ect MITSUBISHI LANCER 2005 Workshop Manual

STRUT ASSEMBLY
FRONT SUSPENSION33-7
STRUT ASSEMBLY
REMOVAL AND INSTALLATIONM1332001100325
INSPECTIONM1332001200247
•Check for oil leaks from the strut assembly.
•Check the strut assembly for damage or
deformation.
Post-installation Operation
•Front Wheel Alignment Adjustment (Refer to P.33-5.)
AC304153
44 ± 5 N·m
1
2
3 4
N
AB
167 ± 9 N·m
5
Removal steps
1. Front ABS sensor harness bracket
2. Brake hose bracket
3. Knuckle connection4. Strut nut (self-locking nut)
5. Strut assemblyRemoval steps (Continued)

STRUT ASSEMBLY
FRONT SUSPENSION33-9
DISASSEMBLY SERVICE POINTS
<<A>> STRUT NUT (SELF-LOCKING NUT)
REMOVAL
CAUTION
•Install special tool arm set (MB991238) evenly,
and so that the maximum length will be
attained within the installation range.
•Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237), otherwise the special tool will
break.
1. Use following special tools to compress the coil
spring.
•MB991237: Spring Compressor Body
•MB991238: Arm Set
WARNING
Do not use an impact wrench to remove the
strut nut (self-locking nut). Vibration of the
impact wrench will cause special tools
(MB991237 and MB991238) to slip and cause
personal injury.
2. Use following special tools to secure the strut, and
then remove the strut nut (self-locking nut).
•MB991681: Wrench
•MB991682: Socket
<<B>> STRUT DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
The gas must be discharged from the strut before
discarding it. Place the strut 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<< SPRING UPPER SEAT
INSTALLATION
If the spring upper seat peeled off the pad, adhere
the seat and the pad with a double-sided tape.
AC001085 AB
MB991238
MB991237
AC006091 AB
MB991681 MB991682
AC001087
AC304396AB
Seat
Pad

STRUT ASSEMBLY
FRONT SUSPENSION33-10
>>B<< STRUT NUT (SELF-LOCKING NUT)
INSTALLATION
1. Ensure that the bearing is seated correctly.
CAUTION
Do not use an impact wrench to tighten the bolt
of special tool spring compressor body
(MB991237), otherwise the special tool will break.
2. Install following special tools to the strut assembly
same as its removal.
•MB991237: Spring Compressor Body
•MB991238: Arm Set
3. While the coil spring is being compressed by the
special tools, temporarily tighten the strut nut
(self-locking nut).
4. Align the hole in the strut spring lower seat with
the hole in the spring upper seat.
NOTE:
Using a rod as shown facilitates the alignment.5. Align lower end of the coil spring with the groove
in the spring lower seat, and then loosen the
special tools.CAUTION
Do not use an impact wrench to tighten the
self-locking nut, otherwise the strut nut
(self-locking nut) will be damaged.
6. Using following special tools, tighten the strut nut
(self-locking nut) to 60 ± 10 N⋅m.
•MB991681: Wrench
•MB991682: Socket
INSPECTIONM1332001400188
•Check the strut bearing for wear or rust.
•Check the rubber parts for damage or
deterioration.
•Check the coil spring for deformation,
deterioration or damage.
•Check the strut for deformation.
AC001085 AB
MB991238
MB991237
AC006091 AB
Rod
AC006091 AB
MB991681 MB991682

LOWER ARM
FRONT SUSPENSION33-12
REMOVAL SERVICE POINT
<<A>> LOWER ARM BOLT REMOVAL
Lift the transmission with a transmission jack, and
then withdraw the lower arm bolt (front) on the lower
arm assembly (L.H.).
INSTALLATION SERVICE POINT
>>A<< SELF-LOCKING NUT
INSTALLATION
Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 22 ± 1.5 mm
INSPECTIONM1332001700286
•Check the lower arm bushings for wear and
deterioration.
•Check the lower arm assembly for bend or
breakage.
•Check all bolts for condition and straightness.
LOWER ARM BALL JOINT ROTATION
STARTING TORQUE CHECK
1. After shaking the ball joint stud several times, use
special tool preload socket (MB991006) to
measure the rotation starting torque of the ball
joint.
Standard value: 0 − 3.9 N⋅m
2. If the measured value is not within the standard
value, or if the ball joint is difficult to turn or does
not turn smoothly, replace the lower arm
assembly.
LOWER ARM BALL JOINT COVER
CHECK
1. Check the lower arm ball joint cover for cracks or
damage by pushing it with your finger.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint. When it is
damaged during service work, replace the lower
arm ball joint cover.
LOWER ARM BALL JOINT COVER
REPLACEMENT
M1332008200260
If the lower arm ball joint cover is damaged
accidentally during service work, replace the lower
arm ball joint cover as follows:
1. Remove the lower arm ball joint cover.
2. Apply specified grease to the lip and the inside of
a new lower arm ball joint cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
Grease amount for the inside the dust cover
(reference): 8 − 10g
AC006133ADLower arm bolt (front)Transmission jackPiece of wood
AC101741AC
A
AC001091 AB
MB991006

