sensor MITSUBISHI DIAMANTE 1900 Owners Manual

SUSPENSION AND STEERING 845
144-188 ft. Ibs. (200-260 Nm). Rotate the hub ing knuckle and install a new nut. Tighten to 52 ft. 3. Remove the cotter pin, halfshaft nut and
to seat the bearing.
Ibs. (72 Nm). washer.
e. Mount the knuckle assembly in a vise.
12. Install the halfshaft into the hub/knuckle as- 4. If equipped with ABS, remove the Vehicle
Check the hub assembly turning torque and end- sembly.
Speed Sensor (VSS).
play as follows: 13. Install the two front strut lower mounting bolts
5. Remove the caliper and brake pads. Support
l Using a torque wrench and socket
and tighten to 80-94 ft. Ibs. (110-130 Nm) on Mirage
the caliper out of the way using wire.
MB990998 or equivalent, turn the hub in the or 65-76 ft. Ibs. (90-105 Nm) on Diamante models. 6. Remove the brake rotor from the hub assembly.
knuckle assembly. Note the reading on the torque
14. Install the tie rod end and tighten the nut to 7. Disconnect the upper ball joint from the
wrench and compare to the desired reading of 16
25 ft. lbs. (34 Nm) for Mirage and 21 ft. Ibs. (29 Nm) steering knuckle and pull the knuckle outward.
inch Ibs. (1.8 Nm) or less. This is known as the ‘on Diamante models
8. From the back of the knuckle, remove the
breakaway torque.
15. Install the brake disc and caliper assembly. ‘four bolts securing the hub to the knuckle.
l Check for roughness when turning the
16. If equipped with Active-ECS, connect the
9. Remove the hub and bearing assembly from
bearing.
height sensor and tighten the mounting bolt to 15 ft.
the knuckle.
0 Mount a dial indicator on the hub so the
Ibs. (20 Nm).
pointer contacts the machined surface on the hub.
17. Install the front speed sensor, if removed.
*The hub assembly is not serviceable and
l Check the end-play.
18. Install the washer and new locknut to the end should not be disassembled.
l Compare the reading to the limit of 0.002
in. (0.05mm). of the halfshaft. Tighten the locknut snugly to To install: 144-188 ft. Ibs. (200-260 Nm).
f. If the starting torque or the hub end-play
19. Install the tire and wheel assembly onto the 10. Install the hub to the steering knuckle and
are not within specifications while the nut is tighten the mounting bolts to 65 ft. Ibs. (88 Nm).
vehicle.
11.
tightened to 144-188 ft. Ibs. (200-260 Nm), the
Lower the vehicle to the ground. Connect the upper ball joint to the steering
20.
bearing, hub or knuckle have probably not been ‘knuckle and tighten the self-locking nut to 21 ft. Ibs.
(28 Nm).
installed correctly. Repeat the disassembly and 1994-98 Galant 12.
‘assembly procedure and recheck starting torque Install the axle washer and nut. Tighten the
and end-play. nut to 145-188 ft. Ibs. (200-260 Nm).
+ See Figures 48 thru 58 13. Position the rotor on the hub.
11. Install the hub and knuckle assembly onto the
vehicle. Install the lower ball joint stud into the steer- 1. Raise the vehicle and support safely. 14. Install the caliper holder and the brake
2. Remove the appropriate wheel assembly. ” caliper.
lshaRBmV * “57pa3~ ~Fig.4g~..thenloosehtheaxlattut~~;.~ Fig. 48 Remove the cotter pm from the axle Fig. 50 Using a suitable punch and ham-
mer, gently tap the halfshaft out of the
the vehicle is still on the ground

SUSPENSION AND STEERING 8-23
i-l
12. Check rear wheel alignment and adjust if nec-
REMOVALANDINSTALLATION
essary.
1990-93 Galant
1. Disconnect the neoative battetv cable.
2. Raise and safely sipport vehicle.
3. Remove the tire and wheel assembly.
4. Support the rear lower control arm.
5. Remove the brake line clamp bolt.
6. Remove the nut and separate the upper ball
joint, using tool MB9f35 or equivalent, from the rear
trailing arm/steering knuckle.
*It is important to use proper method of
joint separation when reusing joint. Damage
can result from unapproved methods, result-
ing in possible joint failure.
7. Matchmark the eccentric nn the IInner instal-
8. Remove the upper arm from the vehicle.
To install:
9. Install the arm to the vehicle and install the
upper arm installation bolt. Align the matchmarks
and tighten the nut snugly only.
10. Install the upper arm ball joint to the rear
spindle assembly and install new nut. Tighten to 52
ft. Ibs. (72 Mm).
11. Install the tire and wheel assembly.
12. Lower the vehicle until the suspension sup-
ports its weight.
13. Tighten the upper arm installation bolt to 116
ft. Ibs. (160 Nmj. 1. Disconnect the negative battery cable.
- . .._...- -.. . ..- -rr-. lation bolt and remove from the control arm.
14. ‘Check the rear wheel alignment.
1994-98 Galant
ti See Figures 65, 66, and 67 1
REMOVAL AND INSTALLATION
1990-93 Galant
2. Raise the vehicle and support safely.
!4315ap22 3. Remove sway bar links or mounting nuts and
Fig. 65 Remove the through-bolt securing bolts from lower control arm. Remove the joint cups
the upper arm to the knuckle and bushings, if equipped.
4. Disconnect the ball joint stud from the steer-
ing knuckle, using tool MB9f35 or equivalent.
*It is important to use proper method when
separating joints. Damage to joint could oc-
cur, resulting in possible failure.
5. Remove the inner lower arm mounting bolts
and nut.
6. Remove the rear mount bolts. Remove the
rear retainer clamp if equipped.
7. Remove the arm from the vehicle.
8. Remove the rear rod bushing, if service is re-
quired.
To install:
9. Assemble the control arm and bushing. In-
stall the control arm to the vehicle and install the in-
ner mounting bolts. Install new nut and snug tem-
nnrarilv md . . . 1 f.r”‘Y”‘,.
10. Install the rear mount clamp, bolts and re-
placement nuts. Tighten the clamp mounting nuts to
34 ft. Ibs. (47 Nm). Temporarily tighten the clamp
mounting bolt. Once the weight of the vehicle is on
the suspension, the bolt will be tightened to 72 ft.
