Mitsubishi Outlander 2003-06

Halfshafts

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Removal & Installation




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 the vehicle and support it safely.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Drain the transfer case, if equipped with AWD.
  8.  
  9. Remove the wheel and tire assembly.
  10.  
  11. Disconnect the front exhaust pipe.
  12.  
  13. Remove the cotter pin, halfshaft nut and washer.
  14.  
  15. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor and harness bracket.
  16.  
  17. Remove or disconnect the following:

    Brake hose bracket
     
    Self-locking nut
     
    Stabilizer rubber insulator
     
    Stabilizer link assembly
     
    Lower control arm ball joint and tie rod end from the steering knuckle
     

  18.  
  19. To remove the halfshaft or halfshaft and inner shaft as follows:
    1. Use Mitsubishi Special tool Nos. MB990241, MB991354 and MB990767, or suitable puller, to push the halfshaft or halfshaft and inner shaft assembly from the hub.
    2.  
    3. Remove the halfshaft from the hub by pulling the bottom of the rotor toward you.
      WARNING
      When pulling the halfshaft from the transaxle, be careful that the spline of the halfshaft does not damage the oil seal.

    4.  
    5. Insert a prybar between the transaxle case and halfshaft, then pry the halfshaft out of the transaxle.
    6.  
    7. If the inner shaft is difficult to remove, tap the bracket assembly lightly with a plastic hammer, then remove the inner shaft.
    8.  
    9. Cover the halfshaft opening in the transaxle case to prevent foreign debris from entering.
      NOTE
      Do not pull on the shaft; doing so damages the inboard joint.

    10.  

  20.  
  21. For AWD vehicles, Use Mitsubishi Special tool No. MB991721 to remove the output shaft.

    Click image to see an enlarged view

    Fig. Front halfshaft and related components

  22.  

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. If AWD, install the output shaft.
    NOTE
    When installing the output shaft, halfshaft or halfshaft and inner shaft assembly, make sure the splines do not damage the oil seal.

  4.  
  5. Insert the halfshaft or halfshaft and inner shaft into the transaxle. Be sure it is fully seated.
  6.  
  7. Push out on the knuckle assembly and install the halfshaft through the hub.
  8.  
  9. Install the self-locking nut. Tighten the nut so the protruding length of the stabilizer link is 0.35-0.39 inches (9.0-9.8mm).
  10.  
  11. Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.
  12.  
  13. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.
  14.  
  15. Install the stabilizer link and rubber insulator.
  16.  
  17. Install the brake hose bracket.
  18.  
  19. Install the ABS sensor harness bracket and ABS sensor, if equipped.
  20.  
  21. Install the washer so the chamfered edge faces outward. Install the halfshaft nut and tighten to 160-201 ft. lbs. (226-274 Nm). Secure with a new cotter pin.
  22.  
  23. Install the wheel and lower the vehicle to the floor.
  24.  
  25. Fill the transaxle and transfer case, if equipped, with fluid.
  26.  

 
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