MITSUBISHI LANCER 2005 Workshop Manual

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-9
REMOVAL SERVICE POINTS
<<A>> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
<<B>> BRAKE DISC REMOVAL
If the brake disc is seized, install M8x1.25-mm bolts
as shown, and remove the disc by tightening the
bolts evenly and gradually.
<<C>> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not apply pressure to wheel bearing by the
vehicle weight to avoid possible damage when
drive shaft nut is loosened.
Use special tool end yoke holder (MB990767) to fix
the hub and remove the drive shaft nut.
<<D>> SELF-LOCKING NUT (TIE ROD
END CONNECTION) REMOVAL
CAUTION
•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 falling.
1. Install special tool ball joint remover (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
tie rod end.
AC209507AC
BOLT
(M8×1.25)
AC102462AC
MB990767
AC208247AD
Cord
BoltMB991897
Nut
Ball joint
AC106821
Knob ParallelBolt
Correct
Wrong
AB

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-10
<<E>> DRIVE SHAFT REMOVAL
1. Use the following special tools to push out the
drive shaft from the hub and knuckle.
•Axle shaft puller (MB990241)
•Puller shaft (MB990242)
•Puller bar (MB990244)
•Puller body (MB991354)
•End yoke holder (MB990767)
2. Withdraw the drive shaft from the hub by pulling
the bottom of the hub and knuckle towards you.
3. Hang the drive shaft on the vehicle body with a
rope.
INSTALLATION SERVICE POINT
>>A<< STABILIZER
RUBBER/SELF-LOCKING NUT
(STABILIZER BAR CONNECTION)
INSTALLATION
Install the stabilizer rubber and collar as shown in the
figure, and tighten the self-locking nut so that the
protruding length of the stabilizer bar mounting bolt
protruding part meets its standard value (A).
Standard value (A): 22 ± 1.5 mm
>>B<< WASHER/ DRIVE SHAFT NUT
INSTALLATION
CAUTION
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 end yoke holder (MB990767),
tighten the drive shaft nut to the specified torque.
Tightening torque: 245 ± 29 N⋅m
AC100128
MB990241 MB990767
AD
<Comfort>
AC303949
MB990244
(Three) <Sport>
MB990767
MB990242 MB991354
AC
AC102551
AC
Drive shaft
AC210393AC
A
AC102465AD
MB990767 Washer

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-11
INSPECTIONM1261001800242
•Check the hub for cracks and spline for wear.
•Check the knuckle for cracks.
•Check for defective bearing.NOTE: If the meshing of the wheel bearing outer
race and the knuckle, or of the wheel bearing
inner race and the hub, is loose, replace the
bearing or damaged parts.
DISASSEMBLY AND REASSEMBLYM1261001900205
AC303659
N
N4 1
5
32
AB
2
<Comfort><Sport>
Disassembly steps
1. Snap ring
<<A>>2. Hub
3. Dust cover
<<B>>4. Wheel bearing
5. KnuckleAssembly steps
5. Knuckle
>>A<<4. Wheel bearing
1. Snap ring
3. Dust cover
2. Hub
>>B<<•Hub starting torque check
>>C<<•Wheel bearing axial play check

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-12
DISASSEMBLY SERVICE POINTS
<<A>> HUB REMOVAL
CAUTION
When the hub has been removed, always replace
the wheel bearing with a new part because wheel
bearing frictional surface will be damaged when
removing the hub.
Use the following special tools to pull out the hub
from the knuckle.
•Knuckle arm bridge (MB991056 or MB991355)
•Front hub remover and Installer (MB991017)
•Spacer (MB991000)
<<B>> WHEEL BEARING REMOVAL
1. Crush the oil seal in two places so that the tabs of
the special tool will be caught on the wheel
bearing inner race (outside).
CAUTION
When removing the inner race (outside) from the
hub, be careful not to let the hub drop.
2. Remove the wheel bearing inner race (outside)
from the front hub by using special tool side
bearing puller (MB990810).
3. Install the inner race (outside) that was removed
from the hub to the wheel bearing, and then use
the following special tools to remove the wheel
bearing.
•Installer bar (MB990938)
•Installer adapter (MB990935)
•Knuckle arm bridge (MB991056 or MB991355)
AC100130 Tighten the nut
with the bolt
securedMB991056 or
MB991355 MB991017
MB991000
AB
AC102508
AC
Inner race
(outside)
Outer oil seal
AC102509
MB990810
Inner race
(outside)
AC
AC102510 AC
MB990938
MB990935
MB991056 or MB991355 Inner race
(outside)

