service MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

26-1
FRONT AXLE
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
SPECIAL TOOLS 3...........................ON-VEHICLE SERVICE 5.....................
Wheel Bearing Axial Play Check 5..............
Hub bolt replacement 5.........................
HUB AND KNUCKLE ASSEMBLY 6...........
DRIVE SHAFT 10............................

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 -On-vehicle Service26-5
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
1. Remove the disc brake caliper 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: 0.06 mm
4. If axial play exceeds the limit, replace the front hub
assembly.
HUB BOLT REPLACEMENT
1. Remove the caliper assembly and secure it with wire
so that it does not fall.
2. Remove the brake disc.
3. Use the special tools to remove the hub bolts.
4. Install the plain washer to the new hub bolt, and install
the bolt with a nut.
MB991618MB990767
Plain
washerMB990767

FRONT AXLE -Hub and Knuckle Assembly26-6
HUB AND KNUCKLE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe out quickly.
Pre-removal and Post-installation Operation
DTransmission Fluid Draining
DTransfer Oil Draining (Refer to GROUP 22 –
On-vehicle Service.)Pre-removal and Post-installation Operation
DCheck the dust cover for cracks or damage by
pushing it with finger.
DTransfer Oil Filling (Refer to GROUP 22 –
On-vehicle Service.)
DTransmission Fluid Filling
25¶5Nm
1
245¶29 Nm
58
3
4
2
108¶10 Nm
10
11
25¶6Nm
6
9
100¶10 Nm*1
108¶10 Nm*2
167¶9Nm
8.9¶1.9 Nm
*1: Vehicles without BREMBO disc brake
*2: Vehicles with BREMBO disc brake
7
Removal steps
1. Front speed sensor ACD or ABS>
AA"2. Caliper assembly
3. Brake disc
4. Split pin
AB""AA5. Castle nut
6. Dust shield7. Connection for lower arm ball joint
AC"8. Connection for tie rod end
AD"9. Drive shaft
10. Front strut to hub and knuckle
mounting bolt and nut
11. Hub and knuckle assembly

FRONT AXLE -Hub and Knuckle Assembly26-7
REMOVAL SERVICE POINTS
AA"CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
Caution
If the vehicle is equipped with the Brembo disc brake,
during maintenance, take care not to contact the parts
or tools to the caliper because the paint of caliper will
be scratched. And if there is brake fluid on the caliper,
wipe out quickly.
AB"CASTLE NUT REMOVAL
Caution
Do not apply the vehicle weight to the wheel bearing
while loosening the castle nut. Otherwise wheel bearing
will be damaged.
AC"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.
AD"DRIVE SHAFT REMOVAL
1. Use the special tools to push out the drive shaft from
the hub.
2. Withdraw the drive shaft from the hub by pulling the bottom
of the brake disc towards you, and then remove the hub
retaining bolts.
MB990767
Nut
Cord
Ball joint
MB991113 or
MB990635
MB990242 MB990767MB991354
MB990244
(Three)

FRONT AXLE -Hub and Knuckle Assembly26-8
INSTALLATION SERVICE POINT
"AACASTLE NUT INSTALLATION
1. Be sure to install the castle nut washer in the specified
direction.
2. Using the special tool, tighten the castle nut.
Caution
Before securely tightening the castle nuts, make sure
there is no load on the wheel bearings. Otherwise
wheel bearing will be damaged.
INSPECTION
INSPECTION OF WHELL BEARING ROTATION STARTING
TORQUE
1. Tighten special tools in hub and knuckle assembly to
the specified torque.
2. Measure the wheel bearing rotation starting torque with
special tools.
Limit: 1.03 N·m or less
3. Wheel bearing rotation starting torque must be under
the limit value and there should be no roughness when
rotating the hub.
WHEEL BEARING AXLE PLAY CHECK
1. Secure knuckle in a vice to measure axle play in wheel
bearing.
Limit: 0.06 mm
2. If the limit value of wheel bearing axle plya cannot be
obtained when tightened to the specified torque (245
±29 N·m), check mounting bolt for hub and knuckle
assembly. If no defects are found, replace hub assembly.
MB990767
245±29 N·m
Washer
MB991000
(MB990998)
Bolt
245±29 N·m
Secure bolt and
tighten nut.
MB991017
MB990326
MB990685
MB991000
(MB990998)
245±29 N·m
Secure bolt and
tighten nut.
MB991017

