sensor MITSUBISHI DIAMANTE 1900 Manual Online

1996-00 DIAMANTE CHASSIS SCHEMATIC
1992-95 DIAMANTE CHASSIS SCHEiWATIC HOT AT ALL TlHES
HOT AT ALL TIMES HOT AT ALL TIMES
FUSS
FUSS
II
12
ISA
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s
KEY
REtllN5ER
SWITCH
I HOT AT
I FUSIGLS
LINK
ETACS ELECTKGMC CONTROL UGT (ECUI
LIGHT AUTOtlATIC SHUf-OFF UNIT
J 5
FRONT OOOR
SWlTCH
LEFT SloEI
1 HEAGLlGHT
SWITCH
s INSTRUMENT PAML
ELECTRONIC CONTROL MT LEFT FGGNT GOGR M0GU.G
(ECU1
VEHICLE
SPEW
SENSOR
RIGHT
FKONT
DooR
LGUt
ACTUATO LEFT 4
.-------------
i
R’z
-r LOCK LNLOCK
ACTUATOi3 ? OOOR
LOCK
ACTUATOR
93156669 DIAGRAM 60 DIAGRAM 59 93156870

1993 MIRAGE 1.8L CHASSIS SCHEMATIC 1994-96 MIRAGE 1.8L CHASSIS SCHEMATIC HOT AT ALL TIMES HOT AT ALL TIMES HOT AT ALL TIMES NOT AT ALL TltlES
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LINK LINK
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IGNITIOW
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COHFRESSOR CONTROL
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DIAGRAM 65 93156B44
d
RADIATOR CONDENSER
FM FAN
MOTOR MOTOR
ENGINE CONTROL MOOLU RAGIATOR
FAN
MOTOR
CONTROL
RELAY
VEHICLE
WEE0
SENSOR
DIAGRAM 66
‘28 93156845

DRIVETRAIN 7-5
1, While the vehicle is still on the ground, re- IO. Insert the halfshaft into the tram&e. Be sure cle is being serviced could make a difference in joint
move the cotter pin, and loosen the axle nut. it is fully seated. type. Be sure to properly identify the joint before at-
2. Raise the vehicle and support it safely. 1 I. Pull the strut assembly out and install the tempting joint or boot replacement. Look for identifi-
3. If equipped with ABS, remove the front wheel other end to the hub. cation numbers at the large end of the boots and/or
speed sensor. 12. Install the center bearing bracket bolts and on the end of the metal retainer bands.
4. If equipped with Active Electronic Control tighten to 33 ft. Ibs. (45 Nm). The 3 types of joints used are the Birfield Joint,
Suspension (Active-ECS), perform the following: 13. Install the washer on the axle shaft so the (B.J.), the Tripod Joint (T.J.) and the Double Offset
a. Loosen the nut that secures the air line to chamfered edge faces outward. Install the axle nut, Joint (D.O.J.).
the to the top of the strut and discard the O-ring.
b. Remove the bolts that secure the actuator but do not tighten it fully at this time.
14. Connect the ball joint to the steering knuckle. *Do not disassemble a Birfield joint. Ser-
to.the top of the strut and remove the compo-
Torque the new retaining nut to 43-52 ft. Ibs. (68-72 vice with a new joint or clean and repack us-
nent. Disconnect the wiring harness.
Nm) and secure with a new cotter pin. ing a new boot kit.
5. Disconnect the lower ball joint and the tie rod
15. Connect the tie rod end to the steering
The distance between the large and small boot
end from the steering knuckle.
knuckle. Torque the retaining nut to 21 ft. Ibs. (29
bands is important and should be checked prior to
6. Remove the axle nut and the washer.
Nm) and secure with a new cotter pin.
and after boot service. This is so the boot will not be
7. If removing the left side axle with an inner 16. If equipped with ABS, install the front wheel
installed either too loose or too tight, which could
shaft, remove the center support bearing bracket speed sensor.
cause early wear and cracking, allowing the grease to
bolts and washers. Then, remove the halfshaft by set-
17. If equipped with Active-KS, perform the fol- get out and water and dirt in, leading to early joint
ting up a puller on the outside wheel hub and push-
lowing:
failure.
ing the halfshaft from the front hub. Tap the shaft a. Install the air line with a new O-ring.
union at the joint case with a plastic hammer to re- b. Install the actuator to the top of the strut. *The drfveshaft joints use special grease;
move the halfshaft and inner shaft from the transaxle. Connect the wiring harness. do not add any grease other than that sup-
8. If removing right side axle shafts without an 18. Install the wheel and lower the vehicle to the plied with the kit.
inner shaft, remove the halfshaft by setting up a floor.
puller on the outside wheel hub and pushing the half- 19. Tighten the axle nut to 145-188 ft. Ibs.
Double Offset Joint
shaft from the front hub. After pressing the outer (200-260 Nm) and secure with a new cotter pin.
shaft, insert a prybar between the transaxle case and The Double Offset Joint (D.O.J.) is bigger than
the halfshaft and pry the shaft from the transaxle.