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-13
REASSEMBLY SERVICE POINTS
>>A<< WHEEL BEARING INSTALLATION
1. Fill the wheel bearing with multipurpose grease.
2. Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
CAUTION
Press the outer race when pressing-in the wheel
bearing. Otherwise the wheel bearing will be
damaged.
3. Press-in the bearing by using the following special
tools.
•Rear suspension bushing arbor (MB990883)
•Rear suspension bushing base (MB990890)
>>B<< HUB STARTING TORQUE CHECK
1. Tighten the following special tools to the specified
torque, and then press-in the hub into the knuckle.
•Front hub remover and installer (MB991017)
•Spacer (MB991000)
2. Rotate the hub in order to seat the bearing.3. Measure the hub starting torque by using the
following special tools.
•Torque wrench (MB990685)
•Preload socket (MB990326)
Limit: 1.8 N⋅m
4. The starting torque must be within the limit and
the hub rotation must be smooth.
>>C<< WHEEL BEARING AXIAL PLAY
CHECK
1. Measure to determine whether the wheel bearing
axial play is within the limit or not by using the
following special tools.
•Front hub remover and installer (MB991017)
•Spacer (MB991000)
Limit: 0.05 mm
2. If the play is not within the limit range while the nut
is tightened to 245 ± 29 N⋅m, the bearing, hub
and/or knuckle have probably not been installed
correctly. Replace the bearing and re-install.
INSPECTIONM1261002000078
•Check the front hub and brake disc mounting
surfaces for galling and contamination.
•Check the knuckle inner surface for galling and
cracks.
AC102511
MB990883
MB990890
AC
AC210929AC
MB991000 MB991017
245 ± 29 N·m
Tighten the nut
with the bolt secured
AC100136
MB990685
MB990326
AB
AC100137
MB991000
MB991017
245 ± 29 N·m
AB Tighten the nut
with the bolt
secured

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-14
DRIVE SHAFT ASSEMBLY
REMOVAL AND INSTALLATIONM1261003500399
CAUTION
•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.
•Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Pre-installation Operation
•Transmission Fluid Draining (Refer to GROUP
22A, On-vehicle Service − Transmission Oil
Replacement P.22A-8).
•Front Exhaust Pipe Removal (Refer to GROUP
15, Exhaust Pipe and Muffler P.15-11).Post-installation Operation
•Front Exhaust Pipe Installation (Refer to
GROUP 15, Exhaust Pipe and Muffler
P.15-11).
•Check the Ball Joint Dust Cover for cracks or
damage by pushing it with your finger.
•Transmission Fluid Filling (Refer to GROUP
22A, On-vehicle Service − Transmission Oil
Replacement P.22A-8).
AC303689AB
9
N
N
NN
10 7
4
3
2
1
25 ± 5 N·m
245 ± 29 N·m
108 ± 10 N·m
8
5 6
1112
7
7
Removal steps
<<A>> >>C<<1. Drive shaft nut
>>C<<2. Washer
3. Front ABS sensor
4. Front ABS sensor bracket
5. Brake hose bracket
>>B<<6. Self-locking nut (stabilizer bar
connection)
>>B<<7. Stabilizer rubber8. Collar
9. Lower arm connecting bolt
<<B>>10. Self-locking nut (tie rod end
connection)
<<C>> >>A<<11. Drive shaft
12. CirclipRemoval steps (Continued)

