boot MITSUBISHI 380 2005 User Guide

26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .26-2
FRONT AXLE DIAGNOSIS . . . . . . . .26-2
TROUBLESHOOTING STRATEGY . . . . . . 26-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 26-3
SYMPTOM PROCEDURES . . . . . . . . . . . . 26-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .26-4
ON-VEHICLE SERVICE . . . . . . . . . . .26-8
WHEEL BEARING END PLAY CHECK . . . 26-8
HUB BOLT REPLACEMENT . . . . . . . . . . . 26-8
FRONT AXLE HUB ASSEMBLY . . . .26-9
REMOVAL AND INSTALLATION . . . . . . . . 26-9
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-12
DRIVE SHAFT ASSEMBLY . . . . . . . .26-13
REMOVAL AND INSTALLATION . . . . . . . . 26-13
DISASSEMBLY AND ASSEMBLY . . . . . . . 26-18
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-25
BJ BOOT REPLACEMENT . . . . . . . . . . . . . 26-26
SPECIFICATIONS . . . . . . . . . . . . . . .26-29
FASTENER TIGHTENING SPECIFICATIONS26-29
GENERAL SPECIFICATIONS . . . . . . . . . . 26-29
SERVICE SPECIFICATIONS . . . . . . . . . . . 26-29
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 26-30

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

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-18
DISASSEMBLY AND ASSEMBLYM1261003700490
For vehicles with ABS, be careful not to damage the ABS rotor, which is attached to the BJ outer
race during disassembly and reassembly.
Never disassemble the BJ assembly except when replacing the BJ boot.
NOTE: .
PTJ: Pillow Tripod Joint
DISASSEMBLY STEPS
>>G<<1. PTJ BOOT BAND (LARGE)
>>G<<2. PTJ BOOT BAND (SMALL)
3. PTJ CASE AND INNER SHAFT
ASSEMBLY RH
<<A>> >>F<<4. PTJ CASE
<<B>> >>E<<5. INNER SHAFT RH
6. DUST COVER RH
7. BRACKET ASSEMBLY RH
>>D<<8. DUST SEAL OUTER RH
>>D<<9. DUST SEAL INNER RH
<<C>> >>C<<10. CENTER BEARING RH11. CENTER BEARING BRACKET RH
12. CIRCLIP
13. SNAP RING
<<A>> >>B<<14. SPIDER ASSEMBLY
<<D>> >>A<<15. PTJ BOOT
19. BJ ASSEMBLY
20. BJ BOOT BAND (SMALL)
21. BJ BOOT BAND (LARGE)
22. BJ BOOTDISASSEMBLY STEPS

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-19
BJ: Birfield Joint
For BJ boot removal and installation, refer to
P.26-26.
Required Special Tools:
MB991248: Inner Shaft Remover
MB990810: Side Bearing Puller
MB990930: Installer Adapter
MB990932: Installer Adapter
MB990934: Installer Adapter
MB990938: Bar (snap-in type)
MB990890: Rear Suspension Bushing Base
MB991172: Inner Shaft Installer Base

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-22
<<C>>CENTER BEARING RH REMOVAL
Use special tools MB990938 and MB990930 to remove the
center bearing from the center bearing bracket.
.
PTJ BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the PTJ boot, wrap plastic tape around the
shaft spline to avoid damaging the boot.
ASSEMBLY SERVICE POINTS
.
DYNAMIC DAMPER LH /DAMPER BAND /PTJ
BOOT INSTALLATION
There should be no grease adhered to the rubber part of
the dynamic damper.
1. Install the dynamic damper in the position (L) shown in the
illustration.
L: 260.5
3 mm LH>
2. Secure the damper bands.
3. Wrap plastic tape around the shaft spline, and then install
the PTJ boot band (small) and PTJ boot.
.
>>B<< SPIDER ASSEMBLY INSTALLATION
The drive shaft joint use special grease. Do not mix old
and new or different types of grease.
If the spider assembly has been cleaned, take special
care to apply the specified grease.
1. Apply the specified grease furnished in the repair kit to the
spider assembly between the spider axle and the roller.
Specified grease: Repair kit grease

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-25
>>F<< PTJ CASE <3.8L> INSTALLATION
The drive shaft joint use special grease. Do not mix old
and new or different types of grease.
After applying the specified grease to the PTJ case, insert the
drive shaft and apply grease again.
Specified grease: Repair kit grease
Amount to use <3.8L>: 220
10 g (7.8 0.3 ounces)
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
.
>>G<< PTJ BOOT BAND (SMALL) <3.8L>/PTJ
BOOT BAND (LARGE) <3.8L> INSTALLATION
Set the PTJ boot bands at the specified distance in order to
adjust the amount of air inside the PTJ boot, and then tighten
the PTJ boot band (small), PTJ boot band (large) securely.
Standard value (A): 85
3 mm (3.35 0.12 inches)
INSPECTIONM1261003800163
Check the drive shaft for damage, bending or corrosion.
Check the inner shaft for damage, bending or corrosion.
Check the drive shaft spline part for wear or damage.
Check the inner shaft spline part for wear or damage.
Check the spider assembly for roller rotation, wear or corro-
sion.
Check the groove inside PTJ case for wear or corrosion.
Check the boots for deterioration, damage or cracking.
Check the center bearing for seizure, discoloration or
roughness of rolling surface.
Check the dust cover for damage or deterioration.