Ibs. (100 Nm).
4. Support the trailing arm assembly and re-
move the Self-locking nut connecting the control arm
.* 11. Connect the ball joint stud to the knuckle. In-
stall a new nut and tighten to 43-52 ft. Ibs. (60-72
Nm).
12. Install the swav bar and links.
to tne tramng arm.
5. Using a joint separation tool, disconnect the
upper ball joint from the trailing ary.
6. Disconnect the control arm from the sub-
frame and remove the assembly.
To install:
7. Install the control arm to the subframe and
liahtlv tiahten the mounting bolt.
rol arm to the trailina arm 13. Lower the vehicle to the floor for the final
torquing of the inner frame mount bolt.
14. Once the full weight of the vehicle is on the
suspension, tighten the inner lower arm mounting
bolt nuts to 87 ft. Ibs. (120 Nm). Tighten the inner
clamp mounting bolt to 72 ft. Ibs. (100 Nm).
15. InSpet all suspension bolts, making sure
they all have been fully tightened.
16. Connect the negative battery cable.
199440 Gafant
LOWER CONTROL ARM
+ See Figures 68 and 69
1. Raise and support the vehicle safely.
2. Remove the appropriate wheel assembly.
3. If equipped with ABS, disconnect the speed
sensor harness brackets from the lower control arm.
4. Disconnect the stabilizer bar link from the
----“‘-‘I’
1 b Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the through-bolt securing the upper
arm to the knuckle.
4. Remove the four bolts securing the upper
arm to the body.
5. Remove the uooer arm assemhlv
re-
move the upper arm to body brackets,
To install:
7. Install the upper arm to body brackets to the
upper arm. Tighten the bolts and nuts to 41 ft. Ibs.
(57 Nm).
8. Install the upper arm to the vehicle and
tighten the four bolts to 28 ft. Ibs. (39 Nm). 6. Remove the through-bolts and nuts and
9. Install the through-bolt securing arm to the knuckle. Do not tighten the nut until the
vehicle is on the floor at normal ridina heiaht.
10. Install the wheel and tire assekbly:
11. Safely lower the vehicle to the floor and
tighten the nut for the through-bolt to 71 ft. Ibs. (98
Nm).
i2. Check and adjust wheel alignment if necessary. 8’. eonnectthe&i
and tighten the self-locki
(75-89 Nm). ng nut to 54-61 ft. Ibs.
connect the lower control arm.
5. Remove the through-bolt, connecting the
knuckle assembly to the lower control arm.
fi Romn\fn +hn mwntinn hnlt cnnnwtinn the 9. Install the strut assembly and
sway bar.
10. Install wheel and lower vehicle. V. IIVIII”“~ OK, ill” -...... J I”.. --....--.... J .,,” lower control arm to the suspension crossmember. Diamante
1, Raise and properly support vehicle.
2. Remove appropriate wheel assembly.
3. Disconnect the sway bar and remove the strut
assembly. 11. With full weight of vehicle on the ground,
tighten the control arm to subframe bolt to 54-61 ft.
Ibs. (75-89 Nm). 7. Remove the lower control arm from the vehi-
cle.

8-24 SUSPENSION AND STEERING
9315t$M 93158p26 Fig. 68 Remove the through-bolt connecting Fig. 70 Disconnect the ball joint stud from
the knuckle assembly to the lower control the steering knuckle
1 arm
Fig. 71 Remove the mounting bolt connect-
Fig, 89 Remove the mounting bolt connect- /
1 ing the toe lower control arm to the SW
Dolt. 9; Connect the knuckle to the lower control arm 9. With the full weigh
ground, tighten the control
and lightly tighten the through-bolt.
10. Connect the stabilizer bar link to the control
arm and tighten the nut to 28 ft. Ibs. (39 Nm).
11. Install the wheels and lower the vehicle to the
floor.
12. Once the full weight of the vehicle is on the
suspension, tighten the lower arm mounting bolt nuts
to 71 ft. Ibs. (98 Nm).
13. Check rear wheel alignment and adjust if nec-
essary.
TOE LOWER CONTROL ARhl
ti See Figures 70 and 71
The lower ball joint is integral with the lower toe
control arm. They are removed and replaced as an
assembly.
1. Raise and support the vehicle safely.
2. Remove the appropriate wheel assembly.
3. Matchmark the control arm adjusting bolt to
aid in reassembly.
4. Using joint separator MB991113, disconnect
the ball joint stud from the steering knuckle.
5. Remove the mounting bolts connecting the
lower control arm to the suspension crossmember. %--56 ft. ibs. (
10. Check
essay. rem an0 aajusr
II nec-
orl vehicle Remove
ldiustina bolt to aid
soen- Diamante
1, Raise and properly supp
appropriate whl
eel assembly.
2. Matchn
narkthe camber a , _
in reassembly.
3. On vehicles equipped with Active Su r
sion, disconnect the ECS height sensor rod from
lower arm.
4. Support trailing arm assembly and remove
the self-locking nut connecting the lower arm to the
trailing arm.
5. Disconnect the lower arm at the rear sub-
frame. Remove the arm assembly.
To install:
6. Connect the control arm to the rear cross-
member. Alion matchmarks and liahtlv tiohten.
7. Connect the control arm tothe trailing arm
and tighten the self-locking nut to 54-P e rho I I IL IY.J.
(75-89 Nm). 8. Connect the ECS height sensor rod to the
lower arm, if equipped.
9. Install wheel and lower vehicle.
IO. With the full weight of the vehicle on the
ground, tighten the control arm to rear crossmember
bolt to 54-61 ft. Ibs. (75-89 Nm).
11,
Check rear wheel alignment and adjust if nec-
essary
1996-93 Galant
1, Raise and safely support the vehicle securely
on jackstands.
2. Remove the wheel and tire assembly.
3. Remove the brake drum or rotor.
4. Remove the hub and bearing assembly.
5.
Support the rear axle using a jack or other
suitable device.
6. Remove the lower shock absorber-to-trailing
arm connection.
7. Remove the trailing arm-to-axle connection.
REMOVAL & INSTALLATION
(80-100 Nm).
12.
Remove the axle suooort device.
on jackstands.
2. Remove the wheel and tire assembly.
3. Remove the brake drum or rotor.
4. Remove the hub and bearing assembly.
5.
