH INSTALLATION

ZC5019040000

MB991172

Inner shaft

1.

Use special tool MB991172 to hold the center bearing inner
race, and then press-in the inner shaft.

 

>>E<< SEAL PLATE/PTJ CASE AND INNER SHAFT
ASSEMBLY INSTALLATIONRH

ZC5019050000

PTJ case

Inner shaft

1.

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.

ZC5019210000

MD998369

Seal plate

2.

Use special tool MD998369 to press in the seal plate.

 

26-28

FRONT AXLE

DRIVESHAFT ASSEMBLY

ZC501930000

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

3.

After applying the specified grease the PTJ case, insert the
driveshaft and apply grease one more time.

Specified grease: Repair kit grease
Amount to use:
255 ± 10 g (9.0 ± 0.3 ounce) RH
245 ± 10 g (8.6 ± 0.3 ounce) LH

NOTE: 

The grease in the repair kit should be divided in

half for use, respectively, at the joint and inside the
boot.

 

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

ZC5019140000

A

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):

95 ± 3 mm (3.74 ± 0.12 inches)

DISASSEMBLY AND ASSEMBLY <AWD>

M12601000037USA0000010001

As for the EBJ assembly, only the EBJ boot can
be  replaceable,  and  other  parts  cannot  be
disassembled.

FRONT AXLE

26-29

DRIVESHAFT ASSEMBLY

ZC5019320000

EBJ grease

PTJ grease

4

3

1

2

5

6

8

N

N

N

11

N

N

12

1

5

2

3

8

1

4

5

6

2

3

8

1

5

11

3

2

9

EBJ boots repair kit

PTJ boots repair kit

PTJ repair kit

10

9

4

1

N

<RH>

<LH>

10

7

7

7

7

Disassembly steps

1.

Circlip

>>C<<

2.

PTJ boot band (large)

>>C<<

3.

PTJ boot band (small)

<<A>>

>>B<<

4.

PTJ case

5.

Snap ring

<<A>>

>>B<<

6.

Spider assembly

7.

Circlip

Disassembly steps

<<B>>

>>A<<

8.

PTJ boot

9.

EBJ boot band (large)

10. EBJ boot band (small)
11. EBJ boot
12. EBJ assembly

26-30

FRONT AXLE

DRIVESHAFT ASSEMBLY