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-26
BJ BOOT REPLACEMENTM1261005200394
Required Special Tool:
MB991561:Boot Band Crimping Tool
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble
the boot band and BJ boot.
4. Align the center groove on the BJ boot small end with the
shaft groove.
5. Turn the adjusting bolt on special tool MB991561 so that the
size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
<If it is larger than 2.9 mm (0.11 inch)> Tighten the
adjusting bolt.
<If it is smaller than 2.9 mm (0.11 inch)> Loosen the
adjusting bolt.
NOTE: The value of W will change by approximately 0.7 mm
(0.03 inch) for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned more than
once.
6. Position the BJ boot band (small) so that there is even
clearance at either end (A and B).

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-27
Secure the drive shaft in an upright position and clamp
part of the boot band to be crimped securely in the jaws
of special tool MB991561.
Crimp the boot band until the special tool touches the
stopper.
7. Use special tool MB991561 to crimp the boot band (small).
8. Check that the crimping amount (C) of the boot band is at
the standard value.
Standard value (D): 2.4
2.8 mm (0.09 0.11 inch)
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 5 according to the
following formula, and then repeat the operation in
step 7.
W = 5.5 mm (0.22 inch)
D
Example: If D = 2.9 mm (0.11 inch), then W = 2.6 mm
(0.10 inch).
<If the crimping amount is smaller than 2.4 mm (0.09
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 5 according to the following formula,
and then repeat the operations in steps 6 and 7
using a new EBJ boot band.
W = 5.5 mm (0.22 inch)
D
Example: If D = 2.3 mm (0.09 inch), then W = 3.2
mm (0.13 inch).
9. Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 6 to 8, using a new boot
band.
The drive shaft joint uses special grease. Do not mix old
and new or different types of grease.
10.Fill the inside of the boot with the specified amount of the
specified grease.
Specified grease: Repair kit grease
Amount to use <3.8L>: 165
10 g (5.8 0.3 ounces)

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-28
11.Align the center groove on the BJ boot big end with the BJ
case groove.
12.Follow the same procedure as in step 5 to adjust the size of
the opening (W) on special tool so that it is at the standard
value.
Standard value (W): 2.9 mm (0.11 inch)
13.Position the BJ boot band (large) so that there is even
clearance at either end (D and E).
14.Use special tool to crimp the BJ boot band (large) in the
same way as in step 7.
15.Check that the crimping amount (F) of the boot band is at
the standard value.
Standard value (F): 2.4
2.8 mm (0.09 0.11 inch)
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 12 according to
the following formula, and then repeat the opera-
tion in step 14.
W = 5.8 mm (0.23 inch)
F
Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm
(0.11 inch).
<If the crimping amount is smaller than 2.4 mm (0.09
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 12 according to the following formula,
and then repeat the operations in steps 13 and 14
using a new EBJ boot band.
W = 5.8 mm (0.23 inch)
F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm
(0.14 inch).
16.Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 13 to 15, using a new boot
band.

SPECIFICATIONS
FRONT AXLE26-29
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1261005400309
GENERAL SPECIFICATIONSM1261000200311
SERVICE SPECIFICATIONSM1261000300426
ITEM SPECIFICATION
Caliper assembly bolt 100
10 Nm (74 7 ft-lb)
Center bearing bracket bolt 41
4 Nm (30 3 ft-lb)
Drive shaft nut 226
29 Nm (167 21 ft-lb)
Dust cover bolt 9.0
2.0 Nm (80 17 in-lb)
Front strut nut 305
25 Nm (225 18 ft-lb)
Front wheel hub bolt 90
10 Nm (67 7 ft-lb)
Self-locking nut (lower arm ball joint connection) 65
6 Nm (48 4 ft-lb)
Self-locking nut (tie rod end connection) 29
4 Nm (21 3 ft-lb)
ITEM SPECIFICATION
Wheel bearing Type Unit ball bearing (Double-row angular contact ball
bearing)
Drive shaft Joint type Outer Birfield joint
Inner Pillow Tripod joint
ITEM STANDARD VALUE LIMIT
Wheel bearing end play mm (in)
0.05 (0.002)
Wheel bearing rotation starting torque N
m (in-lb)1.4 (12)
Setting of PTJ boot length mm
(in)3.8L 85
3 (3.35 0.12)
Opening dimension of the
special tool (MB991561) mm
(in)When the BJ boot band
(small) is crimped2.9 (0.11)
When the BJ boot band
(large) is crimped2.9 (0.11)
Crimped width of the BJ boot band mm (in) 2.4 2.8 (0.09 0.11)