Support the rear axle using a jack or other
suitable device.
6. Remove the lower control arm-to-trailing arm
connection.
7. Remove the upper link-to-trailing arm con-
nection.
8. Remove the trailing arm-to-body mounting
through-bolt and remove the trailing arm.
To install:
9.
Install the trailing arm and install the trailing
arm-to-body mounting through-bolt. Tighten the bolt
to 72-87 ft. Ibs. (100-120 Nm).
10. Install the upper link-to-trailing arm connec-
tion. Tighten the bolt to 65 ft. Ibs. (90 Nm).
11. Install the lower control arm-to-trailing arm
connection. Tighten the bolt to 65 ft. Ibs. (90 Nm).
12. Remove the axle support device.
13. Install 1 he hub and bearing assembly.
14 Install 1
. _ .he brake drum or rotor.
15.
Install the wheel and tire assembly.
16. Lower the vehicle.

SUSPENSION AND STEERING 8-25
1994-00 Galant and 1997-00 Diamante
4. Remove the retainer bolts and the stabilizer
..- 8, Loosely in”,“,, +I?,, r+&,il;7nr kn- h.~r.l,,d” -..
1. Raise and safely support the vehicle securely he bushing.
the vehicle.
on jackstands.
7er hnr with FI wmnph Remnun (1 Alinn th
2. Remove the wheel and tire assembly.
3. Support the rear axle using a jack or other
suitable device.
4. Remove the trailing arm-to-knuckle connec-
tion,
5. Remove the trailing arm-to-body mounting
n~~““yll-““!~ (1II” fWll”“C LllG llcllllll$j a,,,,. To install:
6. Install the trailing arm and install the trailing
arm-to-body mounting through-bolt. Tighten the bolt
to 99-114 ft. Ibs. (137-157 Nm).
7. Install the trailing arm-to-knuckle connection. Dar brackets. Hemove t
5. Hold the stabilL_. __. . . _ . .._..“... ..I . .._._
the self-locking nut.
6. Once the stabilizer bar nut is removed, re-
move the joint cups and stabilizer rubber bushing.
7. Hold the stabilizer link with a wrench and re-
move the self-locking nuts. Remove the stabilizer
link.
8. Lower the jack supporting the rear axle
in a slight gap between the rear sus-
? body of the vehicle.
! the stabilizer bar.
IL_ L__ I__ _)----- .-- .-J JAI.... slightly. Mainta
pension and thf
9. Remow
10. Inspect LIIB uar 101 uamage, wear ana aereno-
ration and replace as required.
-Fe c--a-...
1 IIIJMII UK 3La”III‘w “ill “lduKm “II
“. , ,,LY,, ,,ie side locating markings on the stabi-
lizer bar, so that the marking on the bar extends ap-
proximately 0.39 inches (1Omm) from the outer edge
of the mounting bracket, on both sides.
10. With the stabilizer bar properly aligned,
tighten the mounting bracket bolts to 28 ft. Ibs. (39
Nm).
11. Connect the stabilizer links to the damper fork
andihe stabilizer bar. Tighten the locking nuts to 28
ft. Ibs. (38 Nm).
12. Lower the vehicle and connect the negative
8.. Ia
mery came.
Tighten the bolt to 85-99 ft. Ibs. (118-137 Nm).
nemove me axle suppon
9. Install the wheel and tire
10. Lower the vehicle. aewce.
assembly.
I 0 Insran: 11, Install the stabilizer bar into the vehicle. Raise
the rear axle and suspension into place.
12. Install the stabilizer link into the stabilizer ba
Ir
ADJUSTMENT anfi indc4ll 33 ft. Ibs. (45 Nm).
13. Install the ioint __-_ _.._ __
1. Raise and safely support the vehicle securely the link. Ins’
..I.,
Mlhiln hnlrii, tall a rkW self~locking n
lll~llG llUlulng the stabi” ” ’ ’ ’
wrench, tighten the self,
of the stabilizer link is v
ihe hub and bearing assembly.
5. Support the rear axle using a jack or other
suitable device.
6. Remove the lower shock absorber-to-trailing
arm connection. ocking nut. Tighten the nut to
ClrnC 2nd ?$bilizer rubber to
ut onto the link.
nzer nnK oall studs with a
-locking nut so the protrusion
within 0.354-0.433 in.
I stabilizer bar bushings,
>+nn thn hnk In -I A u (9-llmm).
14. Install the cente
brackets and bolts. Tiqt Mirage
*Never disassemble the rear hub bearing.
The wheel bearing is serviced by replace-
ment of the hub.
1. Raise and safely support the vehicle.
2. Remove the rear wheel.
3. Remove the caliper and brake disc of brake 1992-96 biamante
on IacKsranos.
2. Remove the wheel and tire assembly
3, Remove thn hralm rntnr 4. Remove1
7. Remove the stabilizer bar link-to-trailing arm
connection.
8. Remove the tie rod end-to-trailing arm con-
nection.
9. Remove the lower control arm-to-trailing arm
connection.
10. Remove the trailing arm-to-body mounting
through-bolt and remove the trailing arm. Nm).
15. Install the parking
sensor installation bolt.
, , I oraxe cat * ale ar
member bracket and tighten
i Nm). Tighten the crossmem-
A to 94 ft. Ibs. (130 Nm). 16. Install the cross
the bolt to 61 ft. Ibs. (8!
ber bracket mounting nl
17. Install the rubbe
locking nuts onto the cro:
the nuts to 80-94 fl. Ibs. (
18. Lower the vehicle. id rear speed drum.
4. Remove the dust cab and tighten the flange ll”, *lb+ to 130 ft. Ibs. (180 Nm).
5. Using a dial indicator, measure wheel bear-
!r insulators and new seif-
ismemoer ’ brackets. Tighten
[110-130 Nm). ing end-play. The maximum limit for end-play is
o.oc-- ‘^ -- rzu mcnes (u.usmm).
arol
tanc
sisk 6. Using a spring scale and a rope wrapped
md the bolts, measure the rotary sliding resis-
e of the bearing/hub. The maximum limit for re-
mce is 4 Ibs. (19 N).
7. If any of the readings exceed the specifica-
To install:
11. Install the trailing arm and install the trailina Diamante and 1994-98 Gal&i
t tions, replacement of the hub is required.