CV-JOINTS OVERHAUL other joints and, in these applications, is normally
*Do not pull on the shaft; doing so damages used as an inboard joint.
the inboard joint. b See Figures 14 thru 27 1. Remove the halfshaft from the vehicle.
2. Side cutter pliers can be used to cut the metal
To install: These vehicles use several different types of joints. retaining bands. Remove the boot from the joint outer
9. Replace the circlips on the ends of the half- Engine size, transaxle type, whether the joint is an in- race.
shafts. board or outboard joint, even which side of the vehi-
TCCS7030 TCCS7031
I I TCCS7032 Fig. 15 Removing the outer band from the
Fig. 16 Removing the inner band from the
Fig. 14 Check the CV-boot for wear
W-boot
lho~sing IFi7~ / Fig 17 Removing the CV-boot from the joint 1 1 CV-boot
TCCS7035 Fig 18 Clean the CV-joint housing prior to
removing boot Tccs7W 1 1 sembiy Fig 19 Removing the CV-joint housing as-

DRIVETRAIN 7-11
Fig. 45 location of 4-wheel steering oil
l Park/neutral switch electrical harness l Kickdown servo switch l Pulse generator l Oil temperature sensor electrical harness l Shift control solenoid valve harness.
19. Support the transaxle and remove the
transaxle mounting bracket.
20. Remove the three upper transaxle-to-engine
mounting bolts.
21. For vehicles with 4WS, remove the heat
shield for the 4WS oil pump and remove the pump.
Do not allow the pump to hang from the oil hoses.
22. For vehicles equipped with Active-ECS, dis-
connect the height sensor rod from the lower control
arm.
23. Remove the bolt that secures the Heated Oxy-
gen (HOaS) sensor harness to the right side cross-
member.
’ 24. Remove the starter assembly.
25. Remove the mounting brackets for access to
the bell housing cover,
26. Remove the bell housing/oil pan covers as-
sembly. 27. Remove the bolts holding the flexplate to the
torque converter.
28. Remove the lower transaxle to engine bolts
and remove the transaxle assembly.
To install: 29. Install the transaxle assembly to the engine
block, install the mounting bolts and tighten to 54 ft.
tbs. (75 Nm).
30. Install the bolts that secure the torque con-
verter to the driveplate. Tighten the bolts to 34-38 ft.
Ibs (4653 Nm).
31. Install the bell housing/oil pan covers.
32. Install the transaxle stay brackets that were
removed for access to the bell housing cover.
33. Install the starter assembly and connect the
wiring.
34. Install the bolt that secures the HO& sensor
harness to the right side crossmember and tighten
the bolt to 7-9 ft. Ibs. (X-12 Nm).
35. For vehicles equipped with Active-ECS, con-
nect the height sensor rod from the lower control’
arm. Check the height sensor rod for a length (A) of
10.59-10.63 in. (269-270mm)
36. If removed, install the 4WS oil pump and
tighten the mounting bolts to 17 ft. Ibs. (24 Nm).
37. If removed, install the 4WS oil pump heat
shield and tighten the mounting bolts to 17 ft. Ibs.
(24 Nm).
38. Install the three upper transaxle-to-engine
mounting bolts. Tighten the mounting bolts to 54 ft.
Ibs. (75 Nm).
*One of the upper bolts has a grounding
strap to secure under the bolt.
39. Install and connect the transaxle mounting
bracket. Tighten the mounting nut and bolts to 51 ft.
Ibs. (70 Nm).
40. Connect the shift control solenoid valve har-
ness
Removal steps 1. Transaxle control cable connection
2. Transaxle 011 cooler hoses connection
3. PNP swrtch connector
4. FvT control solenoid valve connector
5. Input shaft speed sensor connector
6. Output shaft speed sensor connector
7. Vehicle speed sensor connector
6. Spht pin
9. Connection of the tie rod end
10. Drwe shaft nut 11. Connectton for the lower arm ball
jomt
12. Drwe shaft and inner shaft assembly
(RH) and the drwe shaft (LH)
Caution
Mounting locations marked by
l should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.
7923PG84
:io. 46 Transaxie removal (1 of 2)-Diamante with F4A51 transaxie
41. Connect the kickdown servo switch, pulse
generator and oil temperature sensor electrical har-
ness
42. Connect the park/neutral switch electrical
harness.
43. Using new hose clamps, install the oil cooler
hoses to the transaxle.
44. Install shifter control cable to the transaxle
and secure the cable with clip.
45. Connect the speedometer cable to the
transaxle.
46. If removed, install the roll stopper stay
bracket and tighten the one through nut and bolt to
36-43 ft. Ibs. (50-60 Nm). Tighten the two mounting
bolts to 16 ft. Ibs. (22 Nm).
47. If removed, install the Active-ECS compres-
sor assembly. Tighten the mounting bolts to 48 inch
Ibs. (5 Nm) and connect the electrical harness.
48. Attach the engine harness connection.
49. Install the air cleaner assembly and adjoining
duct work.
50. Using new circlips, install the halfshafts and
seat halfshafts into the transaxle. Install the bolt that
secure the left side support bearing and tighten the
bolts to 33 ft. Ibs. (45 Nm).
