1991 MITSUBISHI ECLIPSE boot

2-28FRONT SUSPENSION - Drive Shaft
Inner shaft
llA0083
1T.J. case.,
MB9909383%QilD998801
r
IHA00876. INSTALLATION OF INNER SHAFT
Use a pipe to hold the inner race of the center bearing and
“4force the inner shaft into place.
.a3. INSTALLATION OF T.J. CASE AND INNER SHAFT
ASSEMBLY
(1) Apply multipurpose grease to the inner shaft spline,
then press fit it into the T.J. case.
Grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
(2) Using the special tools, press the seal plate into the T.J.
case.
(3) Fill the specified grease furnished in the repair kit to the
T.J. case.Specified grease: Repair kit grease 105
g (3.7 oz.1
NOTEThe 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 use special grease. Do not add
another type of grease.
2. INSTALLATION OF BOOT BAND (SMALL)/ 1. T.J.
BOOT BAND
Set the T.J. boot bands at the specified distance in order toadjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot band securely.
eStandard value:
85f3 mm (3.35+ .12 in.)

3-2REAR AXLE - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSNO3CA- h
ItemsVehicles with
Vehicles with
conventional differential
limited slip differential
Axle shaft
TypeSemi-floating type
Semi-floating type
Shaft dimensions
Outer bearing portion dia.
mm (in.) 35 (1.38)
35 (1.38)
Inner bearing portion dia.
mm (in.) 28 (1.10)
28 (1.10)
Center portion dia.
mm (in.) 34.5 (1.36)
34.5 (1.36)
Overall length
mm (in.) 214.9 (8.46)
214.9 (8.46)
Bearing
O.D. x I.D.
Outer
mm (in.) 72 x 35 (2.83 x 1.38)
72 x 35 (2.83 x 1.38)
Innermm (in.) 58 x 28 (2.28 x 1.10)
58 x 28 (2.28 x 1.10)
Drive shaft
Joint type
Outer
D.O.J.D.O.J.
Inner
B.J.B.J.Length (joint to joint)
x diametermm (in.) 397 x 24 (15.6 x .94)397 x 24 (15.6 x .94)
DifferentialReduction gear type
Hypoid gearHypoid gear
Reduction ratio3.545
, 3.307
3.545 , 3.307 Differential gear type and configuration
Side gearStraight bevel gear
x 2Straight bevel gear x 2
Pinion gearStraight bevel gear
x 2Straight bevel gear x 4
Number of teeth
Drive gear39
. 43 39 , 43 Drive pinion
11 , 13 ll, 13
Side gear
1416Pinion gear
1010
NOTED.O.J.: Double offset joint
B.J.: Birfield joint
SERVICE SPECIFICATIONSNOBCB-
Items
Standard valueRear wheel bearing rotation sliding resistance
Setting of D.O.J. boot length
Final drive gear backlash
Differential gear backlash
Conventional differential
Limited slip differential
Drive pinion rotation starting torque
with oil seal
New part
New part/reusable part
without oil seal
New part
New part/reusable partSpecifications
N (Ibs.) [Nm (in.lbs.)l 12 (2.6) [0.7 (6)l or less
mm (in.)
76+3 (3.00+.12)
mm (in.) 0.1
l-0.16 (.004-,006)
mm (in.)O-0.076
(O-.003)
0.03-0.09 (.0012-.0035)
Nm
(in.lbs.)
1.0-1.3 (9-11)
0.5-0.6 (4-5)
Nm
(in.lbs.)
0.9-I .2 (8-10)
0.4-0.5 (3-4)
A