8. Install the dust cap.
9. Install the brake disc and caliper, or brake
negative battery ( sble.
;“I,-.
I support the vbhlblG.
stabilizer links by removing
Alizer bar mounting brackets
from the vehicle.
lonents for wear or damage,
ded. drum.
10. Install the rear wheel assembly and lower the
vehicle to the floor.
*
1990-93 Galant
*Vehicles equipped with rear disc brakes
use a sealed hub and bearing assembly,
which requires no adjustment. Drum brake
models are
adjusted using the following pro- arm-to-body mounting through-bolt. Tighten the bolt
to 101-116 ft. Ibs. (140-160 Nm). ) See Figure 72
12. Install the trailing arm-to-lower control arm
1. Disconnect the I
connection. Tighten the bolt to 101-116 ft. Ibs.
(140-160 Nm). 2. Raise and safely
13. Install the tie rod end-to-trailing arm connec- 3. Disconnect the I
tion. Tighten the nut to 21 ft. Ibs. (29 Nm). the self-locking nuts.
14. Install the stabilizer bar link-to-trailing arm 4. Remove the stat
connection. Tighten the nut to 29 ft. Ibs. (40 Nm). and bushings.
15. Install the lower shock absorber-to-trailing
5. Remove the bar
arm connection. Tighten the bolt to 65 ft. Ibs. (90 6. Inspect all comr
. and replace parts as nee
Nrn).
16. Remove the axle support device.
17. Install the hub and bkaring assembly,
18. Install the brake rotor.
19. Install the wheel and tire assembly.
20. Lower the vehicle.
REMOVALANDINSTALLATION
1990-93 Gaiant
1. Raise and support the vehicle safely.
2. Place a jack under the rear axle and suspen- To install:
7 InstA the dnhili cedure. ._._ . . .._ -.--.. lzer bar into the vehicle.
1. Raise the vehicle and support it safely.
2. Remove the wheel and tire assemblies.
3. If equipped with rear disc brakes, remove the
caliper assembly.
4. Remove the grease cap and the hub nut.
5. Tighten the wheel bearing nut to 20 ft. Ibs. (27
Nm) while rotatir ” ”
6. Back off th
load and then tighten it to 7 ft. Ibs. (10 Nm).
7. Install the nut lock and a new cotter pin.
8. If brake caliper was removed, reinstall.
9. Install the wheel and lower the vehicle.
Diamante and lQQ44 Galant 10 tne mum/hub.
ie adjusting nut to remove the pre-
Sian assembly.
3. Remove the self-locking nuts and crossmem-
ber bracket.
93158P61 Fig. 72 Remove the self-locking nuts from Measure the wheel bearing end-play using a dial
the stabilizer bar link indicator. The end-play should be 0.002 inches
a (0.05mm) or less with the wheel bearing locknut

8-26 SUSPENSION AND STEERING
torqued to specifications. The wheel bearings are
sealed units and are not adjustable. If defective, re-
placement is the only option.
REMOVAL &INSTALLATION
Mirage
7996-92 MODELS
1. Raise the vehicle and support safely.
2. Remove the tire and wheel assembly.
3. If equipped with rear disc brakes, remove the
caliper from the disc and remove the brake disc.
4. Remove the dust cap and bearing nut. Do not
use an air gun to remove the nut.
5. Remove the outer wheel bearing.
6. Remove the drum and/or axle hub with the
inner wheel bearing and the grease seal.
7. Remove the grease seal and remove the inner
bearing.
To install: 8. Lubricate the inner bearing and install to the
drum or hub.
9. Install a new grease seal.
10. To determine if the self-locking nut is
reusable:
a. Screw in the self-locking nut until about
0.07-0.11 in. (2-3mm) of thread is visible under
the nut.
b. Measure the torque required to turn the
self-locking nut counterclockwise.
c. The lowest allowable torque is 48 inch Ibs.
(6 Nm). If the measured torque is less than the
specification, replace the nut.
11. Install the drum and/or hub to the vehicle.
12. Lubricate and install the outer wheel bearing
to the spindle.
13. Tighten the self-locking nut to 108-145 ft.
Ibs. (150-200 Nm).
14. Set up a dial indicator and measure the end-
play while moving the hub or drum in and out. If the
endplay exceeds 0.008 in. (0.002mm) retorque the
nut. If still beyond the limit, replace the bearings.
15. Install the grease cap and wheel assembly.
7993-60 MODELS
*Never disassemble the rear hub bearing.
The wheel bearing is serviced by replace-
ment of the hub.
1. If equipped with ABS, remove the wheel
speed sensor.
2. Raise and safely support the vehicle.
3. Remove the rear wheel.
4. Remove the caliper and brake disc or brake
drum.
5. Remove the dust cap and flange nut.
6. Remove the rear hub assembly.
To install: 7. Install the rear hub assembly using a new
flange nut. Tighten the flange nut to 130 ft. Ibs. (180
Nm).
8. install the dust cap.
9. Install the wheel speed sensor if removed.
The air gap should be 0.012-0.035 in. (0.3-0.9mm).
10. Install the brake disc and caliper, or brake
drum.
11. Install the rear wheel assembly and lower the
vehicle to the floor.
1990-93 Galant
DRUM BRAKE VEHICLES
1. Raise the vehicle and support it safely.
2. Remove the wheel and tire assemblies.
3. Remove the grease cap and the hub nut.
4. Remove the brake drum. The outer bearing
will fall out while the drum is coming off. Do not drop
it. Remove the hub and rotor assembly.
5. Pry out and discard the oil seal.
6. Remove the inner bearing.
*Check the bearing races. If any scoring,
heat checking or damage is noted, they
should be replaced. When bearing or races
need replacement, replace them as a set.
7. If the bearings and races are to be replaced,
drive out the race with a brass drift.
To install: 8. Before installing new races, coat them with
wheel bearing grease. Drive into place with proper
size driver. Make sure they are fully seated.
9. Thoroughly pack the bearings and lubricate
the hubs with wheel bearing grease. Install the inner
bearing and coat the lip and rim of the grease seal
with grease. Drive the seal into place with a seal dri-
ver.
10. Install the drum assembly on the axle.
11, Lubricate and install the outer wheel bearing,
washer and nut. To properly adjust the wheel bearing
preload:
a. Tighten the wheel bearing nut to 20 ft. Ibs.