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-15
REMOVAL SERVICE POINTS
<<A>> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not apply pressure to the wheel bearing by
the vehicle weight to avoid possible damage
when the drive shaft nut is loosened.
Use special tool end yoke holder (MB990767) to fix
the hub and remove the drive shaft nut.
<<B>> SELF-LOCKING NUT (TIE ROD
END CONNECTION) REMOVAL
CAUTION
•Do not remove the nut from ball joint. Loosen
it and use special tool to avoid possible
damage to ball joint threads.
•Hang special tool with cord to prevent it from
falling.
1. Install special tool ball joint remover (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
tie rod end.
<<C>> DRIVE SHAFT REMOVAL
1. Use the following special tools to push out the
drive shaft from the hub.
•Axle shaft puller (MB990241)
•Puller shaft (MB990242)
•Puller bar (MB990244)
•Puller body (MB991354)
•End yoke holder (MB990767)
2. Remove the drive shaft from the hub by pulling
the bottom of the brake disc towards you.
AC102462AC
MB990767
AC208247AD
Cord
BoltMB991897
Nut
Ball joint
AC106821
Knob ParallelBolt
Correct
Wrong
AB
AC100128
MB990241 MB990767
AD
<Comfort>
AC102550
MB990244
(Three)
MB991354
MB990242 MB990767 <Sport>
AE
AC102551
AC
Drive shaft

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-16
CAUTION
•Do not pull on the drive shaft; doing so will
damage the TJ; be sure to use the pry bar.
•When pulling the drive shaft out from the
transmission, be careful that the spline part of
the drive shaft does not damage the oil seal.
3. Insert a pry bar between the transmission case
and the drive shaft, and then pry and remove the
drive shaft from the transmission.4. Use special tool plug (MB991460) to prevent the
entry of foreign material into the transmission
case.
CAUTION
Do not apply pressure to the wheel bearing by
the vehicle weight to avoid possible damage
when the drive shaft is removed. If, however,
vehicle weight must be applied to the bearing in
moving the vehicle, temporarily secure the wheel
bearing by using the following special tools.
•Spacer (MB991000)
•Front hub remover and installer (MB991017)AC100141
Transmission
TJ assembly
Pry bar
AG
AC102554
MB991460
AC
AC102555
AC
MB991017 MB991000

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-17
INSTALLATION SERVICE POINTS
>>A<< DRIVE SHAFT INSTALLATION
CAUTION
When installing the drive shaft, be careful that
the spline part of the drive shaft does not
damage the oil seal.
>>B<< STABILIZER
RUBBER/SELF-LOCKING NUT
(STABILIZER BAR CONNECTION)
INSTALLATION
Install the stabilizer rubber and collar as shown in the
figure, and tighten the self-locking nut so that the
protruding length of the stabilizer bar mounting bolt
protruding part meets its standard value (A).
Standard value (A): 22 ± 1.5 mm
>>C<< WASHER/DRIVE SHAFT NUT
INSTALLATION
1. Be sure to install the drive shaft washer in the
specified direction.
CAUTION
Before securely tightening the drive shaft nuts,
make sure there is no load on the wheel
bearings. Otherwise the wheel bearing will be
damaged.
2. Using special tool end yoke holder (MB990767),
tighten the drive shaft nut to the specified torque.
Tightening torque: 245 ± 29 N⋅m
AC210393AC
A
AC102465AD
MB990767 Washer

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-18
DISASSEMBLY AND REASSEMBLYM1261003700456
CAUTION
•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: .
•TJ: Tripod Joint
•BJ: Birfield Joint
AC303692
2 1 4
12 8
11 10 97
13 6 5N
N
N
3
N
N
21 4
13 8
11
12
5
21 4
7
65
3
21 4
7
5
AB
N
N
BJ boot repair kitTJ boot repair kit TJ repair kit Grease for TJ
Grease for BJ
Disassembly steps
>>D<<1. TJ boot band (large)
>>D<<2. TJ boot band (small)
<<A>> >>C<<3. TJ case
4. Circlip
5. Snap ring
<<A>> >>B<<6. Spider assembly
<<B>> >>A<<7. TJ boot
>>A<<8. Damper band
>>A<<9. Dynamic damper10. BJ assembly
11. BJ boot band (small)
12. BJ boot band (large)
13. BJ bootDisassembly steps (Continued)