service MITSUBISHI LANCER 2005 Owners Manual

SHOCK ABSORBER ASSEMBLY
REAR SUSPENSION34-16
REMOVAL SERVICE POINT
<<A>> LOWER ARM BOLT REMOVAL
After supporting the lower arm with a jack, remove
the lower arm bolt.
INSTALLATION SERVICE POINTS
>>A<< SHOCK ABSORBER ASSEMBLY
INSTALLATION
Install the spring seat stepped section so that it
points towards the rear side of the vehicle.
>>B<< STABILIZER LINK INSTALLATION
Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 6 − 8 mm
INSPECTIONM1341002600150
•Check the rubber parts for cracks and wear.
•Check the shock absorber for malfunctions, oil
leakage, or abnormal noise.
AC107126AB
Piece of wood
AC304795
AB
Spring seat
stepped section
Rear of
the vehicle
AC103744
A
AC

SHOCK ABSORBER ASSEMBLY
REAR SUSPENSION34-18
DISASSEMBLY SERVICE POINTS
<<A>> REAR SUSPENSION COIL SPRING
NUT (SELF-LOCKING NUT) REMOVAL
CAUTION
•To hold the coil spring securely, install
special tool arm set (MB991239) evenly, and
so that the space between both arms of the
special tool will be maximum within the
installation range.
•Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237). It will break the special tool.
1. Use following special tools to compress the coil
spring.
•MB991237: Spring Compressor Body
•MB991239: Arm Set
WARNING
Do not use an impact wrench to remove the
rear suspension coil spring nut (self-locking
nut). Vibration of the impact wrench will
cause special tools (MB991237 and
MB991239) to slip and cause personal injury.
2. While holding the piston rod, remove the rear
suspension coil spring nut (self-locking nut).
<<B>> REAR SUSPENSION SHOCK
ABSORBER DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
The gas must be discharged from the shock
absorber before discarding it. Place the shock
absorber horizontally with its piston rod extended.
Then drill a hole of approximately 3 mm in diameter
at the location shown in the illustration and discharge
the gas.
REASSEMBLY SERVICE POINTS
>>A<< REAR SUSPENSION SPRING
LOWER PAD INSTALLATION
Align the stepped section of the spring lower pad
with the stepped section of the spring seat of the
shock absorber, and install the spring lower pad.
AC001070
MB991237
MB991239
AB
AC102268AC
Piston rod
AC102270
AC
AC304800AB
Spring lower pad
Stepped section
Spring seat

STABILIZER BAR
REAR SUSPENSION34-21
INSTALLATION SERVICE POINTS
>>A<< STABILIZER
BAR/BUSHING/FIXTURE INSTALLATION
Install the stabilizer bar, the bushings and the fixtures
as illustrated.
>>B<< SELF-LOCKING NUT
INSTALLATION
Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 6 − 8 mm
INSPECTIONM1341001400294
•Check the bushings for wear and deterioration.
•Check the stabilizer bar for deterioration or
damage.
•Check all bolts for condition and straightness.
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK
1. After shaking the ball joint stud several times,
install the nut to the stud and use special tool
preload socket (MB990326) to measure the
turning torque of the ball joint.
Standard value: 0.5 − 1.5 N⋅m
2. If the measured value exceeds the standard
value, replace the stabilizer link.
3. If the measured value is lower than the standard
value, check that the ball joint turns smoothly
without excessive play. If so, it is possible to
re-use that ball joint.
STABILIZER LINK BALL JOINT DUST
COVER CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
2. If the dust cover is cracked or damaged, replace
the stabilizer link.
NOTE: Cracks or damage of the dust cover may
cause damage to the ball joint. When it is
damaged during service work, replace the dust
cover (Refer to P.34-21).
STABILIZER LINK BALL JOINT DUST
COVER REPLACEMENT
M1341010900242
Only when the dust cover is damaged accidentally
during service work, replace the dust cover as
follows:
AC102279AC
Outside of vehicle
Bushing (LH)
Fixture (LH)Identification colourApproximately
9.5 mm
AC103744
A
AC
AC001129
MB990326
AB