(27 Nm) while rotating the drum.
b. Back off the adjusting nut to remove the
preload, then tighten it to 7 ft. Ibs. (10 Nm).
c. Install the nut lock and a new cotter pin.
12. Install the wheel and lower the vehicle.
O/SC BRAKE VEHICLES
1. Raise the vehicle and support safely.
2. Remove the tire and wheel assembly.
3. Remove the bolt(s) holding the speed sensor
bracket to the knuckle and remove the assembly from
the vehicle.
The speed sensor has a pole piece projecting
from it. This exposed tip must be protected
from impact or scratches. Do not allow the
oole oiece to contact the toothed wheel dur-
in0 removal or installation.
4. Remove the caliper from the brake disc and
suspend with a wire.
5. Remove the brake rotor.
6. Remove the grease cap, locking nut and
tongued washer.
7. Remove the rear hub and bearing assembly.
*The rear hub assembly can not be disas-
sembled. If bearing replacement is required,
replace the assembly as a unit.
8. If replacing the hub assembly, remove the
two bolts securing the speed sensor ring to the hub.
To install: 9. Install the speed sensor to the hub and bear-
ing assembly. Tighten the mounting bolts to 8 ft. Ibs.
(11 Nm). 10. Install the hub and bearing assembly to the
axle shaft.
11, Install the tongued washer and a new locking
nut. Tighten the locknut to 144-188 ft. Ibs. (200-260
Nm). Once the locknut has been properly torqued,
crimp the nut flange over the slot in the spindle, and
install the grease cap.
12. Install the brake caliper and rotor.
13. Install the speed sensor and tighten the
mounting bolt to 8 ft. Ibs. (11 Nm).
14. Install the tire and wheel assembly.
Be sure to pump the brake pedal until it’s
firm, before moving vehicle.
1994-00 Galant
DRUM BRAKE VEHICLES
) See Figure 73, 74, 75
1. Raise the vehicle and support safely.
2. Remove the appropriate wheel assembly.
3. If equipped with ABS, remove the vehicle
speed sensor.
4. Remove the brake drum from the hub assem-
bly.
5. From the back of the knuckle, remove the
four bolts securing the hub to the knuckle.
6. Remove the hub and bearing assembly from
the knuckle.
*The hub assembly is not serviceable and
should not be disassembled.
7. If replacing the hub, use special socket
MB991248 and a press to remove the wheel sensor
rotor from the hub.
To install: 8. Press the wheel sensor rotor onto the hub.
9. Install the hub to the knuckle and tighten the
mounting bolts to 54-65 ft. Ibs. (74-88 Nm).
10. Install the brake drum on the hub.
11. If equipped with ABS, install the vehicle
speed sensor.
12. Install the wheel assembly and lower the ve-
hicle.
O/SC BRAKE VEHICLES
1. Remove the cotter pin, halfshaft nut and
washer.
2. Raise the vehicle and support safely.
Fig. 73 The hub and bearing assembly is re-
tained to the knuckle by four bolts

SUSPENSION AND STEERING 8-27
7923PGC7 Fig. 74 Use a press to remove the speed sensor rotor from the hub-Galant
dhk4w with drum,brqb
7923PGCE Fig. 75 Exploded view of the rear hub/bearing assembly and related components=Galant
3. Remove the appropriate wheel assembly. *The hub assembly is not serviceable and 4. If equipped with ABS, remove the vehicle should not be disassembled. speed sensor.
5. Remove the caliper and brake pads, Support
the caliper out of the way using wire.
6. Remove the brake rotor from the hub assem-
hl

10. If replacing the hub, use special socket
MB991248 and a press to remove the wheel sensor
rotor from the hub.
To install: WY. 7. Remove the parking brake shoes as follows:
a. Remove the upper shoe to anchor springs.
b. Remove the lower shoe to shoe spring.
c. Remove the brake shoe hold-down springs.
d. Disconnect the parking brake cable from
the actuating lever.
8. From the back of the knuckle, remove the
four bolts securing the hub to the knuckle.
9. Remove the hub and bearing assembly from
the knuckle. Il. Press the wheel sensor rotor onto the hub.
12. Install the hub to the knuckle and tighten the
mounting bolts to 54-65 ft. tbs. (74-88 Nm).
13. Install the parking brake shoes,
14. Position the rotor on the hub. Install a couple
of lug nuts and lightly tighten to hold rotor on hub.
15. Install the caliper holder and place brake pads
in holder. Slide caliper over brake pads and install
guide pins. Once caliper is secured, lug nuts can be
removed. 16. If equipped with ABS, install the vehicle
speed sensor.
17. Install the wheel assembly and lower the ve-
hicle.
Diamante
*The hub assembly is not repairable; if de-
fective, replacement is the only option. If the
hub is removed for any reason it must be re-
placed.
1. Raise and support vehicle safely.
2. Remove the both of the rear wheels.
3. Remove the caliper and the brake disc. Sup-
port the caliper with wire to prevent stress to the /
brake hose.
4. If equipped with ABS, remove the bolt hold-
ing the speed sensor to the trailing arm and remove
the sensor.
*The speed sensor has a pole piece project-
ing from it. This exposed tip must be pro-
tected from impact or scratches. Do not al-
low the pole piece to contact the toothed
wheel during removal or installation.
5. Remove the grease cap, self-locking nut and
tongued washer.
*Do not use an air gun to remove the hub
locknut.
6. Remove the rear hub assembly from the spin-
dle.
7. Remove the bolts that secure the ABS sensor
ring to the hub and remove the ring from the hub.
To install: 8. Secure the sensor ring to the hub assembly
and tighten the mounting bolts.
9. Install the hub assembly, tongued washer
and a new self-locking nut. Tighten the nut to 166 ft.
Ibs. (230 Nm), align with the indentation in the spin-
dle, and crimp.
IO. Using a rope around the hub bolts and a
spring balance, measure the resistance necessary to
rotate the hub. If the resistance exceeds 7 ft. Ibs. (IO
Nm), loosen and retighten the locknut. If the resis-
tance still exceeds the specification, the hub must be
replaced.
11. Using a dial indicator, measure the hub end-
play. The endplay should be 0.002 inches (0.05mm)
or less.
