boot MITSUBISHI LANCER 2006 Workshop Manual

26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . .26-2
SERVICE SPECIFICATIONS . . . . . . .26-3
LUBRICANTS . . . . . . . . . . . . . . . . . .26-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .26-4
ON-VEHICLE SERVICE . . . . . . . . . . .26-7
WHEEL BEARING AXIAL PLAY CHECK . . 26-7
HUB BOLT REPLACEMENT . . . . . . . . . . . 26-7
FRONT AXLE HUB ASSEMBLY . . . .26-8
REMOVAL AND INSTALLATION . . . . . . . . 26-8
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-11
DISASSEMBLY AND REASSEMBLY . . . . . 26-11
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-13
DRIVESHAFT ASSEMBLY. . . . . . . . .26-14
REMOVAL AND INSTALLATION . . . . . . . . 26-14
DISASSEMBLY AND REASSEMBLY . . . . . 26-18
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-21
BJ BOOT (RESIN BOOT)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 26-21

SERVICE SPECIFICATIONS
FRONT AXLE26-3
SERVICE SPECIFICATIONS
M1261000300675
ItemStandard valueLimit
Wheel bearing axial play mm−0.05
Hub starting torque N⋅m−1.8
Protruding length of stabilizer bar mounting bolt mm22 ± 1.5−
Setting of TJ boot length mm1300-RH, 1600-A/T-RH85 ± 3−
1300-LH, 1600-M/T,
1600-A/T-LH, 200090 ± 3−
Opening dimension of the
special tool (MB991561) mmWhen the BJ boot band
(small) is crimped2.9−
When the BJ boot band
(large) is crimped2.9 −
Crimped width of the BJ boot band mm2.4 − 2.8−
LUBRICANTS
M1261000400735
ItemSpecified lubricantQuantity
TJ boot greaseRepair kit grease1300-LH, 1600-LH,
2000-LH120 ± 10 g
1300-RH, 1600-A/T-RH11 0 ± 10 g
1600-M/T-RH, 2000-A/T-RH120 ± 10 g
2000-M/T-RH105 ± 10 g
BJ boot greaseRepair kit grease95 ± 10 g

SPECIA L T OOLS
FRONT AXLE26-5
MB990685To rqu e wrenchMeas urement o f hub st arting torque
MB990326
MB990326 Prel oad socket
MB990810
MB990810Side be aring
puller•Removal of the centre b earing
bra
c ke t
•Removal of the whee l bea ring inner
r
a ce (o ut side )
MB991460PlugPreven tion of transmission fluid drain
and o
f entry of fore ign o b ject s
MB991561
MB991561Boot ban d
crimpin
g toolBJ boot (resin bo ot) ban d inst a lla tion
MB990925
MB990925Bearing and o il
seal
inst a lle r set•Removal of the whee l bea ring
•Removal and inst a lla tion o f the
centre
bearing
•Press-f i ttin g of th e dust se al ou ter ,
inner
MB990890
MB990890Rear suspension
bush
i ng b a se•In st allatio n of th e wheel bearing
•Press-f i ttin g of th e dust se al ou ter ,
inner
MB990883
MB990883Rear suspension
bush
i ng a r borInstallation of t he wheel bearing
Tool Nu mber Na me Use

DRIVESHAFT ASSEMBLY
FRONT AXLE26-18
DISASSEMBLY AND REASSEMBLY
M1261003701073
CAUTION
•Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly
and reassembly.
•
AC303692
2
1
4
12
8
11
10
9 7
13
6
5N
N
N
3
N
N
2 1
4
13
8
11
12
5
21
4
7
6 5
3 21
4
7
5
AB
N
N
BJ boot repair kit TJ 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 damper
10.BJ assembly
11 .BJ boot band (small)
12.BJ boot band (large)
13.BJ boot
Never disassemble the BJ assembly except when replacing the BJ boot.
NOTE: .
•TJ: Tripod Joint
•BJ: Birfield Joint
Disassembly steps (Continued)