REAR AXLE - Specifications
ItemsLimit
Rear axle total backlash
Drive gear
runoutRear wheel bearing end play
Differential gear backlashSpecifications
mm (in.) 5
(.2)mm (in.) 0.05
(.002)mm (in.) 0.8
(.031)mm (in.) 0.2
(.008)
TORQUE SPECIFICATIONS
ItemsNmft.lbs.
Drive shaft to companion flange55-65
40-47Axle shaft installation nut
160-220116-159Rear brake assembly installation bolts
50-6036-43
Rear speed sensor brackets9-14
7-10Differential carrier to crossmember
100-12072-87
Differential carrier to propeller shaft
30-3522-25
Differential carrier to differential support
member80- 10058-72
Differential support member to bolt
110-13080-94Drain plug
60-7043-51
Filler plug40-6029-43
Companion flange to drive pinion
160-220116-159
Bearing cap installation bolt
40-6029-43
Drive to differential case
gear80-9058-65
Cover to carrier
gear30-4222-30
LUBRICANTS
ItemsRear axle gear oilSpecified lubricantsQuantity
MOPAR Hypoid Gear Oil API classification
GL-5 or higher0.7 lit. (0.74 qts.Above
-23°C (-10°F) SAE 90, 85W-90, 8OW-90From
-34°C (-30°F) to -23°C (-10°F) SAE 8OW, 8OW-90Below
-34°C (-30°F) SAE 75WB.J. boot grease
D.O.J. boot greaseRepair kit grease90
g (3.2 dz.)Seal lip of outer bearingMOPAR Multi-Mileage Lubricant Part No.2525035 or equivalent As required
Trailing arm oil seal lip
Oil seal lip of side bearing
Washer of special tool
(M B990836)Oil seal lip of drive pinion
Differential companion
flange washer
SEALANTS AND ADHESIVES
..-
ItemsSpecified sealants and adhesivesIVent plug
Differential cover3M ATD Part
No.8661, 8663 or equivalent
Drive gear threaded holeMOPAR Part
No.4318031 or 4318032 or equivalent

REAR AXLE - Axle Shaft/Drive Shaft3-13
DRIVE SHAFTN03JA--
PARTS DISTINCTION--
Boots and boot bands can be distinguished by the
indicated part number as below.
10. INSTALLATION OF REAR ROTOR ABS>Press fit the rear rotor to the axle shaft with the rear rotor
groove surface toward the axle shaft flange.
6. INSTALLATION OF SELF LOCKING NUT
With the special tool, secure the axle shaft and tighten the
companion flange self locking nut.
F
I
IIidentification number
location
1 D.O.J. boot 1 nB.J. boot band

3-‘14REAR AXLE - Drive Shaft
REMOVAL AND INSTALLATION55-65
N.m40-47 ft.lbs.
Removal steps
1. Bolt+e l 42. Drive shaft3. Circlip
l * 4. Oil seal
NOTE(1) Reverse the removal procedures to reinstall.(2) l * : Refer to “Service Points of Removal”.<-,(3) ii : Refer to “Service Points of Installation”.
(4) q : Non-reusable partsllA0324
SERVICE POINTS OF REMOVALNO3JEAD2. REMOVAL OF DRIVE SHAFT
Using a tire lever, etc. remove the drive shaft from the
differential carrier.
INSPECTIONNOJJHAA
lCheck the drive shaft boots for damage or deterioration.
lCheck the ball joints (B.J. and D.O.J.) for excessive play orcheck operation.
l Check the drive shaft spline for wear or damage.
SERVICE POINTS OF INSTALLATIONN03JCAE4. INSTALLATION OF OIL SEAL
(1)If the oil seal is to be replaced because of damage, driveit in by using the special tool.
(2) Apply the specified grease to the oil seal lip.
Specified grease:MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalant
,-
-
llK110llK610

REAR AXLE - Drive Shaft
Boot band
CTwo-part serration
llA02802. INSTALLATION OF DRIVE SHAFT
I_ ,T
Caution
1.Be cautious to ensure that the differential carrier oil
seal is not damaged by the drive shaft spline.
2. The drive shafts for models equipped with the
limited-slip differential are of different length and,
in addition, the right drive shaft has a two-part
serration; be very careful to install each one on the
correct side.
NOTE
The left and right drive shafts can also be distinguishedfrom each other by the identification color of boot band
C.
IItemDrive shaftDrive shaft
(left)(right)IIIBoot band
C identification color YellowBlueI
3.Be sure to thoroughly remove any oil or grease, etc.from the threaded part of the bolt and nut used for
installation to the companion flange,
because any
oil, grease, etc. on these parts might cause later
loosening even though tightening is at the specifiedtorque.