12. Install the brake rotor and caliper assembly.
13. Install the speed sensor to the knuckle.
*Route the speed sensor cable correctly.
Improper installation may cause cable dam-
age and system failure. Use the white stripe
on the outer insulation to keep the sensor
harness properly positioned.
14. Use a brass or other non-magnetic feeler
gauge to check the air gap between the tip of the pole
piece and the toothed wheel. Correct gap is
0.008-0.028 in (0.2-0.7mm). Tighten the sensor
bracket nut with the sensor located so the gap is the
same at several points on the toothed wheel. If the
gap is incorrect, it is likely that the toothed wheel is
worn or improperly installed.
15. Bleed the brake system and install the rear
wheels.

SUSPENSION AND STEERING 8-33
*Matchmark the pinion input shaft of the
rack to the lower steering column joint for in-
stallation purposes.
6. Remove the pinch bolt holding the lower
steering column joint to the rack and pinion input
shaft.
7. Remove the cotter pins and disconnect the tie
rod ends from the steering knuckle.
8. Remove the rack and pinion steering assem-
bly and its rubber mounts from the right side of the
vehicle.
To install: 9. Align the matchmarks of the input shaft and
install the rack to the vehicle.
10. Secure the rack using the retainer clamps and
bolts. Tighten the bolts to 51 ft. Ibs. (70 Nm).
11. Tighten the steering column pinch bolt to 13
ft. Ibs. (18 Nm).
12. Install the center member.
13. Install the front exhaust pipe.
14. Connect the HO$ sensor.
15. Connect the tie rod ends to the steering
knuckles and tighten the castle nuts to 25 ft. Ibs. (34
Nm). Install new cotter pins.
16. Install the wheels and connect the negative
battery cable.
17. Have a front end alignment performed.
REMOVAL &INSTALLATION
Diamante
FRONT
*Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clock spring and render SRS system in-
operative.
1. Disconnect the negative battery cable.
2. Disconnect the front exhaust pipe.
3. If equipped with AWD, remove the transfer
case assembly.
4. Remove the bolt holding the lower steering
column joint to the rack and pinion input shaft.
5. Remove the cotter pins and disconnect the tie
rod ends.
6. Remove the left and right frame members.
7. Remove the stabilizer bar bracket.
8. If equipped with four-wheel steering, discon-
nect the lines going to the rear pump.
9. Remove the rack and pinion steering assem-
bly and its rubber mounts. Move the rack to the right
to remove it from the crossmember.
To install: IO. Install the rack and mounting bolts. Tighten
the bolts to 51 ft. Ibs. (70 Nm). When installing the
rubber rack mounts, align the projection of the
mounting rubber with the indentation in the cross:
member. Install the pinch bolt.
11. Connect the pressure and return lines to the
rack and to the rear pump, if equipped.
12. Install the frame members and tighten the
bolts to 43-51 ft. Ibs. (60-70 Nm).
13. Connect the tie rods and install new cotter
pins. 14. Install the transfer case and front exhaust
pipe.
15. Refill the reservoir and bleed the system.
16. Have a front end alignment performed.
REAR
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Drain the power steering fluid.
4. Remove the main muffler assembly.
5. Remove the rear shock absorber lower
mounting bolts.
6. Using the proper equipment, support the
weight of the rear differential. Remove the 2 small
crossmember brackets.
7. Remove the large self-locking crossmember
mounting nuts on the differential side.
8. Remove the oil line clamp bolts.
9. Remove the pressure tubes.
IO. Hold the tie rod ends stationary and remove
the tie rod end nuts. Remove the tie rod ends from
the trailing arms.
11. Remove the mounting bolts and remove the
rear steering gear.
To install: 12. Secure the unit to the crossmember. Move
the power cylinder piston rod over its full stroke to
determine its neutral position.
13. Align the tie rod ends with the holes in the
trailing arms and install the nuts. Adjust the length of
the tie rods with the nuts if necessary. The difference
in length between the 2 tie rod ends should not ex-
ceed 0.04 in. (1 mm). The nuts’ torque specification is
42 ft. Ibs. (58 Nm).
14. Replace the O-rings and install the pressure
tubes. Clamp in place.
15. Install the large self-locking crossmember
mounting nuts on the differential side. Tighten to
80-94 ft. Ibs. (110-130 Nm).
16. Remove the support equipment.
17. Install the 2 small crossmember brackets.
18. Install the shock mounting bolts.
19. Install the muffler assembly.
20. Refill the reservoir and bleed the system.
21. Have a front end alignment performed. _
Galant
1990-93 MODELS
1. Disconnect the negative battery cable.
2. Drain the power steering fluid.
3. Raise the vehicle and support safely.
4. Remove the bolt holding lower steering col-
umn joint to the rack and pinion input shaft.
5. Remove the transfer case, if equipped.
6. Remove the cotter pins and using the proper
tools, separate the tie rod ends from the steering
knuckle.
7. Locate the triangular brace near the stabilizer
bar brackets on the crossmember and remove both
the brace and the stabilizer bar bracket.
8. Support the center crossmember.
9. Remove the through-bolt from the round roll
stopper and remove the rear bolts from the center
crossmember.
10. Disconnect the front exhaust pipe, if
equipped with FWD.
11. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings. Plug the
fittings to prevent excess fluid leakage. 12. Lower the crossmember slightly.
13. Remove the rack and pinion steering assem-
bly and its rubber mounts. Move the rack to the right
to remove from the crossmember. Tilt the assembly
downward and remove from the left side of the vehi-
cle. Use caution to avoid damaging the boots.
To install: 14. Install the rack and install the mounting bolts. Tighten the mounting bolts to 43-58 ft. Ibs. (60-80
Nm). When installing the rubber rack mounts, align
the projection of the mounting rubber with the inden-
tation in the crossmember.
15. Connect the power steering fluid lines to the
rack.
16. Connect the exhaust pipe, if removed.
17. Raise the crossmember into position. Install
the center member mounting bolts and tighten to 72
ft. Ibs. (100 Nm). Install the roll stopper bolt and new
nut. Tighten nut to 47 ft. Ibs. (65 Nm).
18. Install the stabilizer bar brackets and brace.
19. Connect the tie rod ends and tighten nuts to
25 ft. Ibs. (34 Nm).
20. Install the transfer case, if removed. Check
and fill fluid.