FRONT AXLE -Drive Shaft26-10
DRIVE SHAFT
REMOVAL AND INSTALLATION
Caution
1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And
if there is brake fluid on the caliper, wipe out quickly.
2. For vehicles with ABS or ACD, do not strike the rotor for wheel speed sensor installed to
the B.J. outer race of drive shaft against other parts when removing or installing the drive
shaft. Otherwise the rotor for wheel speed sensor will be damaged.
Pre-removal and Post-installation Operation
DTransmission Fluid Draining
DTransfer Oil Draining (Refer to GROUP 22 –
On-vehicle Service.)Pre-removal and Post-installation Operation
DCheck the Dust Cover for cracks or damage by
pushing it with finger.
DTransfer Oil Filling (Refer to GROUP 22 –
On-vehicle Service.)
DTransmission Fluid Filling
1
6 9
8 5
74
3
2 11
25¶4Nm 25¶5Nm
245¶29 Nm
108¶10 Nm
10
11
39¶5Nm
Removal steps
1. Split pin
"BA2. Castle nut
3. Front speed sensor ABS or ACD>
4. Front speed sensor harness brack-
et
5. Brake hose bracket6. Stabilizer bar link connection
7. Lower arm ball joint connection
AA"8. Tie rod end connection
AB""AA9. Drive shaft
AC""AA10. Output shaft
11. Circlip

FRONT AXLE -Drive Shaft26-11
REMOVAL SERVICE POINTS
AA"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.
AB"DRIVE SHAFT REMOVAL
1. Use the special tools to push out the drive shaft from
the hub.
2. Withdraw the drive shaft from the hub by pulling the bottom
of the brake disc towards you, and then remove the hub
retaining bolts.
3. Remove the drive shaft from the transmission by the
following procedure.
Insert a pry bar between the transmission case and the
drive shaft, and then pry the drive shaft from the
transmission.
Caution
(1) Do not pull on the drive shaft; doing so will damage
the T.J.; be sure to use the pry bar.
(2) When pulling the drive shaft out from the
transmission, be careful that the spline part of
the drive shaft does not damage the oil seal.
(3) Do not apply the vehicle weight to the wheel
bearing while loosening the drive shaft nut.
Otherwise wheel bearing will be damaged. If,
however, the vehicle weight must be applied to
the bearing (because of moving the vehicle),
temporarily secure the wheel bearing by using
the special tool.
Nut
Cord
Ball joint
MB991113 or
MB990635
MB990242 MB990767MB991354
MB990244
(Three)
T.J. assembly
Pry bar
Transmission
MB991000
(MB990998)
MB991017

FRONT AXLE -Drive Shaft26-12
AC"OUTPUT SHAFT REMOVAL
Use the special tool to pull out the output shaft.
Caution
Do not damage the oil seal of the transmission by the
output shaft splines.
INSTALLATION SERVICE POINTS
"AAOUTPUT SHAFT/DRIVE SHAFT INSTALLATION
Caution
Do not damage the oil seal of the transmission by the
output shaft and drive shaft splines.
"BACASTLE NUT INSTALLATION
1. Be sure to install the castle nut washer in the specified
direction.
2. Using the special tool, tighten the castle nut.
Caution
Before securely tightening the castle nuts, make sure
there is no load on the wheel bearings. Otherwise
wheel bearing will be damaged.
Output shaft
MB991721
MB990767
245±29 N·m
Washer

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