MITSUBISHI 380 2005 Workshop Manual

SPECIAL TOOLS
FRONT AXLE26-4
STEP 5. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 2: Noise Due to Excessive Play of Wheel in Turning Direction
DIAGNOSIS
STEP 1. Check for play in the inner shaft and side
gear serration, the drive shaft and side gear
serration, or the drive shaft and front hub
serration.
Q: Is the play found?
YES :
Replace the part. Then go to Step 2.
NO : The procedure is complete.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES :
The procedure is complete.
NO : Repeat from Step 1.
SPECIAL TOOLSM1261000600405
TOOL TOOL NUMBER
AND NAMESUPERSESSION APPLICATION
MB990767
Front hub and
flange yoke
holderMB990767-01 Fixing of the hub
MB991618
Hub bolt removerGeneral service
toolRemoval of the hub bolt
MB991897
Ball joint
removerMB991113-01,
MB990635-01 or
General service
tool Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113)is also used
to disconnect knuckle and tie rod end
ball joint.

SPECIAL TOOLS
FRONT AXLE26-5
MB990241 Axle
shaft puller
A: MB990242
Puller shaft
B: MB990244
Puller barMB990241-01 or
General service
toolRemoval of the drive shaft
MB991354
Puller bodyGeneral service
tool
MB990590 Rear
axle shaft oil seal
remover
A: MB990212
Adapter
B: MB990211
Slide hammer
Removal of the front wheel hub
A: MB991017
B: MB990998
C: MB991000
A, B: Front hub
remover and
installer
C: SpacerMB990998-01
Removal of the hub
Provisional holding of the wheel
bearing
Measurement of hub starting torque
Measurement of wheel bearing end
play
NOTE: MB991000, which belongs to
MB990998, should be used as a
spacer.
MB990685
Torque wrenchGeneral service
toolMeasurement of hub starting torque
MB990326
Preload socketGeneral service
tool
MB990810
Side bearing
pullerGeneral service
tool
Removal of the center bearing
bracket
Removal of the wheel bearing inner
race (outside) TOOL TOOL NUMBER
AND NAMESUPERSESSION APPLICATION

SPECIAL TOOLS
FRONT AXLE26-6
MB991172
Inner shaft
installer basePress-fitting of the inner shaft
MB991248
Inner shaft
removerMD998348-01 or
General service
tool Removal of the inner shaft
MB991561
Boot band
crimping toolMB991561 BJ boot (resin boot) band installation
MB990925
Bearing and oil
seal installer setMB990925-01 or
General service
tool
Removal and installation of the
center bearing
Press-fitting of the dust seal outer,
inner
MB990890
Rear suspension
bushing baseMB990890-01 Press-fitting of the dust seal outer, inner TOOL TOOL NUMBER
AND NAMESUPERSESSION APPLICATION

SPECIAL TOOLS
FRONT AXLE26-7
TOOL TYPE TOOL NUMBER O D mm (in)
A MB990926 39.0 (1.54)
MB990927 45.0 (1.77)
MB990928 49.5 (1.95)
MB990929 51.0 (2.00)
MB990930 54.0 (2.13)
MB990931 57.0 (2.24)
MB990932 61.0 (2.40)
MB990933 63.5 (2.50)
MB990934 67.5 (2.66)
MB990935 71.5 (2.81)
MB990936 75.5 (2.97)
MB990937 79.0 (3.11)
B MB990938
C MB990939

ON-VEHICLE SERVICE
FRONT AXLE26-8
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECKM1261000900246
1. Remove the caliper assembly and suspend it with a wire.
2. Remove the brake disc from the front hub.
3. Attach a dial gauge as shown in the illustration, and then
measure the end play while moving the hub in the axial
direction.
Limit: 0.05 mm (0.002 inch)
4. If end play exceeds the limit, disassemble the front hub
assembly and check the parts.
5. Install the brake disc, caliper assembly and tighten the
caliper assembly mounting bolts to the specified torque.
Tightening torque: 100
10 Nm (74 7 ft-lb)
HUB BOLT REPLACEMENTM1261001000310
Required Special Tools:
MB990767: Front Hub and Flange Yoke Holder
MB991618: Hub Bolt Remover
1. Remove the caliper assembly and suspend it with wire so
that it does not fall.
2. Remove the brake disc.
3. Use special tool MB991618 to remove the hub bolts.
4. Install the plain washer to the new hub bolt, and install the
bolt with a nut while holding the hub with special tool
MB990767.
5. Install the brake disc, caliper assembly and tighten the
caliper assembly mounting bolts to the specified torque.
Tightening torque: 100
10 Nm (74 7 ft-lb)

