2006 MITSUBISHI LANCER Special tool

DRIVESHAFT ASSEMBLY
FRONT AXLE26-21
INSPECTION
M1261003800130
•Check the driveshaft for damage, bending or cor-
rosion.
•Check the driveshaft spline part for wear or dam-
age.
•Check the spider assembly for roller rotation,
wear or corrosion.
•Check the groove inside TJ case for wear or cor-
rosion.
•Check the dynamic damper for damage or crack-
ing.
•Check the boots for deterioration, damage or
cracking.
BJ BOOT (RESIN BOOT) REPLACEMENTM1261005200361
AC102658
1.Remove the bo ot ban ds (large a nd small).
NOTE: The boot ba nds canno t be re -used .
2.Remove the BJ boot.
3.W r ap a plastic t a pe arou nd the shaf t spline, an d
asse mble the b oot ba nd and BJ boo t.
AC102659
4.Align th e ce ntre gro o ve o n the BJ boot small end
wit h the shaf t groo ve.
AC102660
WMB991561
Stopper
Adjusting bolt
AC
5. T u rn the ad justing bolt o n sp ecial too l boo t band
crimping tool (MB9915 61) so that the size of the
o penin g (W) is at t he st and ard value .
St andard va lue (W): 2 . 9 mm
T i ghte n the adju s t-
ing bolt.
Loosen the
adjustin g bolt.
NOTE: The value of W will chang e by approxi-
mately 0.7 mm for ea ch tu rn of th e adjusting bolt.
NOTE: The ad justing bolt shou ld no t be tu rned
more th an once.
AC102661AC
Boot
ABoot band
(small)
B
Projection
6. Position the BJ boo t band (small) so th at there is
e v en clea rance at either en d (A and B).
CAUTION
•Secure the driveshaft in an upright position
and clamp part of the boot band to be crimped
securely in the jaws of special tool.
•
AC102663 ACMB991561
Crimp the boot band until special tool
touches the stopper.

DRIVESHAFT ASSEMBLY
FRONT AXLE26-22
7. Use the special tool to crimp the boot band (small).
AC102662
C
AD
8.Check t hat the crimpin g amount (C) of the bo ot
ba nd is at th e st and ard value.
St andard va lue (C): 2.4 − 2.8 mm
>
Readjust th e value of (W) in s t ep 5 acc ord i ng to
the following fo rm ula, and then repea t the
operation in step 7.
W = 5.5 mm − C
Example : If C = 2.9 mm, the n W = 2.6 mm.
mm >
Rem o v e the BJ bo ot ba nd , re ad ju st the v a l ue of
(W) in ste p 5 acc ord i ng to the following for
-
mula, and then repe at the o perations i n
step
s 6 and 7 using a new BJ boot band .
W = 5.5 mm − C
Example : If C = 2.3 mm, the n W = 3.2 mm.
9.Check t hat the boot b and is no t sticking o u t p a st
th e pla c e wher e it h a s be en in st alled. If t he boo t
ba nd is st icking out, remove it a nd the n repea t
step s 6 to 8, u s in g a new b oot ban d.
CAUTION
The driveshaft 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
AC102664AC
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
AC102665 AC
Boot Projection
Boot band
(large)
D
E
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.
AC102666FAD
15.Check that the crimping amount (F) of the 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.

27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . .27-2
SERVICE SPECIFICATIONS . . . . . . .27-2
SEALANT . . . . . . . . . . . . . . . . . . . . . .27-2
SPECIAL TOOLS . . . . . . . . . . . . . . . .27-3
ON-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

SPECIAL TOOLS
REAR AXLE27-3
SPECIAL TOOLS
M1271000600495
ToolNumberNameUse
B990767
MB990767Front hu b and end yoke
holde
rHub fixin g
MB991618
MB991618Hub bolt remo verHub bolt remova l
MD998801Remov e rRemoval of ABS rotor
MD998812Installer cap
MD9988 13Installer 100
MD9988 15Installer ada pter

32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATIO N . . . . . . . .32-2
SERVICE SPECIFICATION . . . . . . . .32-3
SPECIAL TOOL . . . . . . . . . . . . . . . . .32-3
ENGINE MOUNTING . . . . . . . . . . . . .32-4
REMOVAL AND INSTALLATION . . . . . . . . 32-4
TRANSMISSION MOUNTING . . . . . .32-5
REMOVAL AND INSTALLATION . . . . . . . . 32-5
ENGINE ROLL STOPPER,
CENTREMEMBER . . . . . . . . . . . . . . .32-7
REMOVAL AND INSTALLATION . . . . . . . . 32-7
CROSSMEMBER . . . . . . . . . . . . . . . .32-8
REMOVAL AND INSTALLATION . . . . . . . . 32-8

SERVICE SPECIFICATION
POWER PLANT MOUNT32-3
SERVICE SPECIFICATION
M1321000300333
ItemStandard value
Protruding length of stabilizer bar mounting bolt mm22 ± 1.5
SPECIAL TOOL
M1321000600378
ToolNumberNameUse
AC106827
MB991897Ball j o in t remo verKnuckle and tie rod e nd ball joint
discon
nection
NOTE: St eering linkage pu lle r
(MB990 635 o r MB991 1 13) is also
ava
ilab
l e to disconn ect knuckle and
tie ro
d end ball joint.

CROSSMEMBER
POWER PLANT MOUNT32-11
REMOVAL SERVICE POINTS
<> TIE ROD END AND KNUCKLE DIS-
CONNECTION
CAUTION
•Do not remove the nut from ball joint. Loosen
it and use special tool to avoid possible dam
-
age to ball joint threads.
•
AC208247AD
CordBoltMB991897
Self-locking
nut
Ball joint
Hang special tool with a cord to prevent it
from falling.
1. Install the special tool ball joint remover (MB991897) as shown in the figure.
AC106821
Knob
Parallel
Bolt
Good Bad
AB
2. Turn the bolt and knob as necessary to make the jaws of the special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the fig
-
ure.
3. Tighten the bolt with a wrench to disconnect the tie rod end.
<> CROSSMEMBER ASSEMBLY
REMOVAL
AC102600 AD
Piece of wood
Transmission
jack
1. Use a transmission jack to hold the crossmember,
and then remove the crossmember mounting nuts
and bolts.
2. Lower the crossmember with the engine rear roll stopper bracket, the stabilizer bar, the return tube,
and the steering gear.
INSTALLATION SERVICE POINTS
>>A<< STABILIZER BAR FIXTURE
INSTALLATION
AC006141 AD
Fixture (LH)
Outside of
vehicle
Bushing (LH) Approximately
10 mm
Identification
mark
Align the stabilizer bar iden
tification mark with the
right end of the bushing (LH).
>>B<< SELF-LOCKING NUT
INSTALLATION
AC101741AC
A
Tighten the self-locking nut until the stabilizer bar
mounting bolt thread part protruding length meets the
standard value.
Standard value (A): 22 ± 1.5 mm