51. Connect the ball joint and tie rod end to the
steering knuckle. Using new nuts, tighten the ball
joint castle nut to 43-52 ft. Ibs. (60-72 Nm) and
tighten the tie rod castle nut to 22 ft. ibs. (30 Nm). in-
stall new cotter pins.
52. Using new gaskets, install the exhaust sys-
tem.
53. If removed, install front catalytic converter.
54. Install the engine undercovers.
55. Connect the negative battery cable.
56. Fill the transaxle to the correct level.
57. Start the engine and check for leaks.
Gaiant
1999-1993 MODELS
1. On vehicles equipped with auto-cruise, re-
move the control actuator and bracket.
2. If equipped with an active ECS, disconnect
the air compressor.
3. Drain the transaxle fluid into a suitable con-
tainer.
4. Remove the air cleaner assembly, intercooler
and air hose, as required.
5. Mark the shift cable. Remove the adjusting
nut and disconnect the shift cable.
6. Tag and detach the electrical connectors for
the solenoid, neutral safety switch (inhibitor switch),
the pulse generator kickdown servo switch and oil
temperature sensor.
7. Disconnect the speedometer cable and oil
cooler lines.
8. Disconnect the wires to the starter motor and
remove the starter.
9. Remove the upper transaxle to engine bolts.
10. Support the transaxle and remove the
transaxle mounting bracket.
11. Raise the vehicle and support safely. Remove
the sheet metal under guard
12. Remove the tie rod ends and the bail joints
from the steering knuckle.
13. Remove the halfshafts by inserting a prybar
between the transaxle case and the driveshaft and
prying the shaft from the transaxle. Do not pull on the
driveshaft. Doing so damages the inboard joint. Use

.
7-12 DRIVETRAIN
26-33Nm
19 - 24 itlbs.
45 - 52 Nm
69 Nm
51 ftlbs.

66 Nm
65 ftlbs.
52 Nm
36 fl.lbs.
:ig.
the prybar. Do not insert the prybar so far the oil seal
in the case is damaged. Tie the halfshafts aside.
14. On AWD vehicles, disconnect the exhaust
pipe and remove the transfer case.
15. Remove the lower bellhousing cover and re-
move the special bolts holding the flexplate to the
torque converter. To remove, turn the engine crank-
shaft with a box wrench and bring the bolts into a po-
sition appropriate for removal, one at a time. After re-
moving the bolts, push the torque converter toward
the transaxle so it doesn’t stay on the engine allowing
oil to pour out the converter hub or cause damage to
the converter,
16. Remove the lower transaxle to engine bolts
and remove the transaxle assembly. To install: 17. After the torque converter has been mounted
on the transaxle, install the transaxle assembly on the
engine. Tighten the driveplate bolts to 34-38 ft. Ibs.
(4653 Nm). Tighten the transaxle-to-engine bolts to
35 ft. Ibs. (48 Nm). Install the bellhousing cover.
18. On AWD vehicles, install the transfer case
and frame pieces. Connect the exhaust pipe using a
new gasket.
19. Replace the circlips and install the halfshafts
to the transaxle.
20. Install the tie rods and ball joint to the steer-
ing arm.
21. Install the transaxle mounting bracket.
22. install the under guard.
23. Install the starter.
24. Connect the speedometer cable and oil cooler
lines.
25 Connect the solenoid, neutral safety switch
(inhibitor switch), the pulse generator kickdown
servo switch and oil temperature sensor.
26. Install the shift control cable.
27. Install the air hose, intercooler and air cleaner
assembly.
If equipped with an active ECS, connect the
mante with a F4A33 automatic transaxle
30 Refill with Dexron II, Mopar ATF Plus type
7176, Mitsubishi Plus ATF or equivalent, automatic
transaxle fluid. If vehicle is AWD check and fill the
transfer case.
31. Start the engine and allow to idle for 2 min-
utes. Apply parkrng brake and move selector through
each gear posrtion, ending in N. Recheck fluid level
and add if necessary. Fluid level should be between
the marks in the HOT range.
1994-90 MODELS
1. Disconnect the negative battery cable.
2. Remove the air cleaner and intake hoses.
3. Drain the transaxle into a suitable waste con-
tainer.
4. Remove the nut securing the shifter lever to
the transaxle. Remove the cable retaining clip and re-
move the cable from the transaxle.
5. Remove the shifter cable mounting bracket,
6. Tag and detach the electrical connectors for
the speedometer, solenoid, neutral safety switch (in-
hibitor switch), the pulse generator, kickdown servo
switch, and the oil temperature sensor.
7. Tag and disconnect the oil cooler lines at the
transaxle.
8. Remove the bolt securing the fluid dipstick
tube to the transaxle. Remove the dipstrck and tube
from the transaxle.
9. Remove the starter motor and position it
aside.
10. Using special tool MZ203827 or equivalent,
support the engine assembly.
11. Remove the rear roll stopper mounting
bracket.
