check MITSUBISHI LANCER 2005 Repair Manual

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-21
INSPECTIONM1261003800130
•Check the drive shaft for damage, bending or
corrosion.
•Check the drive shaft spline part for wear or
damage.
•Check the spider assembly for roller rotation,
wear or corrosion.
•Check the groove inside TJ case for wear or
corrosion.
•Check the dynamic damper for damage or
cracking.
•Check the boots for deterioration, damage or
cracking.
BJ BOOT (RESIN BOOT) REPLACEMENTM1261005200361
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and
assemble the boot band and BJ boot.4. Align the centre groove on the BJ boot small end
with the shaft groove.
5. Turn the adjusting bolt on special tool boot band
crimping tool (MB991561) so that the size of the
opening (W) is at the standard value.
Standard value (W): 2.9 mm
Tighten the
adjusting bolt.
Loosen the
adjusting bolt.
NOTE: The value of W will change by
approximately 0.7 mm for each turn of the
adjusting bolt.
NOTE: The adjusting bolt should not be turned
more than once.
6. Position the BJ boot band (small) so that there is
even clearance at either end (A and B).
AC102658
AC102659
AC102660
WMB991561
Stopper
Adjusting bolt
AC
AC102661AC
Boot
A
Boot band
(small)
B
Projection

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-22
CAUTION
•Secure the drive shaft in an upright position
and clamp part of the boot band to be crimped
securely in the jaws of special tool.
•Crimp the boot band until special tool
touches the stopper.
7. Use the special tool to crimp the boot band
(small).
8. Check that the crimping amount (C) of the boot
band is at the standard value.
Standard value (C): 2.4 − 2.8 mm

Readjust the value of (W) in step 5 according
to the following formula, and then repeat the
operation in step 7.
W = 5.5 mm − C
Example: If C = 2.9 mm, then W = 2.6 mm.
mm >
Remove the BJ boot band, readjust the value
of (W) in step 5 according to the following
formula, and then repeat the operations in
steps 6 and 7 using a new BJ boot band.
W = 5.5 mm − C
Example: If C = 2.3 mm, then W = 3.2 mm.
9. Check that the boot band is not sticking out past
the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 6 to 8, using a new boot band.
CAUTION
The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
10.Fill the inside of the boot with the specified
amount of the specified grease.
Specified grease: Repair kit grease
Amount to use: 95 ± 10 g
11.Align the centre groove on the BJ boot big end
with the BJ case groove.
12.Follow the same procedure as in step 5 to adjust
the size of the opening (W) on the special tool so
that it is at the standard value.
Standard value (W): 2.9 mm
13.Position the BJ boot band (large) so that there is
even clearance at either end (D and E).
14.Use the special tool to crimp the BJ boot band
(large) in the same way as in step 7.
15.Check that the crimping amount (F) of the boot
band is at the standard value.
AC102663 ACMB991561
AC102662
C
AD
AC102664AC
AC102665
AC
BootProjection
Boot band
(large) D
E
AC102666FAD

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-23
Standard value (F): 2.4 − 2.8 mm

Readjust the value of (W) in step 12
according to the following formula, and then
repeat the operation in step 14.
W = 5.8 mm − F
Example: If F = 2.9 mm, then W = 2.9 mm.
mm >
Remove the BJ boot band, readjust the value
of (W) in step 12 according to the following
formula, and then repeat the operations in
steps 13 and 14 using a new BJ boot band.
W = 5.8 mm − F
Example: If F = 2.3 mm, then W = 3.5 mm.16.Check that the boot band is not sticking out past
the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 13 to 15, using a new boot band.

27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . .27-2
SERVICE SPECIFICATIONS . . . . . . .27-2
SEALANT . . . . . . . . . . . . . . . . . . . . . .27-2
SPECIAL TOOLS . . . . . . . . . . . . . . . .27-3ON-VEHICLE SERVICE . . . . . . . . . . .27-4
WHEEL BEARING AXIAL PLAY CHECK . . 27-4
REAR HUB ROTARY-SLIDING
RESISTANCE CHECK . . . . . . . . . . . . . . . . 27-4
HUB BOLT REPLACEMENT . . . . . . . . . . . . 27-4
REAR AXLE HUB ASSEMBLY . . . . .27-5
REMOVAL AND INSTALLATION . . . . . . . . 27-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 27-6

ON-VEHICLE SERVICE
REAR AXLE27-4
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECKM1271000900452
1. Remove the caliper assembly, and suspend the
caliper assembly with a wire and remove the
brake disc.
2. Check the bearing's axial play. Place a dial gauge
against the hub surface; then move the hub in the
axial direction and check whether or not there is
axial play.
Limit: 0.05 mm
3. If the play exceeds the limit, the self-locking nut
should be tightened to the specified torque and
check the axial play again.
Tightening torque: 175 ± 25 N⋅m
4. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.
REAR HUB ROTARY-SLIDING
RESISTANCE CHECK
M1271001100244
1. Remove the caliper assembly, and suspend the
caliper assembly with a wire and remove the
brake disc.
2. Turn the hub a few times to seat the bearing.3. Wind a rope around the hub bolt and turn the hub
by pulling at a 90° angle with a spring balance.
Measure to determine whether or not the
rotary-sliding resistance of the rear hub is at the
limit value.
Limit: 19 N
4. If limit value is exceeded, loosen the self-locking
nut and then tighten it to the specified torque and
check the rear hub rotary sliding resistance again.
Tightening torque: 175 ± 25 N⋅m
5. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.
HUB BOLT REPLACEMENTM1271001000258
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 60 ± 5 N⋅m.
AC303736AB
AC303737
AC302114
MB991618
AD
Hub bolt
AC104588
MB990767
Plain
washer
AC

REAR AXLE HUB ASSEMBLY
REAR AXLE27-6
REMOVAL SERVICE POINTS
<> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
<> SELF-LOCKING NUT REMOVAL
CAUTION
Do not apply the vehicle weight to the wheel
bearing while loosening the self-locking nut, or
the wheel bearing will be damaged.
<> ABS ROTOR REMOVAL
Use the following special tools to press out ABS rotor
from the rear hub assembly.
•Remover (MD998801)
•Installer cap (MD998812)
•Installer100 (MD998813)
•Installer adapter (MD998815)
INSTALLATION SERVICE POINTS
>>A<< ABS ROTOR INSTALLATION
CAUTION
When installing, take care not to deform the ABS
rotor.
Press-fit the ABS rotor to the rear hub assembly.
>>B<< SELF-LOCKING NUT
INSTALLATION
CAUTION
Before securely tightening the self-locking nuts,
make sure there is no load on the wheel
bearings. Otherwise the wheel bearing will be
damaged.
Tighten the self-locking nut to the specified torque.
INSPECTIONM1271002100258
•Check the rear hub assembly for crack or
damage.
•Check the oil seal of the rear hub assembly for
crack or damage.
•Check the ABS rotor for chipped teeth.
AC303738
AC210936AC
MD998815
MD998801MD998813 MD998812
Rear hub assembly ABS rotor
AC102209
Iron piece
ABS rotor
Rear hub
assembly
Iron piece
AC
AC303739
175 ± 25 N·m
AB