boot MITSUBISHI LANCER EVOLUTION 2007 Service User Guide

PROPELLER SHAFT - Propeller Shaft25-9
4. Apply a little specific sealant to the surface which has
groove (for packing) of LJ assembly (allow as shown
in the illustration), fix the rubber packing.
Specified sealant: 3M Stud Locking 4170 or equivalent
5. Install the surface which has groove (for packing) of LJ
assembly to LJ boot side.
6. Aline the mating marks of LJ assembly and center propeller
shaft, then punch the LJ assembly to center propeller shaft
using socket wrench.
7. Aline the position of bolt holes of LJ boot and LJ assembly,
install the LJ boot to LJ assembly.
8. Fix the rubber packing of companion flange side in a
similar to step 4.
"CABOOT BAND INSTALLATION
Caution
1.Tighten the boot band part in opposite direction of
convex part for bleeding the boot.
2.If there is grease in the convex part, wipe out the
grease in order to bleed the boot.
Rubber packing
LJ assembly
Socket wrench
Bolt
LJ boot
Boot band Installation position
Projection
Boot

FRONT AXLE -Service Specifications/Lubricants/Special Tools26-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Wheel bearing axial play mm-0.06
WheelbearingrotationstartingtorqueN·m-103orlessWheelbearing rotation startingtorqueN·m-1.03orless
Setting of T.J. boot length mm85±3-
Opening dimension of the
special tool (MB991561) mmWhen the B.J.boot band
(small) is crimped.2.9-
When the B.J.boot band
(big) is crimped.3.2-
Crimped width of the B.J.boot band mm2.4 - 2.8-
LUBRICANTS
ItemsSpecified lubricantsQuantity g
T.J. boot greaseRepair kit grease120±10
B.J.boot greaseRepair kit grease11 0±10
SPECIAL TOOLS
ToolNumberNameUse
MB990767End yoke holderFixing of the hub
MB991618Hub bolt removerRemoval of the hub bolt
MB991113 or
MB990635Steering linkage
pullerDisconnection of ball joint
A
B
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller barDRemoval of the drive shaft
DRemoval of the hub
MB991354Puller bodyDRemoval of the drive shaft
DRemoval of the hub

FRONT AXLE -Special Tools26-4
Tool UseName Number
MB990685Torque wrenchMeasurement of wheel bearing rotation
starting torque
MB990326Preload socketMeasurement of wheel bearing rotation
starting torque
A
B
C
A: MB991017
B: MB990998
C: MB991000A,B: Front hub
remover and
installer
C: SpacerDProvisional holding of the wheel bearing
DMeasurement of wheel bearing rotation
starting torque
DMeasurement of wheel bearing axial play
MB991000, which belongs to MB990998,
should be used as a spacer.
MB991721Sliding hammerOutput shaft removal
MB991561Boot band clipping
toolResin boot band installation
MB990925
Brass bar
Installer adapterTool box
Bar (snap-in type) ACB
TypeTool numberO.D. mmTypeTool numberO.D. mm
MB99092639MB99093363.5
MB99092745MB99093467.5
MB99092849.5AMB99093571.5
AMB99092951MB99093675.5
MB99093054MB99093779
MB99093157BMB990938-
MB99093261CMB990939-

FRONT AXLE -Drive Shaft26-13
DISASSEMBLY AND REASSEMBLY
Caution
(1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be
careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race
to prevent the rotor from damage.
(2) Never disassemble the B.J. assembly except when replacing the B.J. boot.
2
6
4
3
5
7
1
4
2
43
61
2
4
51
2
9
10
1
8
8
97
6
T.J. repair kitT.J. boot repair kit B.J. boot repair kit
Disassembly steps
"BA1. T.J. boot band (large)
"BA2. T.J. boot band (small)
AA""AA3. T.J. case
4. Snap ring
AA""AA5. Spider assemblyAB"6. T.J. boot
7. B.J. boot band (large)
8. B.J. boot band (small)
9. B.J. boot
10. B.J. assembly

FRONT AXLE -Drive Shaft26-14
DISASSEMBLY SERVICE POINTS
AA"T.J. CASE/SPIDER ASSEMBLY REMOVAL
1. Wipe off grease from the spider assembly and the inside
of the T.J. case.
2. Always clean the spider assembly when the grease
contains water or foreign material.
Caution
Do not disassemble the spider assembly.
AB"T.J. BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the T.J. boot, wrap plastic tape around
the shaft spline to avoid damaging the boot.
REASSEMBLY SERVICE POINTS
"AASPIDER ASSEMBLY/T.J. CASE INSTALLATION
1. Apply the specified grease furnished in the repair kit to
the spider assembly between the spider axle and the
roller.
Specified grease: Repair kit grease
Caution
(1) The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
(2) If the spider assembly has been cleaned, take
special care to apply the specified grease.
2. Install the spider assembly to the shaft from the direction
of the spline bevelled section.
3. After applying the specified grease to the T.J. case, insert
the drive shaft and apply grease one more time.
Specified grease: Repair kit grease
Amount to use: 120±10 g
NOTE
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint uses special grease. Do not mix
old and new or different types of grease.Bevelled
section

