Front Suspension - Lancer Mitsubishi Lancer Evolution VIII

GENERAL INFORMATION

The front suspension is a McPherson strut with coil spring. The shock absorber is gas-filled hydraulic double-acting type.

Scheme 1

INTRODUCTION TO FRONT SUSPENSION DIAGNOSIS

If the front suspension is faulty, the vehicle will not run straightforward or noise will occur, Incorrect wheel alignment, malfunction of strut assembly, stabilizer bar, coil spring, or worn or out-of-balance tires can cause these problems.

FRONT SUSPENSION DIAGNOSIS TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will sure that you have exhausted most of the possible ways to find a front suspension fault.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find and repair the malfunction by following the Symptom Chart and Symptom Procedures.
4. Verify malfunction is eliminated.

Scheme 2

DIAGNOSIS

1. STEP 1. Check the tires. Q: Are the tires in normal condition? YES: Replace the tires as necessary, then go to Step 2 . NO: If out of balance, balance the tires as necessary. If excessively worn, replace the tires as necessary and go to Step 5 .
2. STEP 2. Check the wheel alignment. Q: Is the wheel alignment correct? YES: Go to Step 3 . NO: Adjust it, then go to Step 5 .
3. STEP 3. Check the ball joint. Q: Is the ball joint in good condition? YES: Go to Step 4 . NO: Replace it, then go to Step 5 .
4. STEP 4. Check the coil spring. Q: Is the coil spring in good condition? YES: Go to Step 5 . NO: Replace it, then go to Step 5
5. STEP 5. Check symptoms. Q: Is the malfunction eliminated? YES: The procedure is complete. NO: Return to Step 1 .

1. STEP 1. Check for broken or deteriorated stabilizer bar. Q: Is the stabilizer bar in good condition? YES: Go to Step 2 . NO: Replace it, then go to Step 3 .
2. STEP 2. Check the strut assembly for damage. Q: Is the strut assembly in good condition? YES: Go to Step 3 . NO: Replace it, then go to Step 3 .
3. STEP 3. Check symptoms. Q: Is the malfunction eliminated? YES: The procedure is complete. NO: Return to Step 1 .

1. STEP 1. Check for improper tire inflation pressure. Q: Is the tire inflation correct? YES: Go to Step 2 . NO: Adjust it, then go to Step 4 .
2. STEP 2. Check for broken or deteriorated coil spring(s). Q: Are the coil spring(s) broken or deteriorated? YES: Replace the spring(s), then go to Step 4 . NO: Go to Step 3 .
3. STEP 3. Check for strut assembly damage. Q: Is the strut assembly damaged? YES: Replace it, then go to Step 4 . NO: Go to Step 4 .
4. STEP 4. Check symptoms. Q: Is the malfunction eliminated? YES: The procedure is complete. NO: Return to Step 1 .

1. STEP 1. Check for broken or deteriorated coil spring(s). Q: Is the coil spring(s) broken or deteriorated? YES: Replace it, then go to Step 2 . NO: Go to Step 2 .
2. STEP 2. Check symptoms. Q: Is the malfunction eliminated? YES: The procedure is complete. NO: Return to Step 1 .

1. STEP 1. Check for lack of lubrication. Q: Is Lubrication inadequate? YES: Lubricate it, then go to Step 5 . NO: Go to Step 2
2. STEP 2. Check the tightened parts for looseness as well as the bushings for wear. Q: Are the tightened parts and bushings in good condition? YES: Go to Step 3 . NO: Replace it, then go to Step 5 .
3. STEP 3. Check for broken coil spring. Q: Is the coil spring broken? YES: Replace it, then go to Step 5 . NO: Go to Step 4.
4. STEP 4. Check for strut assembly damage. Q: Is the strut assembly damaged? YES: Replace it, then go to Step 5 . NO: Go to Step 5 .
5. STEP 5. Check symptoms. Q: Is the malfunction eliminated? YES: The procedure is complete NO: Return to Step 1 .

Scheme 3

Scheme 4

FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT

Required Special Tool

1. MB991004: Wheel Alignment Gauge Attachment. Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition before measuring wheel alignment.

TOE-IN

Standard value: 1.2 mm (0.04 . O.09 inch)

Scheme 5

Scheme 6

1. Adjust the toe-in by undoing the clip and jam nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turn buckle is turned toward the front of the vehicle and the right turn buckle is turned toward the rear of the vehicle.
2. Install the clip and tighten the jam nut to the specified torque. Standard value: 40.5 N.m (30.3 ft-lb)
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the steering angle is at the standard value.

Scheme 7

Note. Camber and caster are preset at the factory and cannot be adjusted.

For vehicle with aluminum type wheels, attach the camber/caster/kingpin gauge to the drive shaft by using special tool MB991004. Tighten special tool MB991004 to the same torque 245 +/- N.m (181 +/- 21 ft-lb) as the drive shaft nut.

Scheme 8

LOWER ARM BALL JOINT END PLAY CHECK

1. Raise the vehicle.
2. Remove the stabilizer bar from the lower arm assembly.
3. Move the lower arm up and down with your hands to check for an excessive play axial direction of the ball joint. If there is an excessive play, replace the lower arm assembly.

BALL JOINT DUST COVER CHECK

1. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.
2. If the dust cover is cracked or damaged, replace the lower arm assembly. NOTE: If the dust cover is cracked or damaged, it is possible that there may also be damage to the ball joint.