LOWER ARM
FRONT SUSPENSION33-13
3. Using special tool ball joint remover and installer
(MB990800), drive in the lower arm ball joint
cover until it is fully seated.
4. Position the lower arm ball joint cover as shown in
the illustration. Make sure that there is no
abnormal bulge or pressure applied on the lower
arm ball joint cover.
5. Check the lower arm ball joint cover for cracks or
damage by pushing it with your finger.
LOWER ARM BUSHING (REAR)
REPLACEMENT
M1332008100348
Replace the lower arm bushing (rear) as follows:1. Use following special tools to drive out the lower
arm bushing (rear).
•MB990883: Rear Suspension Bushing Arbor
•MB990972: Torsion Bar Bushing Remover Base
•MB990887: Ring
•MB990890: Rear Suspension Bushing Base
2. Position the lower arm bushing (rear) so that its
projection is as shown, and then use the special
tools to press in the bushing.
3. Press the lower arm bushing (rear) until its outer
tube is flush with the lower arm assembly surface.
AC006135
AD
MB990800
Lower arm
ball joint
cover
AC107030AC
22 mm
Lower arm
ball joint cover
AC006136
AD
Lower arm bushing (rear)
AC006137
AC
MB990883
MB990972
MB990887
MB990890 Lower arm
assembly
AC006138
AC
MB990883
MB990972
MB990887
MB990890 Lower arm
assembly
Projection30˚ Lower arm assemblyOuter tube

STABILIZER BAR
FRONT SUSPENSION33-15
AC006139
AD
49 ± 10 N·m
108 ± 10 N·m
167 ± 9 N·m 167 ± 9 N·m 52 ± 7 N·m*25 ± 5 N·m 21 ± 4 N·m 18 ± 2 N·m
7 6
9
10
1
2
2 3
5
4 2 11
8
Removal steps
>>B<<1. Self-locking nut
2. Stabilizer rubber
3. Collar
4. Lower arm and knuckle
connection
<<A>>5. Tie rod end and knuckle
connection
6. Steering shaft cover7. Steering gear and joint
connecting bolt
8. Engine rear roll stopper
bracket connecting bolt
<<B>> >>A<<9. Stabilizer bar bracket
<<B>> >>A<<10. Stabilizer bushing
<<B>> >>A<<11. Stabilizer barRemoval steps (Continued)

STABILIZER BAR
FRONT SUSPENSION33-16
REMOVAL SERVICE POINTS
<<A>> TIE ROD END AND KNUCKLE
DISCONNECTION
CAUTION
•Do not remove the nut from the tie rod end
ball joint. Loosen it and use special tool ball
joint remover (MB991897) to avoid possible
damage to the ball joint threads.
•Hang special tool ball joint remover
(MB991897) with rope or wire to prevent them
from falling.
1. Install the special tool ball joint remover
(MB991897) as shown in the figure.
2. After turning the bolt and knob to adjust the insert
arms of the special tool in parallel, tighten the bolt
by hand and confirm that the insert arms are
parallel.
NOTE: When adjusting the insert arms in parallel,
turn the knob in the direction shown in the figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
<<B>> STABILIZER BAR
BRACKET/STABILIZER
BUSHING/STABILIZER BAR REMOVAL
Carry out the following operations to ensure working
space in order to remove the stabilizer bar brackets,
the stabilizer bushings and the stabilizer bar.
1. Use a transmission jack to hold the crossmember,
and then remove the crossmember mounting nuts
and bolts.
CAUTION
Be careful not to lower the crossmember
excessively, otherwise the power steering return
hose bracket may deform.
2. Lower the crossmember until the stabilizer bar
brackets, the stabilizer bushings and the stabilizer
bar can be removed.
INSTALLATION SERVICE POINTS
>>A<< STABILIZER BAR/STABILIZER
BUSHING/STABILIZER BAR BRACKET
INSTALLATION
Align the stabilizer bar identification mark with the
right end of the stabilizer bushing (LH).
AC208247AD
Cord
BoltMB991897
Nut
Ball joint
AC106821
Knob ParallelBolt
Good
Bad
AB
AC102600
AD
Piece of wood
Transmission
jack
AC006141
AI
Stabilizer bar
bracket (LH) Outside of
vehicle
Stabilizer
bushing (LH)Approximately
10 mm
Identification
mark