35-1
GROUP 35
SERVICE BRAKES
CONTENTS
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35A
ANTI-SKID BRAKING SYSTEM (ABS) . . . . . . . . . . . . . . . . . . .35B

36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . .36-2
SERVICE SPECIFICATIONS . . . . . . .36-2
LUBRICANTS . . . . . . . . . . . . . . . . . .36-3
ON-VEHICLE SERVICE . . . . . . . . . . .36-3
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT . . . . . . . . . . . 36-3
LINING RUNNING-IN . . . . . . . . . . . . . . . . . 36-3
PARKING BRAKE SWITCH CHECK . . . . . 36-4
PARKING BRAKE LEVER . . . . . . . . .36-5
REMOVAL AND INSTALLATION . . . . . . . . 36-5
PARKING BRAKE CABLE . . . . . . . . .36-6
REMOVAL AND INSTALLATION . . . . . . . . 36-6
PARKING BRAKE LINING AND
DRUM . . . . . . . . . . . . . . . . . . . . . . . . .36-7
REMOVAL AND INSTALLATION . . . . . . . . 36-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 36-9

GENERAL INFORMATION
PARKING BRAKES36-2
GENERAL INFORMATION
M1361000100496
The parking brake is of a mechanical rear-wheel
acting type, and its operation utilises a parking brake
lever.
SPECIFICATIONS
CONSTRUCTION DIAGRAM
SERVICE SPECIFICATIONS
M1361000300382
Item Specification
Type Drum-in disc
Clearance adjustment Manual
AC211553
AC104333
AC304152
Parking brake lever assembly
Parking brake cable
AB
Drum-in-disc brake
Item Standard value Limit
Parking brake lever stroke 5 − 7 notches
−
Rear brake lining thickness mm 2.8 1.0
Rear drum inside diameter mm 168.0 169.0

LUBRICANTS
PARKING BRAKES36-3
LUBRICANTS
M1361000400293
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT
M1361000900339
1. Pull the parking brake lever with a force of
approximately 200 N and count the number of
notches.
Standard value: 5 − 7 notches
2. If the parking brake lever stroke is not the
standard value, adjust as described below.
(1) Remove the rear console assembly (Refer to
GROUP 52A, Rear Floor Console P.52A-8).
(2) Loosen the adjusting nut to move it to the
cable rod end so that the cable will be free.
(3) Remove the wheels.
(4) Complete air bleeding of brake circuit. (Refer
to GROUP 35A, On-vehicle Service, Bleeding
P.35A-6.)(5) Remove the rear wheel hub plug, and then
use a flat-tipped screwdriver to turn the shoe
slack adjuster in the direction of the arrow (the
direction which expands the shoe) so that the
disc will not rotate.
Return the shoe slack adjuster 5 notches in
the direction opposite to the direction of the
arrow.
(6) Turn the adjusting nut to adjust the parking
brake lever stroke to the standard value. After
adjusting, check that there is no space
between the adjusting nut and the parking
brake lever. Check that the adjusting nut is
secured with the nut holder.
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
(7) Release the parking brake and turn the rear
wheels to check that the rear brakes are not
dragging.
LINING RUNNING-INM1361001100240
CAUTION
Carry out running-in in a place with good
visibility, and pay careful attention to safety.
Carry out running-in by the following procedure when
replacing the parking brake linings or the rear brake
disc rotors, or when brake performance is
insufficient.
1. Adjust the parking brake lever stroke to the
standard value.
Specified value: 5 − 7 notches (Operation
force: Approximately 200 N) Item Specified lubricant
Rear brake shoe and backing plate contact surface Brake grease SAE J310, NLGI No.1
Rear brake shoe assembly
Rear brake shoe slack adjuster
AC006190
Cable rod
Adjusting nut
AD
AC304403AB
Shoe slack
adjuster