12. Remove the transaxle mount bracket.
13. Remove the upper transaxle mounting bolts.
14. Raise and safely support the vehicle.
15. Remove the front wheel assemblies.
16. Remove the right hand undercover.
17. Remove and discard the cotter pin, then dis-
connect the tie rod end from the steering knuckle,
18. Disconnect the stabilizer bar link from the
damper fork.
19. Disconnect the damper fork from the lateral
lower control arm.
20. Disconnect the lateral lower arm, and the
compression arm lower ball joints from the steering
knuckle.
21. Pry the halfshafts from the transaxle, and se-
cure aside.
22. Remove the cover from the transaxle bell-
housing.
23. Remove the engine front roll stopper
through-bolt.
24. Remove the crossmember and the triangular
right hand stay.
25. Remove the bolts holding the flexplate to the
torque converter with a box wrench Rotate the engine
to bring the bolts into a position appropriate for re-
moval, one at a time. After removing the bolts, push
the torque converter toward the transaxle. This will
prevent the converter from remaining intact with the
engine, possibly damaging the converter,
26. Support the transaxle, using a transmission
jack, and remove the transaxle lower coupling bolt.
*The coupling bolt threads from the engine
side, into the transaxle, and is located just
above the halfshafl opening.

DRIVETRAIN 7-13
27. Shde the transaxle rearward and carefully
lower it from the vehicle.
To install: 28. After the torque converter has been mounted
on the transaxle, install the transaxle assembly to the
engine. Install the mounting bolts and tighten to 35
ft. Ibs. (48 Nm).
29. Install the transaxle lower coupling bolt and
tighten to 21-25 ft Ibs. (29-34 Nm).
30. Connect the torque converter to the flexplate
and tighten the bolts to 33-38 ft. Ibs. (45-52 Nm).
31. Install the cover to the transaxle bellhous-
ing and tighten the mounting bolts to 7 ft. Ibs. (9
Nm).
32 Install the crossmember and tighten the front
mounting bolts to 65 ft. Ibs (88 Nm) and the rear
bolt to 54 ft. Ibs. (73 Nm) Install the front engine roll
stopper through-bolt and lightly tighten. Once the full
weight of the engine is on the mounts, tighten the ’
bolt to 42 ft. Ibs. (57 Nm),
33. Install the triangular stay bracket and tighten
the mounting bolts to 65 ft. Ibs. (88 Nm).
34. Install the halfshafts, using new circlips on
the axle ends.
When installing the axleshaft, keep the in-
board joint straight in relation to the axle, so
as not to damage the oil seal lip of the
transaxle with the serrated part of the half-
shaft.
35. Connect the tie rod and ball joints to the
steering knuckle. Tighten the ball joint self-locking
nuts to 48 ft. Ibs. (65 Nm). Tighten the tie rod end nut
to 21 ft. Ibs. (28 Nm) and secure with a new cotter
pin.
36. Connect the damper fork to the lower control
arm and tighten the through-bolt to 65 ft Ibs. (88
Nm).
37. Connect the stabilizer link to the damper fork,
and tighten the self-locking nut to 29 ft. Ibs. (39 Nm).
38. Install the undercover.
39. Install the wheels and carefully lower the ve-
hicle
40. Install the transaxle mount bracket to the
transaxle, and tighten the mounting nuts to 32 ft. Ibs.
(43 Nm).
41. Install the rear roll stopper mounting bracket.
42. Remove the engine support. Tighten the
transaxle mount through-bolt to 51 ft. Ibs. (69 Nm)
and tighten the front engine roll stopper through-bolt.
43. Install the upper transaxle mounting bolts
and tighten to 35 fl. Ibs. (48 Nm).
44. Install the starter motor.
45. Install the dipstick tube and the dipstick
46. Install the shifter cable mounting bracket.
47. Connect the shifter lever and tighten the re-
taining nut to 14 ft. Ibs. (19 Nm).
48. Connect the oil cooler lines and secure with
clamps.
49. Attach the electrical connectors for the
speedometer, solenoid, neutral safety switch (in-,
hibitor switch), the pulse generator, kickdown servo
switch and oil temperature sensor.
50. Install the air cleaner and the air intake hose.
51. Connect the negative battery cable.
52. Make sure the vehicle is level, and refill the
transaxle. Start the engine and allow to idle for 2 minutes. Apply parking brake and move selector
through each gear position, ending in N. Recheck
fluid level and add if necessary. Fluid level should be
between the marks in the HOT range.
53. Check the transaxle for proper operation.
Make sure the reverse lights come on when in re-
verse and the engine starts only in
P or N.
Mirage
*If the vehicle is going to be rolled on its
wheels while the halfshafts are out of the ve-
hicle, obtain two outer CV-joints or proper
equivalent tools and install to the hubs. If the
vehicle is rolled without the proper torque
applied to the front wheel bearings, the bear-
ings will no longer be usable.
1. Disconnect the negative battery cable then
the positive battery cable.
2. Remove the battery and battery tray.
3. Remove the air hose and air cleaner assem-
bly.
4. Raise the vehicle and support safely.
5. Remove the under guard pan.
6. Drain the transaxle oil into a suitable con-
tainer.
7. If equipped with 1.6L engine, remove the ten-
sion rod.