FRONT AXLE -Drive Shaft26-15
"BAT.J. BOOT BAND (SMALL)/T.J. BOOT BAND
(LARGE) INSTALLATION
Set the T.J. boot bands at the specified distance in order
to adjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot bands securely.
Standard value (A): 85±3mm
INSPECTION
DCheck the drive shaft for damage, bending or corrosion.
DCheck the drive shaft spline part for wear or damage.
DCheck the spider assembly for roller rotation, wear or
corrosion.
DCheck the groove inside T.J. case for wear or corrosion.
DCheck the boots for deterioration, damage or cracking.
DCheck the dust cover for damage or deterioration.
B.J. BOOT (RESIN BOOT) REPLACEMENT
1. Remove the B.J. boot bands (large and small).
NOTE
The B.J. boot bands cannot be re-used.
2. Remove the B.J. boot.
3. Wrap a plastic tape around the shaft spline, and assemble
the B.J. boot band and B.J. boot.
4. Install the groove in the center of the small diameter
part of the resin boot by fitting to the groove of the shaft.
5. Turn the adjusting bolt on the special tool 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
(1) The value of W will change by approximately 0.7
mm for each turn of the adjusting bolt.
A
MB991561
Stopper
Adjusting bolt W

FRONT AXLE -Drive Shaft26-16
(2) The adjusting bolt should not be turned more than
once.
6. Install the boot band (small) in order to create clearance as
A and B in the illustration.
7. Use the special tool to crimp the B.J. boot band (small).
Caution
(1) Secure the drive shaft in an upright position and
clamp the part of the B.J. boot band to be crimped
securely in the jaws of the special tool.
(2) Crimp the B.J. boot band until the special tool
touches the stopper.
8. Check that the crimping amount (C) of the B.J. 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.

Remove the B.J. 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 B.J. boot band.
W = 5.5 mm - C
Example: If C = 2.3 mm, then W = 3.2 mm.
9. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps 6 to 8 using a new B.J.
boot band.
B.J. boot
B.J. boot band
(small)
Projection
A
B
MB991561
C

FRONT AXLE -Drive Shaft26-17
10. Fill the inside of the B.J. boot with the specified amount
of the specified grease.
Specified grease: Repair kit grease
Amount to use: 110±10 g
Caution
The drive shaft joint uses special grease. Do not mix
old and new or different types of grease.
11. Install the groove in the center of the large diameter part of
the resin boot by fitting to the groove of the shaft.
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): 3.2 mm
13. Install the boot band(large) in order to create clearance
as D and E in the illustration.
14. Use the special tool to crimp the B.J. boot band (large)
in the same way as in step 7.
15. Check that the crimping amount (F) of the B.J. boot band
is at the standard value.
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.

Remove the B.J. 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 B.J. boot band.
W = 5.8 mm - F
Example: If F = 2.3 mm, then W = 3.5 mm.
16. Check that the B.J. boot band is not sticking out past
the place where it has been installed.
If the B.J. boot band is sticking out, remove it and then
repeat the operations in steps 13 to 15 using a new
B.J. boot band.
B.J. boot
Projection
B.J. boot band
(large)
D
E
F

REAR AXLE -Service Specifications/Lubricants27B-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Rear axle total backlash mm-6
Wheel bearing rotation starting torque N·m-1.0
Wheel bearing axial play mm-0.05 or less
Wheel bearing rotary-sliding resistance N-22 or less
TJ boot assembly dimension mm90±3-
Drive gear backlash mm0.11 – 0.16-
Drive gear runout mm-0.05
Drive pinion turning
torqueN·m
Without oil seal0.88 – 1.17-
torqueN·m
With oil sealCompanion flange (oil seal contact-
ing area) with anti-rust agent0.98 – 1.27-
Companion flange (oil seal contact-
ing area) with gear oil applied0.49 – 0.58-
Vehicles with mechani-
cal LSDRight-to-left difference in combined thickness of friction
plate and friction disc
mm
0 – 0.05-
Clearance between spring plate and differential case
mm
0.06 – 0.25-
LSDdifferential
torqueN·m
When new clutch plate is installed5–19-
torqueN·m
When existing clutch plate is
installed2–19-
Distortion of friction plate and friction discmm-0.08
Difference in thickness between friction plate, friction
disc, and spring plate
mm
-0.1
Vehicles with ACD and
AY CPressure generated by hydraulic unit (pressure sensor
value
)MPa
0.9 – 1.1-
LUBRICANTS
ItemSpecified lubricantsQuantity
Vehicles with
mechanical
S
Gear oilHypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 81496300.55L
LSDMITSUBISHIGenuineGearOilPartNo.8149630
EX, CASTROL HYPOY LS (GL-5, SAE 90),
SHELL-LSD (GL-5, SAE 80W - 90) or equivalent
Vehicles with
ACD and
AY CGear oilDifferentialHypoid gear oil
API classification GL-5 or higher SAE viscosity
No.90, 80W0.55±0.02L
Torque transfer
mechanismATF-SP™0.65 - 0.7L

REAR AXLE -Drive Shaft27B-32
DISASSEMBLY AND REASSEMBLY
Caution
(1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be
careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race
to prevent the rotor from damage.
(2) Never disassemble the B.J. assembly except when replacing the B.J. boot.
2
6
4
3
5
7
1
4
2
43
61
2
4
51
2
9
10
1
8
8
97
6
T.J. repair kitT.J. boot repair kit B.J. boot repair kit
Disassembly steps
"BA1. T.J. boot band (large)
"BA2. T.J. boot band (small)
AA""AA3. T.J. case
4. Snap ring
AA""AA5. Spider assemblyAB""AA6. T.J. boot
7. B.J. boot band (large)
8. B.J. boot band (small)
9. B.J. boot
10. B.J. assembly