21. Refill the reservoir with power steering fluid
and bleed the system.
22. Have a front end alignment performed.
1994-M MODELS
+ See Figure 96
Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clock spring and render SRS system in-
operative.
1. Disconnect the negative battery cable.
2. Raise and properly support the vehicle.
3. Remove both front wheel assemblies.
4. Remove the bolt holding lower steering col-
umn joint to the rack and pinion input shaft.
5. Remove the stabilizer bar.
6. Remove the cotter pins, and using joint sepa-
rator MB991 113 or equivalent, disconnect the tie rod
ends from the steering knuckle.
7. On vehicles equipped with Electronic Control
Power steering (EPS), detach the wiring harness from
the solenoid connector.
8. Locate the two triangular braces near the
crossmember and remove both.
9. Support the center crossmember. Remove the
through-bolt from the front round roll stopper and re-
move the bolts securing the center crossmember.
10. Remove the center crossmember. ,
Il. Properly support the engine and remove the
rear roll stopper through-bolt.
12. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings. Plug the
fittings to prevent excessive fluid leakage.
13. Remove the clamp bolts and the two bolts se-
curing the rack assembly to the chassis.
14. Remove the rack and pinion steering assem-
bly and its rubber mounts.
*When removing the rack and pinion as-
sembly, tilt the assembly to the vehicle side
of the compression lower arm and remove
from the left side of the vehicle.

SUSPENSION AND STEERING 8-35
1. Steering shaft assembly and gear
box connecting bolt
2. Band
3. Cotter pin
4. Tie-rod end and knuckle connection
5. Return tube connection 6. Pressure tube connection
7. Cylinder clamp
8. Gear housing clamp
9. Gear box assembly 10. Steering cover assembly
7923PGAl FiD= 97 Exploded view of the power steering gear assembly-Mirage
1993-90 MODELS To install:
) See Figure 97
*Prior to removal of the steering gear box,
center the front wheels and remove the igni-
tion key. Failure to do so may damage the
SRS clockspring and render SRS system in-
operative.
,mr;iin thepower steering system.
2. Disconnect the battery negative cable. Raise
the vehicle and support safely.
3. Disconnect the Heated Oxygen (HOPS) sen-
sor and remove the front exhaust pipe.
4. Properly support the engine.
5. Remove both roll stopper mounting bolts and
the four center member installation bolts. Remove the
center member.
6. Remove the center member. 11. Align the matchmarks of the input shaft and
install the rack to the vehicle.
12. Secure the rack using the retainer clamps and
bolts. Tighten the bolts to 51 ft. Ibs. (70 Nm).
13. Tighten the steering column pinch bolt to 13
ft. Ibs. (18 Nm).
14. Using new O-rings, connect the power steer-
ing fluid lines to the rack fittings.
15. Install the center member.
16. Install the front exhaust pipe.
17. Connect the H02S sensor.
18. Connect the tie rod ends to the steering
knuckles and tighten the castle nuts to 25 ft. Ibs. (34
Nm). Install new cotter pins.
19. Install the wheels and connect the negative
battery cable.
20. Refill ‘the reservoir and bleed the system.
21. Have a front end alignment performed.
stallation purposes. -
7. Remove the pinch bolt holding the lower REMOVALANDINSTALLATION
steering column joint to the rack and pinion input
shaft.
8. Remove the cotter pins and disconnect the tie
rod ends from the steering knuckle.
9. Disconnect the power steering fluid pressure
pipe and return hose from the rack fittings.
IO. Remove the rack and pinion steering assem-
bly and its rubber mounts from the right side of the
vehicle. Mirage
1, Drain the power steering system as follows:
a. Disconnect the return hose at the reservoir
and place into a suitable container.
b. Disable the ignition system. While crank-
ing the engine, turn the wheels several times, un-
til system has been drained. 2. Disconnect the battery negative cable.
3. Remove the pressure switch connector from
the side of the pump.
4. If the alternator is located under the oil pump,
cover it with a shop towel to protect it from oil.
5. Disconnect the pressure line.
6. Remove the steering pump drive belt and the
water pump pulley drive belt.
7. Remove the water pump pulley.
8. Remove the bolts that secure the oil pump,
then remove the pump from its bracket.
To install: 9. Install the power steering pump and tighten
the mounting bolts to specifications.
IO. Install the water pump pulley and tighten the
mounting bolts 14 ft. Ibs. (19 Nm).
11. Install and adjust the drive belts.
12. Replace the O-rings and connect the pressure
line. Connect the pressure line so the notch in the fit-
ting aligns and contacts the pump’s guide bracket.
Tighten the nut that secures the pressure line to 13 ft.
Ibs. (18 Nm).
13. Connect the return line.
14. Attach the pressure switch connector.
15. Refill the reservoir and bleed the system.
1990-93 Galant
FRONT
1. Disconnect the battery negative cable.
2. Remove the pressure switch connector from
the side of the pump.