8. Disconnect the control cable and cooler
lines.
9. On 3-speed transaxles, disconnect the throt-
tle control cable.
10. On 4-speed transaxles, perform the following:
a. Detach the shift control solenoid valve
connector.
b. Disconnect the inhibitor switch and kick-
down servo switch.
c. Disconnect the pulse generator and oil
temperature sensor.
11. Disconnect the speedometer cable and re-
move the starter.
12. Remove the transaxle mounting bolts and
bracket.
13. Disconnect the stabilizer bar from the lower
control arm.
14. Disconnect the steering tie rod end and the
ball joint from the steering arm.
15. Remove the halfshafts at the inboard side
from the transaxle. Tie the joint assembly aside.
*It is not necessary to disconnect the half-
shafts from the wheel hubs.
16. Support the engine and remove the center
member.
17. Remove the bellhousing cover and remove
the driveplate bolts.
18 Remove the transaxle assembly lower con-
necting bolt, located just over the halfshaft opening.
19. Properly support the transaxle assembly, then
lower it, moving it to the right for clearance.
To install: 20. After the torque converter has been mounted
on the transaxle, install the transaxle assembly on the
engine. Install the mounting bolts and tighten to
31-40 ft. Ibs. (43-55 Nm) on 1990-92 models and
35 ft. Ibs. (48 Nm) on 1993-00 models.
21. Tighten the driveplate bolts to 33-38 ft. Ibs.
(46-53 Nm). Install the bellhousing cover.
22. Install the center member. 23. Replace the circlips and install the halfshafts
to the transaxle.
24. Install the tie rods, ball joints and stabilizer
links to the steering arm
25. Install the transaxle mounting bracket and
bolts.
26. Install the starter.
27. Connect the speedometer cable.
28. Connect the inhibitor switch, kickdown servo
switch, the pulse generator and oil temperature sen-
sor, if disconnected.
29. Connect the shift control solenoid valve con-
nector.
30. Connect the control cables and oil cooler
lines.
31. Install the tension rod, if removed.
32. Install the air cleaner assembly.
33. Install the battery tray and battery.
34. Connect the positive then the negative termi-
nal.
35. Refill with Dexron@ II, Mopar ATF Plus type
7176 or equivalent, automatic transaxle fluid.
36. Start the engine and allow to idle for two min-
utes. Apply parking brake and move selector through
each gear position, ending in N. Recheck fluid level
and add if necessary. Fluid level should be between
the marks in the HOT range.
ADJUSTMENTS
Shifter Control Cable Adjustment
1. The shifter cable adjustment is done at the
neutral safety switch (inhibitor switch). Locate the
switch on the transaxle and note the alignment holes
in the arm and the body of the switch. Place the se-
lector lever in N. Place the manual lever of the
transaxle in the neutral position.
2. Check alignment of the hole in the manual
control lever to the hole in the inhibitor switch body.
If the holes do not align, adjustment is required.
3. To adjust, loosen the nut on the cable end and
pull the cable end by hand until the alignment holes
match. Tighten the nut. Check that the transaxle
shifts and conforms to the positions of the selector
lever.
Throttle Valve Cable
The throttle valve adjustment applies only to the
1990-96 Mirage.
1. Place selector lever and manual control lever
in N position.
2. Loosen adjusting nut. While lightly pulling on
control cable tighten mounting nut to 7-10 ft. Ibs.
(X-14 Nm).
3. When adjustment is complete, be sure selector
lever is still in the N position. Verify all functions
correspond to the position indicated on the selector
lever.
The halfshaft removal and installation and over-
haul are the same as a manual transaxle Please refer
to Manual Transaxle in this Section

DRIVETRAiN 7-15
MATING MARKS
/
89577Q5E Fig. 52 Apply mating marks on the flange
yoke and differential companion flange
5. Once all bearings are removed, remove the
journal.
To install:
6. Apply multi-purpose grease to the shafts,
grease sumps, dust seal lips and needle roller bear-
ings of the replacement U-joint Do not apply exces-
sive grease Otherwse, faulty fitting of bearing caps
and errors in selection of snaprings may result.
7. Press fit the journal bearings to the yoke using
a C-clamp as follows:
a. Install a solid base onto the bottom of the
C-clamp.
b. Insert both bearings into the yoke. Hold
and press fit them by tightening the C-clamp.
c. Install snaprings of the same thickness
onto both sides of each yoke.
d. Press the bearing and journal into one side, using a brass bar with diameter of 0.59 in.
(15mm).
8. Measure the clearance between the snapring
and the groove wall of the yoke with a feeler gauge. If
the clearance exceeds 0.0008-0.0024 in.
(0.02-O.O6mm), the snap rings should be replaced.
DRIVESHAFT BALANCING
Driveshaft balancing is a process best left for a
professional wrth the proper equipment. Makeshift
methods using hose clamps or similar devices can
work, but the process of correcting the imbalance in
this manner is very tough and extremely time con-
suming.
Many machine shops can balance driveshafts;
some parts stores and jobbers can also balance dri-
veshafts using outside contractors.
