Repair Procedure
REPAIR PROCEDUREA. LEFT FRONT DRIVESHAFT (ALL)
RIGHT FRONT DRIVESHAFT FOR THE FOLLOWING VEHICLES ONLY:
^ Outlander 2.4L
^ Outlander V6 with 2WD, Outlander GT (S-AWC)
Refer to Section B for all other vehicles.
1. Replace the EBJ (outer joint) boot. Refer to Group 26 - Front Axle of the applicable Service Manual for instructions.
CAUTION!
- Thoroughly clean all of the old grease from the boot and joint. Only a small amount of grease can remain in the joint for reassembly.
NOTE:
Installing the EBJ boot securing bands requires the use of a band tightening tool such as MB991561.
The bands have a specific tightening procedure described in the service manual.
Use the small grease container (labeled NKG 509) for the EBJ. Put approximately 50% of the container in the boot and 50% in the joint.
2. Reinstall the driveshaft to the vehicle.
B. RIGHT FRONT DRIVESHAFT FOR THE FOLLOWING VEHICLES ONLY:
^ Outlander V6 4WD (except Outlander GT)
^ Lancer & Lancer Sportback 2.0L & 2.4L except Ralliart
1. Remove the affected drive shaft. Refer to Group 26 - Front Axle of the applicable Service Manual for instructions.
!!CAUTION!!
If the EBJ (outer joint) boot is damaged and the joint is exposed, replace the driveshaft assembly. Refer to CAPS for the correct part number.
Disassembly - PTJ (Inner Joint)
1. Refer to Group 26 - Front Axle of the applicable Service Manual to remove drive shaft.
NOTE:
Separate the right front outer driveshaft from the inner driveshaft at the PTJ. It is not necessary to remove the inner driveshaft from the transmission.
2. Disassemble the PTJ (inner joint) to allow installation of a smaller boot band for the EBJ (outer joint).
a. Remove the boot bands for the PTJ.
Pry the crimped tabs apart using a small screwdriver. Lift the end of the large band to release and remove it.
Repeat for the small band securing the boot to the driveshaft.
b. Slide the boot off of the PTJ case.
c. Remove the internal retaining clip to release the PTJ case from the driveshaft.
d. Remove the bearings from the spider assembly.
e. Remove the snap ring from the end of the driveshaft.
f. Remove the spider assembly from the driveshaft.
g. Remove the PTJ boot from the driveshaft.
Disassembly - EBJ (Outer Joint)
1. Release the boot band clips from the outer (EBJ) boot (see photo "a" below, left).
a. Use a screwdriver (or similar tool) and pry the end of the retaining clip tab up to release it (see photo a below). Remove the clips from the boot.
!!CAUTION!!
- Take extra care to not damage the boot. It will be reused. DO NOT slide the boot over the shoulder on the drive shaft.
b. Detach the boot from the EBJ and carefully slide it along with the drive shaft to the shoulder of the thick section of the drive shaft. This will give you better access to clean grease from both the joint and boot (see photo "b" below right).
2. Remove grease from the the joint and boot.
a. Remove as much grease as possible from the EBJ joint and boot using a plastic spoon com pressed air a trim tool or other tool that will not damage any parts. Then clean the remainder of the grease from the joint and boot by repeatedly rotating the assembly and wiping it with a clean dry lint-free cloth. Repeatedly refold your cloth and change it as necessary. Only a small amount of the original grease can remain in the joint.
^ Thoroughly clean all of the old grease from the boot and joint.
^ Only a small amount of grease can remain in the joint for reassembly.
^ DO NOT use solvent or other degreasing agents to remove grease from the boot.
Reassembly - EBJ (Outer Joint)
1. Reassemble the boot to the EBJ and secure it with new boot bands included in the boot kit using the following instructions.
NOTE:
Installing the EBJ boot securing bands requires the use of a band crimping tool such as special tool MB991561. The bands have a specific tightening procedure as described. Additional information can be found in Group 26 - Front Axle of the service manual.
a. Slide the small EBJ boot band onto the driveshaft from the disassembled PTJ side.
b. Clamp the driveshaft into a vise with the large end of the EBJ boot at the top.
c. For the small end of the boot align the rib on the inside of the boot band recess to the groove on the driveshaft.
d. Turn the adjusting bolt on special tool MB991561 so that the jaw opening (W) measures 2.9mm.
e. Center the small band in the recess of the boot and crimp it until the stopper on MB991561 bottoms.
f. Measure dimension C in the illustration.
Specification: 2.4-2.8 mm (0.095 - 0.110 in)
If the crimp measurement (c) is not to specification readjust the jaw opening (W) using the formula in the following Readjustment Procedure.
!!CAUTION!!
- If the crimp measurement (c) is less than 2.4 mm, the band must be replaced. Refer to CAPS for correct part numbers (PNC 32174B = small, 32174C = large).
Readjustment Procedure Formula
2. Fill the EBJ and boot with grease from the small container (labelled NKG509) included in the repair kit. Put approximately 50% of the container in the boot and 50% in the joint. Use all of the grease from the container in the joint and boot. Fit the boot to the EBJ.
3. Install the large EBJ boot band to the recess of the EBJ boot. Follow the the same tightening procedures and specification as for the small band.
Reassembly - PTJ (Inner Joint)
1. Thoroughly clean all old grease from the PTJ (inner joint) case spider assembly and driveshaft.
!!CAUTION!!
- DO NOT use solvent or other degreasing agents to remove grease from the boot.
2. Remove as much grease as possible from the PTJ boot using a plastic spoon compressed air a trim tool or other tool that will not damage the boot.
3. Clean the remainder of the grease from the boot by wiping it with a clean dry lint-free cloth. Repeatedly refold the cloth and change it as necessary. Only a small amount of the original grease can remain in the joint for reassembly.
4. Turn the driveshaft in the vise to place the EBJ at the bottom.
5. Install the small PTJ boot band to the driveshaft.
6. Cover the driveshaft splines with electrical tape to prevent damage to the inside of the boot. Then carefully slide the PTJ boot onto the driveshaft.
7. Install the PTJ spider tripod to the driveshaft and secure it with the new snap ring included in the boot kit.
!!CAUTION!!
The tripod must be installed correctly. Install the tripod chamfered side first.
8. Reassemble the PTJ spider bearings to the tripod.
9. Install the PTJ case to the driveshaft and secure it with the new retaining clip included in the boot kit.
10. Fill the PTJ and boot with grease from the large container (labelled NKG 302) included in the repair kit. Put approximately 50% of the container in the boot and 50% in the joint. Fit the boot to the PTJ.
Use all of the grease from the container in the joint and boot.
11. Secure the inner boot to the PTJ joint using new bands supplied with the boot kit.
NOTE:
PTJ boot bands must be properly positioned. Refer to the service manual "Service Points of installation" for details.
12. Reinstall the driveshaft to the vehicle.
13. Test drive the vehicle to confirm a successful repair.