3-16REAR AXLE - Drive Shaft
DISASSEMBLY AND REASSEMBLY
N03JD--Drive shaft and B.J. kit
1 lA6969D.O.J. kitB.J. boot repair kit1 lAO967Disassembly steps
I. Circlip2. Boot band(B)
3. Boot band
(C)4.Circrip
5. D.O.J. outer race
6. Snap ring7. D.O.J. Inner race, cage and ball assembly
8.Balls9. D.O.J. inner race
10. D.O.J. cage
11, D.O.J. boot
12. Boot band (A)13. Boot band (C)14. B.J. boot
15.Dust cover16. Drive shaft and B.J.
Reassembly steps
16. Drive shaft and B.J.15. Dust cover
l + 14. B.J. boot
l + 12. Boot band (A)
l + 13. Boot band (C)l + 3. Boot band (Cll + 2. Boot band(B)l + 11. D.O.J. bootl +7. D.O.J. inner race, cage and ball assembly10. D.O.J. cage9. D.O.J. inner race
8. Balls
6. Snap ring
I)+ 5. D.O.J. outer race
4. CirclipI. Circlip
!ygeverse the disassembly procedures to reassemble.(2) +* : Refer to “Service Points of Disassembly”.(3) I)+ : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

REAR AXLE - Drive Shaft3-1711
ES07
.-
llYO97
8.J: bootBoot bands
D.O.J. bootllW592
11KOOOSERVICE POINTS OF DISASSEMBLY
NO3JEAC6. REMOVAL OF SNAP RING/8.
BALLS/S. D.O.J. INNER
RACE/IO. D.O.J. CAGE
(1)Remove the snap ring with the snap ring pliers and then
remove the D.O.J. inner race, the D.O.J. cage, and theballs as a unit.
(2) Clean the D.O.J. inner race, the D.O.J. cage, and the
balls, without dismantling them.
Caution
1.Be careful that balls do not drop out of the cage.2. If the balls drop out, press them back into the
D.O.J. cage with the D.O.J. inner race.
I I. REMOVAL OF D.O.J.
BOOT/I4. B.J. BOOT
(1) Wipe the grease off of the spline portion.
(2) Remove the D.O.J. boot and B.J. boot.
NOTE
If the boots are reused, wrap vinyl tape around the driveshaft spline so that the boots are not damaged when
they are removed.
Caution
Do not disassemble the B.J.
INSPECTIONNOJJFACl Check the drive shaft for damage, bending or corrosion.
l Check the drive shaft spline for wear or damage.
lCheck the B.J. for entry of water and/or foreign material.
l Check the D.O.J. outer race for damage or corrosion.
l Check the D.O.J. cage, balls and D.O.J. inner race for
damage, corrosion or wear.
SERVICE POINTS OF REASSEMBLYN03JGAD14. INSTALLATION OF B.J.
BOOT/I*. BOOT BAND (A)/I3.BOOT BAND
(C)/3. BOOT BAND (C)/2. BOOT BAND
(B)/II. D.O.J. BOOT
(1) Wrap vinyl tape around the drive shaft spline.
(2) Insert the drive shaft in B.J. boot, boot band (A), (C), (C),(B), D.O.J. boot in that sequence.
(3) Fill the inside of the B.J. and B.J. boot with the
specified grease.
Specified grease: Repair kit grease
Caution
90 g (3.2 oz.)
The grease in the repair kit should be divided in halffor use, respectively, at the joint and inside the
boot.A special type of grease is used on the joint. Be
cautious to ensure that not other grease is allowed
to come in contact with the joint.