REMOVAL&INSTALLATION
1. Place matmg marks on the companron flange
and the Lobro joint assembly
2. Remove the Lobro joint installation bolts.
Separate the Lobro joint from the companion flange.
3. Place mating marks on the center yoke and
center propeller shaft, and the companion flange and
the rear propeller shaft.
4. Remove the self-locking nuts. Remove the
center yoke and companion flange. 5. Place mating marks on the center bearing as-
sembly front bracket and the center propeller shaft,
and the center bearing assembly rear bracket and the
rear propeller shaft. Remove the center bearing
bracket.
*The mounting rubber can not be removed
from the center bearing bracket.
6. Pull out the front and rear center bearings
with a commercially available puller
To install:
7. Apply multi-purpose grease to the center
bearing front and rear grease grooves and to the dust
seal lip Be sure to fit the bearing into the rubber
mount groove on the center bearing bracket.
*Face the bearing dust seal to the side of
the center bearing bracket mating mark.
8. Assemble the center bearing to the center
propeller shaft and rear propeller shaft. Face the side
onto which the center bearing bracket mating marks
IS placed and the dust seal is installed toward the
side of the center propeller shaft and rear propeller
shaft.
9 Apply a thin and even coat of the grease, en-
closed with the repair kit, to the rubber packing on
the companion flange. Align the mating marks on the
center propeller shaft and the companion flange, then
press fit the center bearing with self-locking nuts.
10 Install the Lobro joint assembly installation
bolts. Secure the companron flange and Lobro joint
assembly with the installation bolts Check for grease
leakage from the Lobro joint boot and companion
flange installabon parts.
The only model covered by this manual equipped
with a rear axle differential is the 1990-93 AWD
Galant.
REMOVAL &INSTALLATION
# See Figures 53 and 54
1. Disconnect the negative battery cable. Raise
the vehicle and support safely.
2. Remove the bolts that attach the rear halfshaft
to the comoanion flanae.
3. Use’a prybar topry the inner shaft out of the
I Fig. 53 Rear driveshaft mounting
89577g5
differential case. Don’t insert the prybar too far or the
seal could be damaged.
4 Remove the rear driveshaft from the vehicle.
5. If necessary, carefully pry the oil seal from the
rear differential using a flat tipped prying tool.
To install:
6. Install a new oil seal into the rear differential
housing using proper size driver.
7. Replace the circlip and install the rear drive-
shaft to the differential case. Make sure it snaps in
place.
8. Install the companion flange bolts and tighten
to 40-47 ft. Ibs. (55-65 Nm).
9. Check the fluid level in the rear differential.
69577958 Fig. 54 Remove the driveshaft from the dif-
ferential carrier with a prybar
REMOVAL &INSTALLATION
1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3 Remove the tire and wheel assembly from the
vehicle.
4 If equipped with ABS, remove the rear wheel
speed sensor.
*Be cautious to ensure that the tip of the
pole piece on the rear speed sensor does not
come in contact with other parts during re-
moval. Sensor damage could occur.
5. Remove the rear caliper and support assem-
bly out of the way. Remove the brake disc.
6. Remove the driveshaft and companion flange
installation bolts, nuts and washers. Move the end of
shaft slightly to access the self-locking nut.
7. Using axle holding tool MBSbll-01 or
equivalent, secure the rear axle shaft in position, then
remove the self-locking nut.
8. Using puller and adapter MBSbll-01 and
MB9b41-01 or equivalents, remove the rear axle
shaft from the trailing arm
9. If equipped with ABS, remove the rear rotor
from the axle assembly using collar and press. The
rotor is a press fit.
10 Remove the outer bearing and dust cover
concurrently from the axle shaft using a press.

SUSPENSION AND STEERING 8-7
1 Cotter p,n
2 Drive shaft
3 Washer
4 Caliper assembly connecf~on
5 Self-IockIng ““f
6 Lower arm ball ,Ol”f Connectlo”
7 cotter PI”
8 T,e rod end connectton
9 Drive Shaft
10 Strut assembly connection
11 Hub and knuckle
1990-92 Mirage front suspension components
-
1 Cutter PI”
2 Drtve shaft
3 Washer
4 Ca,,perassembly connect~o”
5 Self-locking nut
6 Lower arm ball ,o,nt connection
7 cotter PI”
8 Tie rod end connection
9 Dwe shaft
10 Strut assembly connection
11 Hub and knuckie
Diamante front suspension components
1
to knuckle bolts Use a piece of wire to suspend the
knuckle to keep the weight off the brake hose.
6. If equipped with Active Electronrc Control
Suspension (Active-ECS) perform the followrng:
REMOVAL &INSTALLATION a. Loosen the nut that secures the an line to
the to the too of the strut and discard the O-ring.
Diamante, 1990-93 Galant, and 1999-00
Galant
1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the brake hose and the tube bracket.
40 not pry the brake hose and tube clamp
awav when removino it.
b. Remove the bolts that secure the actuator
to the top of the strut and remove the compo-
nent. Disconnect the wiring harness.
*Before removing the top bolts, make
matchmarks on the body and the strut insula-
tor for proper reassembly.
