front MITSUBISHI LANCER 2005 User Guide

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-6
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAMM1173000900417
AK300964
To
fuel tankFuel pressure
regulatorFrom
fuel pump
Catalytic
converter
Catalytic
converter Oxygen sensor
(front)
Oxygen sensor (rear)EGR valve <4G1>
EGR control
solenoid valvePurge control
solenoid valveCanisterAir
AB
Air cleaner
AK204364
AC
Air cleaner
Air
Canister
Purge control
solenoid valve EGR control
solenoid valve EGR valve From
fuel pump To
fuel tankFuel pressure
regulator
PCV valve
Oxygen sensor
(front)
Oxygen sensor (rear) Catalytic
converter
Catalytic
converter
<4G6>

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
DRIVE SHAFT ASSEMBLY . . . . . . . .26-14
REMOVAL AND INSTALLATION . . . . . . . . 26-14
DISASSEMBLY AND REASSEMBLY . . . . . 26-18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 26-21
BJ BOOT (RESIN BOOT)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 26-21

GENERAL INFORMATION
FRONT AXLE26-2
GENERAL INFORMATION
M1261000100347
The front axle consists of front hubs, knuckles, wheel
bearings and driveshafts, and has the following
features:
•The wheel bearing is a double-row angular
contact ball bearing which incorporates the oil
seals and is highly resistant to thrust loads.
•The driveshaft incorporates BJ-TJ type constant
velocity joints with high transmission efficiency for
low vibration and noise.•The dynamic damper has been mounted on the
driveshaft to reduce differential gear noise.
•ABS rotor for detecting the wheel speed is
press-fitted to the BJ.
NOTE: .
•TJ: Tripod Joint
•BJ: Birfield Joint
SPECIFICATIONS
CONSTRUCTION DIAGRAM
Item 1.3L, 1.6L 2.0L
Wheel bearing Type Double-row angular contact ball bearing
Bearing (OD x ID) mm 80 x 40 80 x 40
Driveshaft Joint type Outer BJ BJ
Inner TJ TJ
Length (joint to joint) ×
diameter mm LH 375.9 × 23.2 375.9 × 23.2
RH 699 × 23.2 (1.6L-M/T),
703.2 × 22 (1.3L-M/T,
1.6L-A/T)700 × 23.2
AC303569
Front hubKnuckleStrut assembly
TJ (LH)
Drive shaft (LH)
Dynamic damper
BJ
Wheel bearing
Drive shaft (RH) TJ (RH)
AB
ABS rotorDynamic damper

SERVICE SPECIFICATIONS
FRONT AXLE26-3
SERVICE SPECIFICATIONS
M1261000300396
LUBRICANTS
M1261000400382
Item Standard value Limit
Wheel bearing axial play mm
−0.05
Hub starting torque N⋅m
−1.8
Protruding length of stabilizer bar mounting bolt mm 22 ± 1.5
−
Setting of TJ boot length mm 1.3L-RH, 1.6L-A/T-RH 85 ± 3
−
1.3L-LH, 1.6L-M/T,
1.6L-A/T-LH, 2.0L90 ± 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 mm 2.4 − 2.8
−
Item Specified lubricant Quantity
TJ boot grease Repair kit grease 1.3L-LH, 1.6L-LH, 2.0L-LH 120 ± 10 g
1.3L-RH, 1.6L-A/T-RH 110 ± 10 g
1.6L-M/T-RH 120 ± 10 g
2.0L-RH 105 ± 10 g
BJ boot grease Repair kit grease 95 ± 10 g

SPECIAL TOOLS
FRONT AXLE26-4
SPECIAL TOOLS
M1261000600375
Tool Number Name Use
MB990767 End yoke holder Fixing of the hub
MB991618 Hub bolt remover Removal of the hub bolt
MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113)is also used
to disconnect knuckle and tie rod end
ball joint.
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller barRemoval of the drive shaft
MB991354 Puller body
MB991056 or
MB991355Knuckle arm
bridge•Removal of the hub
•Removal of the wheel bearing
A: MB991017
B: MB990998
C: MB991000A, B: Front hub
remover and
installer
C: Spacer•Removal of the hub
•Provisional holding of the wheel
bearing
•Measurement of hub starting torque
•Measurement of wheel bearing axial
play
NOTE: MB991000, which belongs to
MB990998, should be used as a
spacer.
B990767
MB991618
AC106827
MB990241AB
A
B
MB991354
AC100320 ABA
B
C

