Mitsubishi Outlander 2003-06

Overhaul

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NOTE
If the vehicle is equipped with ABS, do not strike the ABS rotors installed to the outer BL outer race of the halfshaft against other parts when removing or installing the halfshaft. Otherwise the ABS rotors will be damaged.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Halfshaft assembly from the vehicle
     
    Large Pillow Tripod Joint (PTJ) boot band
     
    Small PTJ boot band
     
    PTJ case and inner shaft assembly, right side FWD vehicles
     
    PTJ case
     
    Inner shaft and dust cover, right side FWD vehicles
     
    Bracket assembly, right side FWD vehicles
     
    Outer and inner dust seals, right side FWD vehicles
     
    Center bearing and bracket, right side FWD vehicles
     
    Circlip
     
    Snapring
     
    Spider assembly
     
    PTJ boot
     
    Damper band
     
    Dynamic Damper
     
    Birfield Joint (BJ) assembly
     
    Small and large BJ boot bands
     
    BJ boot

    Click image to see an enlarged view

    Fig. Front halfshaft assembly exploded view



    Click image to see an enlarged view

    Fig. Front halfshaft assembly lubrication points and grease specifications

     

  6.  

To install:


NOTE
Refer to the illustration for the lubrication points and grease specifications.



BJ boot
 
Large and small BJ boot bands
 
BJ assembly
 
Dynamic Damper
 
Damper band
 
PTJ boot
 
Spider assembly.
 
Snapring
 
Circlip
 
Center bearing and bracket, right side FWD vehicles
 
Outer and inner dust seals, right side FWD vehicles
 
Bracket assembly, right side FWD vehicles
 
Inner shaft and dust cover, right side FWD vehicles
 
PTJ case
 
PTJ case and inner shaft assembly, right side FWD vehicles
 
Small PTJ boot band
 
Large PTJ boot band
 
Halfshaft assembly into the vehicle
 


NOTE
If the vehicle is equipped with ABS, do not strike the ABS rotors installed to the outer BL outer race of the halfshaft against other parts when removing or installing the halfshaft. Otherwise the ABS rotors will be damaged.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Halfshaft assembly from the vehicle
     
    Large and small Tripod Joint (TJ) boot bands
     
    TJ case
     
    Circlip
     
    Snapring
     
    Spider assembly
     
    TJ boot
     
    Large and small Birfield Joint (BJ) boot bands
     
    BJ boot
     
    BJ assembly

    Click image to see an enlarged view

    Fig. Rear halfshaft assembly exploded view



    Click image to see an enlarged view

    Fig. Rear halfshaft assembly lubrication points and grease specifications

     

  6.  

To install:



BJ assembly
 
BJ boot
 
Small and large Birfield Joint (BJ) boot bands
 
TJ boot
 
Spider assembly
 
Snapring
 
Circlip
 
TJ case
 
Small and large TJ boot bands
 
Halfshaft assembly to the vehicle
 

Front Shaft



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Halfshaft assembly from the vehicle
     
    Large Pillow Tripod Joint (PTJ) boot band
     
    Small PTJ boot band
     
    PTJ case and inner shaft assembly, right side FWD vehicles
     
    PTJ case
     
    Inner shaft and dust cover, right side FWD vehicles
     
    Bracket assembly, right side FWD vehicles
     
    Outer and inner dust seals, right side FWD vehicles
     
    Center bearing and bracket, right side FWD vehicles
     
    Circlip
     
    Snapring
     
    Spider assembly
     
    PTJ boot
     
    Damper band
     
    Dynamic Damper
     
    Birfield Joint (BJ) assembly
     
    Small and large BJ boot bands
     
    BJ boot
     

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the front halfshaft assembly



    Click image to see an enlarged view

    Fig. Halfshaft assembly lubrication points and grease specifications


To install:


NOTE
Refer to the illustration for the lubrication points and grease specifications.



BJ boot
 
Large and small BJ boot bands
 
BJ assembly
 
Dynamic Damper
 
Damper band
 
PTJ boot
 
Spider assembly.
 
Snapring
 
Circlip
 
Center bearing and bracket, right side FWD vehicles
 
Outer and inner dust seals, right side FWD vehicles
 
Bracket assembly, right side FWD vehicles
 
Inner shaft and dust cover, right side FWD vehicles
 
PTJ case
 
PTJ case and inner shaft assembly, right side FWD vehicles
 
Small PTJ boot band
 
Large PTJ boot band
 
Halfshaft assembly into the vehicle
 

Rear Halfshaft



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Halfshaft assembly from the vehicle
     
    Large and small Tripod Joint (TJ) boot bands
     
    TJ case
     
    Circlip
     
    Snapring
     
    Spider assembly
     
    TJ boot
     
    Large and small Birfield Joint (BJ) boot bands
     
    BJ boot
     
    BJ assembly
     

  6.  

To install:



BJ assembly
 
BJ boot
 
Small and large Birfield Joint (BJ) boot bands
 
TJ boot
 
Spider assembly
 
Snapring
 
Circlip
 
TJ case
 
Small and large TJ boot bands
 
Halfshaft assembly to the vehicle
 

 
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