7. Remove the strut upper nuts and remove the
strut assemblv from the vehicle.
4. If equipped with ABS, disconnect the front
speed sensor mounting clamp from the strut.
5. Support the lower arm and remove the strut
To instalf: 8. Install the strut to the vehicle and tighten the
upper mounting nuts to 33 ft. Ibs. (45 Nm)
9 Align the strut to the knuckle and connect with the mounting bolts. Tighten the mounting bolts
to 70-76 ft. Ibs. (90-105 Nm).
10. If equipped with Active-ECS, perform the fol-
lowing,
a. Install the air line with a new O-ring.
b Install the actuator to the top of the strut
Connect the wiring harness.
11. Install the brake hose bracket and the ABS
clamp, if equipped.
12. Install the wheel and tire assembly.
13. Have a front end alignment performed.
Mirage
# See Figure 11
1, Disconnect the negative battery cable.
2. Raise and safely support vehicle.
3. Remove the brake hose and tube bracket re-
tainer bolt and bracket from the front strut. Do not pry
the brake hose and tube clamp away when removrng.
4. If equipped with ABS, disconnect the front
speed sensor mounting clamp from the strut.
5. Support the lower arm usmg floor jack or
equivalent Remove the lower strut to knuckle bolts.
*Before removing the top bolts, make
matchmarks on the body and the strut insula-
tor for proper reassembly.
6. Remove the strut upper mounting bolts.
7. Remove the strut assembly from the vehicle.
To install: 8. Install the strut to the vehicle and install the
top mounting bolts, Tighten the mountrng bolts to 29
ft. Ibs. (40 Nm)
9. Position the strut on the knuckle and mstall
the mounting bolts, While holdrng the head of the
lower mounting bolt, tighten the nuts to 80-94 ft. Ibs.
(110-130 Nm).
10. Install the brake hose bracket and the ABS
clamp, if equipped
11 Install the wheel and tire assembly
12. Have a front end alignment performed.
OVERHAUL
) See Figures 12 thru 22
1. Remove the strut assembly from the vehicle, as
outlined earlier in this Section.
2. Mount the strut assembly into a suitable
spring compressor.
3. Compress the strut approximately r/a its height
after initial contact with the top cap.
Never bottom the spring or dampener rod!
4. Remove the center nut from the strut and re-
move the upper mounting bracket and bushings.
5. Remove the coil spring.
To install: 6. Install the compressed spring on the strut as-
sembly.
7. Install the upper bushings and the mounting
bracket Install the nut and tighten it to 43 ft. Ibs. (59
Nm).
8. Remove the strut from the spring compressor.
9. Install the strut into the vehrcle

8-8 SUSPENSION AND STEERING
REMOVAL &INSTALLATION
199443 Galant
u See Figures 23 and 24
1 a Disconnect the neaative batterv cable.
I 3. Remove the appronnate wheel assembly.
25
Nm
18 fths.
I 2. Raise and safelv su~oort vehicle.
I I ,I 4. Disconnect the sway bar link from the
oamper rork.
5. Remove the damper fork lower through-bolt
and upper pinch bolt. Remove the damper fork as-
sembly.
6. Remove the shock absorber upper nuts and
remove the shock and spring assembly from the ve-
hicle.
To install:
7. Install the upper bracket assembly and position
it so that the three bolts are in the correct position.
8. Install the upper bushing, washer, and lock-
nut. Tighten the locknut to 18 ft.-lbs.
9. Install the shock absorber and tighten the up-
Removal steps
csution
1. Brake hose clamp For vehicles with ABS, be careful when handling
2. Front speed sensor the pole piece at the tip of the spaed sensor so
as not to damage it by striking against other parts.
3. Bolts
4. Self-locking nut
5. Strut assembly
I
7wmA6
Fig. 11 Front strut assembly and related parts---Mirage ft. Ibs. (103 Nm).
11. Connect the sway bar link to the damoer fork per mounting nuts to 32 ft. Ibs. (44 Nm).
IO. Align the shock to the damper fork and install
the damper fork. Tighten the lower through-bolt/nut
to 65 ft. Ibs. (88 Nm) and the upper pinch bolt to 76
and tighten the link nut tb 29 ft. Ibs. (39 Nm):
12. Install the wheel and tire assembly.
13. Have a front end alignment performed.
I STRUT ASSEMBLY EXPLODED VIEW
I ,-
:-, : ;i
,\,.^ -_ I~.’ :“:;rL~~<
-_ cy -.:;;yp;:,
91146p?Jl Fig. 12 Install a suitable strut spring com-
91146p61 Fig. 13 Tighten down the nuts on the top of
the forcing screws on this type of spring
pressor onto the strut spring
compressor
Fig. 14 A special set of sockets Is available
to remove the nut from the top of the strut
Fig. 15 Place the larger socket over the nut
1 ;ir ;;ostrut;;; install the small soi8oet

SUSPENSION AND STEERING 8-13
W-118 Nm*
71-W ft.lbs: 83Nm

69-78 Nm
Compression lower arm assembly
removal steps
1. Connection for compression lower
arm ball joint and knuckle
2. Comoression lower arm mouniina Lateral lower tmn assembly removal
steps
4. stay
bon ’ 3. Compression lower arm assembly 6. CMlnection for lateral lower arm
ball joint and knuckle
7. lateral lower arm mounting boll
andnllt
0. hleral lower am7 assembly
CWtlOtl
l : Indicates parts which should be temporarily tightened,
and then fully tightened with the vehicle on the ground
in the unladen condition
7923PGB8 Fig. 40 Exploded view of the lower control arms-Galant
tion and replace as required. 8.