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-9
FRONT AXLE HUB ASSEMBLY
REMOVAL AND INSTALLATIONM1261001700386
For vehicles with ABS, do not strike the ABS rotors installed to the BJ outer race of drive shaft
against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be
damaged.
For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
Required Special Tools:
MB990767: Front Hub and Flange Yoke Holder
MB990242: Puller Shaft
MB990244: Puller Bar
MB991354: Puller Body
MB990211: Slide Hammer
MB991897:Ball Joint Remover
Post-installation Operation
Check the dust cover for cracks or damage by pushing it with
your finger.
REMOVAL STEPS
1. SPLIT PIN
<<A>> >>A<<2. DRIVE SHAFT NUT
>>A<<3. WASHER
4. FRONT WHEEL SPEED SENSOR
BRACKET <VEHICLES WITH ABS>
5. FRONT WHEEL SPEED SENSOR
<VEHICLES WITH ABS>
6. BRAKE HOSE BRACKET
<<B>> 7. CALIPER ASSEMBLY
<<C>> 8. BRAKE DISC
9. DRIVE SHAFT
<<E>>10.FRONT WHEEL HUB ASSEMBLY
11 .DUST COVER
<<D>> 12. SELF LOCKING NUT (CONNECTION
FOR LOWER ARM BALL JOINT)
<<D>> 13. SELF LOCKING NUT (CONNECTION
FOR TIE ROD END)
14.FRONT STRUT TO KNUCKLE
MOUNTING BOLT AND NUT
15.KNUCKLE
REMOVAL STEPS (Continued)

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-10
REMOVAL SERVICE POINTS
.
<<A>> DRIVE SHAFT NUT REMOVAL
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage when drive shaft nut is
loosened.
Use special tool MB990767 to fix the hub and remove the drive
shaft nut.
.
<<B>> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
.
<<C>> BRAKE DISC REMOVAL
If the brake disc is seized, install a M8 x 1.25 bolts as shown,
and remove the disc by tightening the bolts evenly and gradu-
ally.
.

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-11
<<D>> SELF LOCKING NUT (CONNECTION FOR
LOWER ARM BALL JOINT AND TIE ROD END)
REMOVAL
Do not remove the nut from ball joint. Loosen it and use
the special tool to avoid possible damage to ball joint
threads.
Hang the special tool with cord to prevent it from fall-
ing.
1. Replace the self locking nut for lower arm ball joint with a
regular nut, because the original one is a little bit large to
install the special tool. Install special tool MB991897 as
shown in the figure.
2. Turn the bolt and knob as necessary to make the jaws of
special tool parallel, tighten the bolt by hand and confirm
that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make sure the
knob is in the position shown in the figure.
3. Tighten the bolt with a wrench to disconnect the lower arm
ball joint, tie rod end and remove the self locking nut.
.
<<E>> FRONT WHEEL HUB ASSEMBLY
REMOVAL
1. Use special tools MB990242, MB990244, MB991354 and
MB990767 to push out the drive shaft from the hub and
knuckle.
2. If the front wheel hub is seized, remove the knuckle together
with front wheel hub and fix them with a vise.
3. Hang the drive shaft on the vehicle body with a rope.

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-12
4. Use special tools MB990244, MB991354 and MB990211 to
pull out the front wheel hub from the knuckle.
INSTALLATION SERVICE POINT
.
>>A<<WASHER/ DRIVE SHAFT NUT INSTALLA-
TION
Before securely tightening the drive shaft nuts, make sure
there is no load on the wheel bearings. Otherwise the
wheel bearings will be damaged.
1. Be sure to install the drive shaft washer in the specified
direction.
2. Using special tool MB990767, tighten the drive shaft nut to
the specified torque.
Tightening torque: 226
29 Nm (167 21 ft-lb)
INSPECTIONM1261001800264
WHEEL BEARING ROTATION STARTING
TORQUE AND AXIAL PLAY CHECK
Required Special Tools:
MB990998: Front Hub Remover and Installer
MB991000: Spacer
MB990326: Preload Socket
MB990685: Torque Wrench
1. Install special tools MB991000, MB990998 and tighten them
to the specified torque.
Tightening torque: 226
29 Nm (167 21 ft-lb)
2. Hold front wheel hub assembly in a vice, using wooden
blocks.
3. Rotate the hub in order to seat the bearing.

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-13
4. Measure the wheel bearing rotation starting torque by using
the special tools MB990326 and MB990685.
Limit: 1.4 N
m (12 in-lb)
5. If the rotation starting torque is not within the limit when the
nut is tightened to 226
29 Nm (167 21 ft-lb), replace the
front wheel bearing assembly. If there is any signs of binding
or tight spots when the wheel bearing turns, replace it.
6. Measure to determine whether the wheel bearing axial play
is within the specified limit or not.
Limit: 0.05 mm (0.002 inch)
7. If the play exceeds the limit when the nut is tightened to 226
29 Nm (167 21 ft-lb), replace the front wheel hub
assembly.
DRIVE SHAFT ASSEMBLY
REMOVAL AND INSTALLATIONM1261003500429
For vehicles with ABS, do not strike the ABS rotors installed to the BJ outer race of drive shaft
against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be
damaged.
For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
Pre-installation Operation
Front Under Cover, Side Under Cover Removal
Transmission Fluid Draining (Refer to GROUP
23A, On-vehicle Service
Transmission Fluid
Change P.23A-292).
Front Exhaust Pipe Removal <3.8L-RH side>
(Refer to GROUP 15, Exhaust Pipe and Muffler
P.15-14).Post-installation Operation
Front Exhaust Pipe Installation <3.8L-RH side>
(Refer to GROUP 15, Exhaust Pipe and Muffler
P.15-14).
Check the ball joint dust cover for cracks or
damage by pushing it with your finger.
Transmission Fluid Filling (Refer to GROUP
23A, On-vehicle Service
Transmission Fluid
Change P.23A-292).
Front Under Cover, Side Under Cover
Installation