Mitsubishi Outlander 2003-06

Removal & Installation

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  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:

    Rear wheel
     

  6.  
  7. Prevent the hub assembly from turning by using a tool such as MB990767 and remove the halfshaft nut and washer.

    Anti-lock Brake System (ABS) sensor, if equipped
     
    Brake drum and shoes, if equipped with drum brakes
     
    Brake hydraulic line from the wheel cylinder
     
    Parking brake cable from the rear brakes
     
    Lower end of the shock absorber from the knuckle
     
    Trailing and lower arms from the knuckle
     
    Toe control arm ball joint from the knuckle
     

  8.  
  9. Remove the differential mount support.
  10.  


WARNING
Do not pull on the halfshaft to remove it from the differential. Damage to the inner CV-joint will occur.

  1. Push the lower part of the knuckle outward and pry the inner halfshaft out of the differential.
  2.  
  3. Push the outer end of the halfshaft through the hub/knuckle and remove it.
  4.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the rear halfshaft assembly-AWD vehicles

  1. Install the outer end of the halfshaft through the hub/knuckle.
  2.  
  3. Place a new circlip on the inner halfshaft and install the halfshaft in the differential.
  4.  
  5. Install or connect the following:

    Differential mount support
     
    Washer and a new nut on the end of the halfshaft. Tighten the nut to 160-201 ft. lbs. (226-274 Nm).
     
    Toe control arm to the knuckle. Tighten the new nut to 20 ft. lbs. (28 Nm).
     
    Lower and trailing arms to the knuckle. Do not tighten the fasteners at this time.
     
    Shock absorber. Tighten the bolt to 70 ft. lbs. (95 Nm).
     

  6.  
  7. Assemble the brake components.
  8.  
  9. Install or connect the following:

    Rear wheel speed sensor
     
    Rear wheel and lower the vehicle to the floor. Tighten the lower arm nut to 71 ft. lbs. (98 Nm) and the trailing arm nut to 85-99 ft. lbs. (118-137 Nm).
     

  10.  

Front



  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 and the transfer case fluid, if AWD.
  6.  
  7. Remove the wheel and tire assembly.
  8.  
  9. Remove the cotter pin, halfshaft nut and washer.
  10.  
  11. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor and harness bracket.
  12.  
  13. 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
     

  14.  
  15. 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.
    4.  

  16.  


WARNING
When pulling the halfshaft from the transaxle, be careful that the spline of the halfshaft does not damage the oil seal.

  1. Insert a prybar between the transaxle case and halfshaft, then pry the halfshaft out of the transaxle.
  2.  
  3. If the inner shaft is difficult to remove, tap the bracket assembly lightly with a plastic hammer, then remove the inner shaft.
  4.  
  5. Cover the halfshaft opening in the transaxle case to prevent foreign debris from entering.
  6.  


NOTE
Do not pull on the shaft; doing so damages the inboard joint.

  1. For AWD vehicles, Use Mitsubishi Special tool No. MB991721 to remove the output shaft.
  2.  


    Click image to see an enlarged view

    Fig. Exploded view of the halfshaft mounting


To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. If AWD, install the output shaft.
  4.  


NOTE
When installing the output shaft, halfshaft or halfshaft and inner shaft assembly, make sure the splines do not damage the oil seal.

  1. Insert the halfshaft or halfshaft and inner shaft into the transaxle. Be sure it is fully seated.
  2.  
  3. Push out on the knuckle assembly and install the halfshaft through the hub.
  4.  
  5. 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).
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Install the stabilizer link and rubber insulator.
  12.  
  13. Install the brake hose bracket.
  14.  
  15. Install the ABS sensor harness bracket and ABS sensor, if equipped.
  16.  
  17. 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.
  18.  
  19. Install the wheel and lower the vehicle to the floor.
  20.  
  21. Fill the transaxle and transfer case, if equipped, with fluid.
  22.  

Rear




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. Drain the gear oil. Remove the tire and wheel assembly.
  6.  
  7. Remove the halfshaft nut and washer.
    NOTE
    Prevent the hub assembly from turning by using a tool such as MB990767 and remove the halfshaft nut and washer.

  8.  
  9. Remove the ABS sensor, if equipped.
    NOTE
    Be careful not to strike the pole piece at the tip of the rear wheel speed sensor, as damage may result.

  10.  
  11. Disconnect the lower arm and trailing arm connection.
  12.  
  13. Disconnect the control link and trailing arm connection.
  14.  
  15. Remove the halfshaft and circlip.

    Click image to see an enlarged view

    Fig. Rear halfshaft assembly-AWD vehicle

  16.  

To install:

  1. Replace the circlip on the end of the halfshaft. Install the halfshaft.
  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Fill the differential with the proper grade and type fluid.
  6.  
  7. Check and adjust the rear alignment, as required.
  8.  

 
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