ON-VEHICLE SERVICE
PARKING BRAKES36-4
2. Hook a spring balance onto the centre of the
parking brake lever grip and pull it with a force of
100 − 150 N in a direction perpendicular to the
handle.
3. Drive the vehicle at a constant speed of 35 − 50
km/h for 100 metres.
4. Release the parking brake and let the brakes cool
for 5 − 10 minutes.
5. Repeat the procedure in steps 2 to 4, four or five
times.
PARKING BRAKE SWITCH CHECKM1361003300381
1. Remove the rear console assembly (Refer to
GROUP 52A, Rear Floor Console P.52A-8).
2. Remove the front seat assembly (RH). (Refer to
GROUP 52A, Front Seat P.52A-24).
3. Check for continuity between the parking brake
switch terminal and the switch mounting bolt.
AC212035AC
Spring balance
Approximately
40 mmPull
When parking brake lever is pulled Less than 2 Ω
When parking brake lever is
releasedOpen circuit
AC304746AB

PARKING BRAKE LINING AND DRUM
PARKING BRAKES36-8
REMOVAL SERVICE POINTS
<<A>> REAR BRAKE ASSEMBLY
REMOVAL
Remove the rear brake assembly and support it with
wire or something similar.
<<B>> REAR BRAKE CHAMBER
RETAINER REMOVAL
Use a flat-tipped screwdriver or a similar tool to open
up the rear brake chamber retainer joint. Then
remove the rear brake chamber retainer.
INSTALLATION SERVICE POINTS
>>A<< REAR BRAKE WASHER
INSTALLATION
Install the rear brake washer in the direction shown
in the illustration.
>>B<< REAR BRAKE CHAMBER
RETAINER INSTALLATION
Use pliers or a similar tool to close the rear brake
chamber retainer end onto the pin.
>>C<< SHOE SLACK ADJUSTER
INSTALLATION
Install the shoe slack adjuster so that the shoe
adjusting bolt for the left rear wheel is attached
towards the front of the vehicle, and the shoe
adjusting bolt for the right rear wheel is towards the
rear of the vehicle.
AC000924
AG
Rear brake secondary
shoe assembly pin
Rear brake chamber retainer
AC304675ABRear brake secondary
shoe assemblyRear brake
chamber retainer
Parking brake
operating lever Rear brake
washer
AC000926
AI
Rear brake secondary
shoe assembly pin
Rear brake chamber retainer
AC304676AB
Shoe adjusting bolt
Shoe adjusting bolt
Left rear wheel
Right rear wheel
Rear of
the vehicle
Rear of
the vehicle

37-1
GROUP 37
POWER STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . .37-3
SERVICE SPECIFICATIONS . . . . . . .37-6
LUBRICANTS . . . . . . . . . . . . . . . . . .37-7
SEALANTS . . . . . . . . . . . . . . . . . . . .37-7
SPECIAL TOOLS . . . . . . . . . . . . . . . .37-8
ON-VEHICLE SERVICE . . . . . . . . . . .37-11
STEERING WHEEL FREE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-11
STEERING ANGLE CHECK . . . . . . . . . . . . 37-11
TIE ROD END BALL JOINT TURNING
TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37-12
STATIONARY STEERING EFFORT
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-12
STEERING WHEEL RETURN TO
CENTRE CHECK . . . . . . . . . . . . . . . . . . . . 37-13DRIVE BELT TENSION CHECK . . . . . . . . . 37-13
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13
POWER STEERING SYSTEM AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-13
OIL PUMP PRESSURE TEST . . . . . . . . . . 37-14
POWER STEERING PRESSURE
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . 37-15
TIE ROD END BALL JOINT DUST COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-15
STEERING COLUMN SHAFT
ASSEMBLY SHOCK ABSORBING
MECHANISM CHECK . . . . . . . . . . . . . . . . . 37-15
STEERING WHEEL* . . . . . . . . . . . . . .37-17
REMOVAL AND INSTALLATION
<COMFORT> . . . . . . . . . . . . . . . . . . . . . . . 37-17
REMOVAL AND INSTALLATION
<SPORT> . . . . . . . . . . . . . . . . . . . . . . . . . . 37-19
Continued on next page
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
•Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
paassenger (from rendering the SRS inoperative).
•Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
•MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS air bag control unit, SRS warning light, front impact sensors, air bag module,
clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection
with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).