STABILIZER BAR
FRONT SUSPENSION33-17
>>B<< SELF-LOCKING NUT
INSTALLATIONTighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 22 ± 1.5 mm
INSPECTIONM1332002000279
•Check the stabilizer rubbers and stabilizer
bushings for wear and deterioration.
•Check the stabilizer bar for deterioration or
damage.
•Check all bolts for condition and straightness.
AC101741AC
A

34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . .34-2
SERVICE SPECIFICATIONS . . . . . . .34-3
LUBRICANT . . . . . . . . . . . . . . . . . . . .34-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .34-4
ON-VEHICLE SERVICE . . . . . . . . . . .34-5
REAR WHEEL ALIGNMENT CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 34-5
CONTROL LINK PILLOW BALL BUSHING
AXIAL PLAY CHECK <Sport> . . . . . . . . . . 34-6
UPPER ARM PILLOW BALL BUSHING
AXIAL PLAY CHECK <Sport> . . . . . . . . . . 34-7
LOWER ARM PILLOW BALL BUSHING
AXIAL PLAY CHECK . . . . . . . . . . . . . . . . . 34-7
STABILIZER LINK BALL JOINT
DUST COVER INSPECTION . . . . . . . . . . . 34-7
CONTROL LINK, UPPER ARM AND
LOWER ARM . . . . . . . . . . . . . . . . . . .34-8
REMOVAL AND INSTALLATION . . . . . . . . 34-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-9
LOWER ARM BUSHING AND LOWER
ARM PILLOW BALL BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-10
TRAILING ARM ASSEMBLY . . . . . . .34-12
REMOVAL AND INSTALLATION . . . . . . . . 34-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-13
TRAILING ARM BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-13
SHOCK ABSORBER ASSEMBLY . . .34-15
REMOVAL AND INSTALLATION . . . . . . . . 34-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-16
DISASSEMBLY AND REASSEMBLY . . . . . 34-17
STABILIZER BAR. . . . . . . . . . . . . . . .34-20
REMOVAL AND INSTALLATION . . . . . . . . 34-20
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-21
STABILIZER LINK BALL JOINT
DUST COVER REPLACEMENT . . . . . . . . . 34-21

ON-VEHICLE SERVICE
REAR SUSPENSION34-5
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1341011000372
Measure wheel alignment with an alignment
equipment on level earth.
The rear suspension, wheels, and tyres should be
serviced to the normal condition prior to wheel
alignment measurement.
CAMBER
Standard value: -0° 40' ± 30' (Left/right
deviation within 30')
CAUTION
Never subject the wheel bearings to the vehicle
load when the rear wheel hub nuts (self-locking
nuts) or special tool wheel alignment gauge
attachment (MB991014) are loosened.
NOTE:
For vehicles with aluminium wheels, attach the
camber/caster/kingpin gauge to the trailing arm
spindle by using special tool wheel alignment gauge
attachment (MB991014). Tighten the special tool to
the same torque 175
± 25 N⋅m as the rear wheel hub
nut (self-locking nut). MB990947 Lower arm bushing arbor Trailing arm bushing
removal and press-fitting
MB991816 Bushing remover and
installer base
MB990890 Rear suspension bushing
base
A: MB991237
B: MB991239A: Spring compressor
body
B: Arm setCoil spring compressing Tool Number Name Use
MB990947
MB990890
MB991237
A
B
AC001079
MB991014
AG
<Vehicles with aluminium wheels>