DRIVESHAFT ASSEMBLY
FRONT AXLE26-19
LUBRICATION POINTS
AC504520AB
Grease: repair kit grease
Amount used: 95 ± 10 g
The driveshaft joint uses special
grease. Do not mix old and new or
different types of grease.
CAUTION
Grease: repair kit grease
Amount used: <1300-LH, 1600-LH, 2000-LH>:
120 ± 10 g, <1300-RH,1600-A/T-RH>: 110 ± 10 g,
<1600-M/T-RH, 2000-A/T-RH>: 120 ± 10 g,
<2000-M/T-RH>: 105 ± 10 g
The driveshaft joint uses special grease. Do not
mix old and new or different types of grease.
CAUTION
DISASSEMBL Y SER V ICE POINTS
<<A>> TJ CASE/SPIDER ASSEMBL Y
REMOV
A L
CAUTION
Do not disassemble the spider assembly.
1. Wipe off grease from the spider assembly and the inside of the TJ case.
2. Always clean the spider assembly when the
grease contains water or foreign material.
<<B>> TJ BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the TJ boot, wrap plastic tape around the shaft spline to avoid damaging the
boot.

DRIVESHAFT ASSEMBLY
FRONT AXLE26-20
REASSEMBLY SERVICE POINTS
>>A<< DYNAMIC DAMPER/DAMPER
BAND/TJ BOOT INSTALLATION
CAUTION
There should be no grease adhered to the rubber
part of the dynamic damper.
AC101695AC
L
1. Install the dynamic damper in the position (L)
shown in the figure .
L: 230 ± 3 mm <LH>, 415 ± 3 mm <RH>
2. Secure the damper bands.
3. Wrap plastic tape around the shaft spline, and then install the TJ boot band (small) and TJ boot.
>>B<< SPIDER ASSEMBLY
INSTALLATION
CAUTION
•The driveshaft 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
AC102654AC
Chamfered
side
2. Install the spider assembly to the shaft from the direction of the spline chamfered side.
>>C<< TJ CASE INSTALLATION
CAUTION
The driveshaft joint use special grease. Do not
mix old and new or different types of grease.
AC102656AC
After applying the specified grease to the TJ case,
insert the driveshaft and apply grease one more
time.
Specified grease: Repair kit grease
Amount to use:
<1300-LH, 1600-LH, 2000-LH>: 120 ± 10 g
<1300-RH, 1600-A/T-RH>: 110 ± 10 g
<1600-M/T-RH, 2000-A/T-RH>: 120 ± 10 g
<2000-M/T-RH>: 105 ± 10 g
NOTE: The grease in the repair kit should be divided
in half for use, respectively, at the joint and inside the
boot.
>>D<< TJ BOOT BAND (SMALL)/TJ BOOT
BAND (LARGE) INSTALLATION
AC102657
A
AC
Set the TJ boot bands at the specified distance in
order to adjust the amount of air inside the TJ boot,
and then tighten the TJ boot band (small), TJ boot
band (large) securely.
Standard value (A):
<1300-RH, 1600-A/T-RH>: 85 ± 3 mm
<1300-LH, 1600-M/T, 1600-A/T-LH, 2000>: 90 ± 3
mm

DRIVESHAFT ASSEMBLY
FRONT AXLE26-21
INSPECTION
M1261003800130
•Check the driveshaft for damage, bending or cor-
rosion.
•Check the driveshaft spline part for wear or dam-
age.
•Check the spider assembly for roller rotation,
wear or corrosion.
•Check the groove inside TJ case for wear or cor-
rosion.
•Check the dynamic damper for damage or crack-
ing.
•Check the boots for deterioration, damage or
cracking.
BJ BOOT (RESIN BOOT) REPLACEMENTM1261005200361
AC102658
1.Remove the bo ot ban ds (large a nd small).
NOTE: The boot ba nds canno t be re -used .
2.Remove the BJ boot.
3.W r ap a plastic t a pe arou nd the shaf t spline, an d
asse mble the b oot ba nd and BJ boo t.
AC102659
4.Align th e ce ntre gro o ve o n the BJ boot small end
wit h the shaf t groo ve.
AC102660
WMB991561
Stopper
Adjusting bolt
AC
5. T u rn the ad justing bolt o n sp ecial too l boo t band
crimping tool (MB9915 61) so that the size of the
o penin g (W) is at t he st and ard value .
St andard va lue (W): 2 . 9 mm
<If it is larger than 2.9 mm > T i ghte n the adju s t-
ing bolt.
<If it is sm aller than 2.9 mm > Loosen the
adjustin g bolt.
NOTE: The value of W will chang e by approxi-
mately 0.7 mm for ea ch tu rn of th e adjusting bolt.
NOTE: The ad justing bolt shou ld no t be tu rned
more th an once.
AC102661AC
Boot
ABoot band
(small)
B
Projection
6. Position the BJ boo t band (small) so th at there is
e v en clea rance at either en d (A and B).
CAUTION
•Secure the driveshaft in an upright position
and clamp part of the boot band to be crimped
securely in the jaws of special tool.
•
AC102663 ACMB991561
Crimp the boot band until special tool
touches the stopper.