9. Inspect all bushings for wear and deteriora-
Check the sway bar for damage, and replace
as required.
To install: 10. Install the sway bar into the vehicle.
11. Install the sway bar brackets on the vehicle,
following any side locating markings on the brackets.
Temporarily tighten the sway bar bracket. Align the
bushing end with the marked part of the sway bar and
then fully tighten the sway bar bracket.
12. If equipped with the pillow-ball type mount-
ing, install the sway bar links and link mounting nuts.
Using a wrench, secure the ball studs at both ends of
the sway bar link while tightening the mounting nuts.
Tighten the nuts on the sway bar bolt so that the dis-
tance of bolt protrusion above the top of the nut is
0.63-0.70 in. (1&18mm).
13. Install the front exhaust pipe with new gasket
in place. Tighten new self-locking nuts to 29 ft. Ibs.
(40 Nm). and the sway bar bracket and bushing.
6. 5. Remove the sway bar bracket installation bolt
Disconnect the sway bar coupling at the right
lower control arm. Pull out the left side sway bar
edge, pulling it out between the driveshaft and the
lower arm. Pull out the right side bar below the lower
arm.
To install:
14. Connect the negative battery cable.
A WD VEHICLE
I
1. Disconnect the negative battery cable.
2. Remove the front exhaust pipe.
3. Remove the center gusset and transfer as-
sembly.
4. Using a wrench to secure the ball studs at
both ends of the sway bar link, remove the sway bar
link mounting nuts. Remove the sway bar link. 11. Connect the negative battery cable.
REMOVAL & INSTALLATION
7. Install the bar into the vehicle in the same Diamante, Mirage, 1996-93 Galant, and manner as removal. 1999-00 Galant 8. Temporarily tighten the sway bar bracket.
Align the bushing end with the marked part of the
sway bar and then fully tighten the stabilizer bar
bracket.
9. Install and tighten the sway bar bracket bolt.
10. Install the sway bar links and link mounting
nuts Using a wrench, secure the ball studs at both
ends of the sway bar link while tightening the mount-
ing nuts. Tighten the nuts on the sway bar bolt so
that the distance of bolt protrusion above the top of
the nut is 0.63 to 0.70 in. (16 to 18mm).
11. Install the transfer assembly and gusset.
12. Install the left crossmember. Tighten the rear
mounting bolts to 58 ft Ibs. (80 Nm) and the front
mounting bolts to 72 ft. Ibs. (100 Nm). ) See Figures 45, 46, and 47
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely. Remove
the halfshaft nut.
3. If equipped with ABS, remove the front wheel
speed sensor
1994-90 Galant
4. If equipped with Active Electronic Control
Suspension (Active-ECS), disconnect the height sen-.
sor from the lower control arm.
5. Remove the caliper assembly and brake pads.
Suspend the caliper with a wire
6. Using a suitable ball joint separator tool, dis-
connect the ball joint and tie rod end from the steer-
ing knuckle.
7. Remove the halfshaft from the hub.
8. Unbolt the lower end of the strut and remove
the hub and steering knuckle assembly from the vehi-
cle.
9 Remove the hub, bearings and races as fol-
lows.
# See Figures 42, 43, and 44
1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle 3. Disconnect the sway bar links by removing
the self-locking nuts.
4. Remove the sway bar mounting brackets and
bushings.
5. Remove the bar from the vehicle.
6. Inspect all components for wear or damage,
and replace parts as needed.
To install: 7. Install the sway bar into the vehicle.
8. Loosely install the sway bar brackets on the
vehicle.
9. Align the side locating markings on the sway
bar, so that the marking on ihe bar, extends approxi-
mately 0.40 inches (1Omm) from the Inner edge of
the mounting bracket, on both sides.
10. With the sway bar properly aligned, tighten
the mounting bracket bolts to 28 ft. Ibs. (39 Nm).
11. Connect the sway links to the damper fork
and the sway bar. Tighten the locking nuts to 28 ft.
Ibs (39 Nm).
12. Lower the vehicle and connect the negative
battery cable.
Diamante
1. Disconnect the negative battery cable.
2. Raise the vehicle and support safely.
3. Remove the front exhaust pipe and engine
undercover.
4. Remove the left and right frame members.
5. Remove the sway bar link.
6. Remove the sway bar brackets and remove
the sway bar from the vehicle.
To install: 7. Note that the bar brackets are marked left and
right. Lubricate all rubber parts and install the bush-
ings, the sway bar and brackets.
8. Install the sway bar link.
9. Install the frame members.
10. Install the engine undercover and exhaust
pipe.