BRAKE OPERATING SYSTEM 9-2
BASIC OPERATING PRINCIPLES 9-2
DISC BRAKES 9-2
DRUM BRAKES 9-2
POWERBOOSTERS 9-2
BRAKE LIGHT SWITCH 9-3
REMOVAL&INSTALLATION 9-3
MASTER CYLINDER 9-3
REMOVAL&INSTALLATION 9-3
' BRAKE PEDAL ADJUSTMENTS 9-4
POWER BRAKEBOOSTER 9-5
REMOVAL &INSTALLATION 9-5
PROPORTIONING VALVE 9-6
REMOVAL &INSTALLATION 9-6
BRAKEHOSESAND LINES 9-6
REMOVAL&INSTALLATION 9-6
BLEEDING BRAKESYSTEM 9-7
DISC BRAKES 9-8
BRAKE PADS 9-8
REMOVAL &INSTALLATION 9-8
INSPECTION 9-11
BRAKE CALIPER 9-11
REMOVAL & INSTALLATION 9-11
OVERHAUL 9-12
BRAKE DISC (ROTOR) 9-13
REMOVAL &INSTALLATION 9-13
INSPECTION 9-14
DRUM BRAKES 9-15
BRAKEDRUMS 9-16
REMOVAL &INSTALLATION 9-16
INSPECilON 9-16
BRAKESHOES 9-16
INSPECTION 9-16
REMOVAL&INSTALLATION 9-17
ADJUSTMENTS 9-18
WHEELCYLINDERS 9-19
REMOVAL &INSTALLATION 9-19
. OVERHAUL 9-19
PARKING BRAKE 9-20
CABLE(S) 9-20
REMOVAL&INSTALLATION 9-20
ADJUSTMENT 9-22
BRAKESHOES 9-23
REMOVAL &INSTALLATION 9-23
ADJUSTMENT 9-24
ANTI-LOCKBRAKE SYSTEM 9-24
GENERAL INFORMATION 9-24
PRECAUTIONS 9-24
DIAGNOSIS AND TESTING 9-24
HYDRAULIC CONTROL UNIT 9-25
REMOVAL&INSTALLATION 9-25
ANTI-LOCK CONTROL UNIT 9-27
REMOVAL&INSTALLATION 9-27
SPEED SENSORS 9-28
REMOVAL &INSTALLATION 9-28
b G-SENSOR 9-29
REMOVAL &INSTALLATION 9-29
' TONE (EXCITER) RING 9-29
REMOVAL&INSTALLATION 9-29
BLEEDINGTHEABSSYSTEM 9-30 COMPONENTLOCATIONS
DRUM BRAKECOMPONENTS 9-15
SPECIFICATIONS CHARTS
ABS DIAGNOSTICTROUBLE CODES 9-25
BRAKE SPECIFICATIONS 9-31

9-4 BRAKES
Fig 8 Unfasten the master cylinder-to-
power booster retaining nuts . . . F57g’6~ Fig. 9 . . . then remove the master cylinder
assembly from the vehicle Fig. 10 The brake booster pushrod and prf-
mary piston clearance (A) must be adjusted
1. Disconnect the negative battery cable.
2. Remove the master cylinder reservoir cap,
then use a clean turkey baster or equivalent to siphon
out as much fluid as possible and place in a suitable
container. Install the cap.
Brake fluid contains polyglycol ethers and
polyglycols. Avoid contact with the eyes and
wash your hands thoroughly after handling
brake fluid. If you do get brake fluid in your
eyes, flush your eyes with clean, running wa-
ter for 15 minutes. If eye irritation persists,
or if you have taken brake fluid internally,
IMMEDIATELY seek medical assistance.
3. Disconnect and plug the lines from the brake
master cylinder reservoir.
4. Detach the fluid level sensor connector, un-
fasten the retainers, then remove the master cylinder
reservoir.
5. For vehicles equipped with manual transaxle,
remove the clutch master cylinder reservoir bracket.
6. Disconnect and plug the brake lines from the
master cylinder.
7. Unfasten the master cylinder-to-power
booster retainino nuts, then remove the master cvlin- ante value will become 0.004-0.012 in.
(0.1-0.3mm).
9. install the master cylinder to the brake
booster, then install the retaining nuts. Tighten the
nuts to 7 ft. Ibs. (10 Nm).
10. Install the master cylinder reservoir, securing
the retainers.
11. Attach the fluid level sensor connector, then
unplug and connect the fluid lines to the reservoir.
12. The remainder of installation is the reverse of
the removal procedure. Fill the reservoir with the
proper type and amount of DOT 3 brake fluid from a
fresh, sealed container.
I l
Clean, high quality brake fluid is essential to
the safe and proper operation of the brake
system. You should always buy the highest
quality brake fluid that is available. If the
brake fluid becomes contaminated, drain and
flush the system, then refill the master cylin-
der with new fluid. Never reuse any brake
fluid. Any brake fluid that is removed from
the system should be discarded. Also, do not
allow any brake fluid to come in contact with
a painted surface; it will damage the paint. Measure the brake pedal height from the floor of
the vehicle to the upper surface of the brake pedal.
The distance should be 6.9-7.1 in (176181mm). If
the brake pedal height is incorrect, adjust as follows:
1. Detach the stop lamp switch connector.
2. Loosen the locknut on the base of the stop
light switch and move the switch to a position where
it does not contact the brake pedal.
3. Loosen the operating rod locknut. Adjust the
height of the brake pedal by turning the operating rod
using pliers. Once the desired pedal height is ob-
tained, tighten the locknut on the operating rod.
4. Screw the stop light switch until the it contacts
the brake pedal stopper. Turn switch in until the
brake pedal just starts to move. At this point, return
(loosen) the stoplight switch $-1 turn and secure in
this position by tightening the locknut. In this posi-
tion, the distance between the lower stop light switch
case and the brake pedal stop should be 0.02-0.04
in. (0.5-l .Omm).
5. Attach the electrical connector to the stop light
switch.
6. Check to be sure that the stop lights are not il-
luminated with no pressure on the brake pedal.
7. Without starting the vehicle, depress the brake
pedal. If the brake light switch is properly connected,
the brake lights will illuminate.
der from the vefiicle.
To install:
8. Adjust the clearance (A)
booster pushrod ant
a. Calculate tl -,
between the brake
I the primary piston as follows:
le clearance A from the B, C
accompa-
i D.
I.335 in.
negative and D measurements, as shown in the
nying figure.A equals B minus C minus
b. The clearance should be 0.256-t
(0.65-0.858mm). When brake booster I
pressure 9.7 psi (67 kPa) is applied, then clear- 13. Bleed the brake system, as outlined later in
this section.
14. Adjust the brake pedal, as outlined later in
this section.
BRAKE PEDAL ADJUSTMENTS
Brake Pedal Height
b See Figures 11, 12, and 13 Brake Pedal Free-Play
II See Figure 14
1. With the engine off, depress the brake pedal
fully several times to evacuate the vacuum in the
booster.
2. Once all the vacuum assist has been elimi-
nated, press the brake pedal down by hand and con-
/
0.5-1.0 mm (.020-B40in.J I
I
I I
Fig. 12 Adjust the brake pedal height by in- I I.
@57w
Cir 44 “a*., .._^ *I.- 9.--l,- ---I-* L-@-L. -I Fig. 13 Inspect the clearance between thf . . - _-.L -*.a- - . . * _ . . . . ._ . rly. I I rnca~urc we urime peoai nefgnr ar
A and compare to specifications creasmg or aecreasing the lengrn or me op-
erating rod mop llgnt WItCh arm the brake pedal stop
and compare to specifications