DRIVESHAFT ASSEMBLY
FRONT AXLE26-22
7. Use the special tool to crimp the boot band (small).
AC102662
C
AD
8.Check t hat the crimpin g amount (C) of the bo ot
ba nd is at th e st and ard value.
St andard va lue (C): 2.4 − 2.8 mm
<If the crimpin g amoun t is larger tha n 2.8 m m
>
Readjust th e value of (W) in s t ep 5 acc ord i ng to
the following fo rm ula, and then repea t the
operation in step 7.
W = 5.5 mm − C
Example : If C = 2.9 mm, the n W = 2.6 mm.
<If the crimpin g amoun t is sma ller than 2 . 4
mm >
Rem o v e the BJ bo ot ba nd , re ad ju st the v a l ue of
(W) in ste p 5 acc ord i ng to the following for
-
mula, and then repe at the o perations i n
step
s 6 and 7 using a new BJ boot band .
W = 5.5 mm − C
Example : If C = 2.3 mm, the n W = 3.2 mm.
9.Check t hat the boot b and is no t sticking o u t p a st
th e pla c e wher e it h a s be en in st alled. If t he boo t
ba nd is st icking out, remove it a nd the n repea t
step s 6 to 8, u s in g a new b oot ban d.
CAUTION
The driveshaft 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: 95 ± 10 g
AC102664AC
11.Align the centre 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 the special tool so
that it is at the standard value.
Standard value (W): 2.9 mm
AC102665 AC
Boot Projection
Boot band
(large)
D
E
13.Position the BJ boot band (large) so that there is even clearance at either end (D and E).
14.Use the special tool to crimp the BJ boot band
(large) in the same way as in step 7.
AC102666FAD
15.Check that the crimping amount (F) of the boot band is at the standard value.
Standard value (F): 2.4 − 2.8 mm
<If the crimping amount is larger than 2.8 mm >
Readjust the value of (W) in step 12 according to the following formula, and then repeat the
operation in step 14.
W = 5.8 mm − F
Example: If F = 2.9 mm, then W = 2.9 mm.

DRIVESHAFT ASSEMBLY
FRONT AXLE26-23
<If the crimping amount is smaller than 2.4
mm >
Remove the BJ boot band, readjust the value of
(W) in step 12 according to the following for
-
mula, and then repeat the operations in
steps 13 and 14 using a new BJ boot band.
W = 5.8 mm − F
Example: If F = 2.3 mm, then W = 3.5 mm.
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.

SERVICE SPECIFICATIONS
POWER STEERING37-6
SERVICE SPECIFICATIONS
M1372000300795
ItemStandard valueLimit
Steering wheel free
play mmWith engine running−30
With engine stopped10 or less−
Steering angleInner wheelInvite39°30' ± 1°30'−
Intense (LH drive vehicles)33°40' +1°00'/-2°00'−
Intense (RH drive vehicles)37°00' +1°00'/-2°00'−
Outer wheel
(reference)Invite32°30'−
Intense (LH drive vehicles)28°46'−
Intense (RH drive vehicles)30°00'−
Toe-inAt the centre of tyre tread mm1 ± 2−
Toe-angle (per wheel)0°03' ± 06'−
Tie rod end ball joint turning torque N⋅m0.5 − 2.5−
Tie rod swing resistance N [Tie rod swing torque N⋅m]8 − 27 [1.5 − 4.9]−
Stationary steering effort N [Fluctuation allowance N]29 or less [5.9 or less]−
Oil pump pressure
MPa (750
± 100 r/min.)
Oil pump relief pressure8.8 − 9.5−
Pressure under no-load conditions0.2 − 0.7−
Steering gear retention hydraulic pressure8.8 − 9.5−
Oil pressure switch operating pressure
MPaOFF → ON1.5 − 2.0−
ON → OFF0.7 − 2.0−
Steering gear total pinion torque N⋅m
[Change in torque N
⋅m]
Invite0.8 − 2.1 [0.6 or less]−
Intense0.7 − 2.1 [0.6 or less]−
Opening dimension of special tool boot band crimping tool (MB991561)
mm2.9−
Band crimped width mm2.4 − 2.8−