SPECIAL TOOLS
FRONT AXLE26-5
MB990685 Torque wrench Measurement of hub starting torque
MB990326 Preload socket
MB990810 Side bearing
puller•Removal of the centre bearing
bracket
•Removal of the wheel bearing inner
race (outside)
MB991460 Plug Prevention of transmission fluid drain
and of entry of foreign objects
MB991561 Boot band
crimping toolBJ boot (resin boot) band installation
MB990925 Bearing and oil
seal installer set•Removal of the wheel bearing
•Removal and installation of the
centre bearing
•Press-fitting of the dust seal outer,
inner
MB990890 Rear suspension
bushing base•Installation of the wheel bearing
•Press-fitting of the dust seal outer,
inner
MB990883 Rear suspension
bushing arborInstallation of the wheel bearing Tool Number Name Use
MB990326
MB990810
MB991561
MB990925
MB990890
MB990883

SPECIAL TOOLS
FRONT AXLE26-6
Tool Type Tool number O D mm
A MB990926 39.0
MB990927 45.0
MB990928 49.5
MB990929 51.0
MB990930 54.0
MB990931 57.0
MB990932 61.0
MB990933 63.5
MB990934 67.5
MB990935 71.5
MB990936 75.5
MB990937 79.0
B MB990938
−
C MB990939
−
ACX02372
A
BCBrass bar
Bar (snap-in type)
Tool box MB990925
AC
Installer adapter

ON-VEHICLE SERVICE
FRONT AXLE26-7
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECKM1261000900224
1. Remove the caliper assembly and suspend it with
a wire.
2. Remove the brake disc from the front hub.
3. Attach a dial gauge as shown in the illustration,
and then measure the axial play while moving the
hub in the axial direction.
Limit: 0.05 mm
4. If axial play exceeds the limit, disassemble the
front hub assembly and check the parts.
5. Install the brake disc, caliper assembly and
tighten the caliper assembly mounting bolts to the
specified torque 100 ± 10 N⋅m.
HUB BOLT REPLACEMENTM1261001000291
1. Remove the caliper assembly and suspend it with
wire so that it does not fall.
2. Remove the brake disc.3. Use special tool hub bolt remover (MB991618) to
remove the hub bolts.
4. Install the plain washer to the new hub bolt, and
install the bolt with a nut while holding the hub
with special tool end yoke holder (MB990767).
5. Install the brake disc, caliper assembly and
tighten the caliper assembly mounting bolts to the
specified torque 100 ± 10 N⋅m.
AC209503AC
AC302114
MB991618
AD
Hub bolt
AC104588
MB990767
Plain
washer
AC

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-8
FRONT AXLE HUB ASSEMBLY
REMOVAL AND INSTALLATIONM1261001700353
CAUTION
•Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when
removing or installing the drive shaft. Otherwise the ABS rotors will be damaged.
•Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Post-installation Operation
•Check the dust cover for cracks or damage by pushing it
with your finger.
AC209505
N
N
N
5
4 3 1 810
9 2 76
167 ± 9 N·m25 ± 5 N·m
108 ± 10 N·m245 ± 29 N·m
100 ± 10 N·m
AC
7
7
111213
Removal steps
1. Front ABS sensor
<>
2. Caliper assembly
<>
3. Brake disc
<> >>B<<4. Drive shaft nut
>>B<<5. Washer
>>A<<6. Self-locking nut (stabilizer bar
connection)
>>A<<7. Stabilizer rubber8. Collar
9. Lower arm connecting bolt
<>
10. Self-locking nut (tie rod end
connection)
<>
11 . D r i v e s h a f t
12. Nut (hub and knuckle to strut
connection)
13. Hub and knuckle
Removal steps (Continued)