REMOVAL AND INSTALLATION

Scheme 9

INSPECTION

1. Check for oil leaks from the strut assembly.
2. Check the strut assembly for damage or deformation.

Scheme 10

Required Special Tools

1. MB991237: Spring Compressor
2. MB991238: Arm Set
3. MB991680: Wrench set

<< A >> SELF-LOCKING NUT REMOVAL

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Scheme 12

1. Use special tools MB991237 and MB991238 to compress the coil spring. WARNING: To prevent the piston rod self-locking nut inside the strut from loosening, do not use an impact wrench when the self-locking nut is loosened.
2. Use special tools MB991681 and MB991682 to secure the strut, and then remove the self-locking nut.

<< B >> STRUT ASSEMBLY DISPOSAL

The gas must be discharged from the strut assembly from the strut assembly before discarding it. Place the assembly horizontally with its piston rod extended. Then drill a hole of approximately 3 mm (0.1 inch) in diameter at the location shown in the illustration and discharge the gas.

Scheme 13

>> A << UPPER SPRING SEAT INSTALLATION

If the upper spring seat peeled off the pad, adhere seat and the pad with a double-sided tape.

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1. Ensure that the bearing is seated correctly. CAUTION: Do not use an impact wrench to tighten the bolt of special tool MB991237, otherwise the special tool will break.
2. Install special tool MB991237 to the strut assembly same as its removal.
3. While the coil spring is being compressed by the special tools, temporarily tighten the self-locking nut.
4. Align the hole in the strut assembly lower seat with the hole in the upper spring seat. NOTE: Using a road as shown facilitates the alignment.
5. Align both ends of the coil spring with the grooves in the spring seat, and then loosen the special tools. CAUTION: Do not use an impact wrench to tighten the self-locking nut, otherwise the self-locking nut will not be tightened securely.
6. Using special MB991681 and MB991682, tighten the self-locking nut to 60 +/- 10 N.m (45 +/- 7 ft-lb).

1. Check the bearing for wear or rust.
2. Check the rubber parts for damage or deterioration.
3. Check the spring for deformation, deterioration or damage.
4. Check the shock absorber for deformation.

Scheme 17

Required Special Tools

1. MB991006: Preload Socket
2. MB990800: Ball Joint Remover and Installer
3. MB990883: Rear suspension bushing arbor
4. MB990974: Rear wheel bearing and Installer joint
5. MB990887: Ring
6. MB990890: Rear suspension bushing base

<< A >> LOWER ARM AND CROSSMEMBER DISCONNECTION

Lift the transmission with a garage jack, and then withdraw the front mounting bolt on the left lower arm assembly.

Scheme 18

<< A >> SELF-LOCKING NUT INSTALLATION

Tighten the self-locking nut until the bolt protruding length meets the standard value.

Standard value (A): 22 +/- 1.5 mm (0.87 +/- 0.06 inch)

Scheme 19

1. Check the bushing for wear and deterioration.
2. Check the lower arm for bend or breakage.
3. Check all bolts for condition and straightness.

Scheme 20

1. After shaking the ball joint stud several times, use special tool MB991006 to measure the breakaway torque of the ball joint. Standard value: 0 - 3.9 N.m (0 - 35 in-lb)
2. If the measured value is not within the standard value, or if the ball joint is difficult to turn or does not turn smoothly, replace the lower arm assembly.

LOWER ARM BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing it with your finger.
2. If the dust cover is cracked or damaged, replace the lower arm. NOTE: Cracks or damage to the dust cover may cause damage to the ball point. When it is damaged during service work, replace the dust cover.

BALL JOINT DUST COVER REPLACEMENT

If the dust cover is damaged accidentally during service work, replace the dust cover as follows

Scheme 21

1. Remove the dust cover.
2. Apply multipurpose grease to the lip and inside of the dust cover.
3. Using special tool MB990800, drive in the dust cover until it is fully seated.
4. Check the dust cover for cracks or damage by pushing it with your finger.

LOWER ARM REAR BUSHING REPLACEMENT

Replace the bushing as follows

Scheme 22

Scheme 23

Scheme 24

1. Use special tools MB990883, MB990887, and MB990890 to drive out the bushing.
2. Position the bushing so that its projection is as shown in illustration, and then use special tools MB990883, MB990971, MB990887, and MB990890 to press in the bushing.
3. Press the bushing until its outer tube is flush with the lower arm assembly surface.

Scheme 25

Scheme 26

Required Special Tool

1. MB991897: Ball Joint Remover

<< A >> TIE ROD END AND KNUCKLE DISCONNECTION

Scheme 27

Scheme 28

1. Install the special tool MB991897 as shown in the figure.
2. After turning the bolt and knob to adjust the insert arms of the special tool MB991897 in parallel, tighten the bolt by hand and confirm that the insert arms are parallel. NOTE: When adjusting the insert arms in parallel, turn the knob in the direction shown in the figure.
3. Tighten the bolt with a wrench to disconnect the tie rod end.

<< B >> FIXTURE/BUSHING/STABILIZER BAR REMOVAL

Carry out the following operations to ensure working space in order to remove the fixture, the bushing and the stabilizer bar.

Scheme 29

1. Use a transmission jack to hold the crossmember, and then remove the crossmember mounting nuts and bolts. CAUTION: Be careful not to lower the crossmember excessively, otherwise the power steering return hose bracket may deform.
2. Lower the crossmember until the fixture, the bushing and the stabilizer bar can be removed.

>> A << STABILIZER BAR/BUSHING/FIXTURE INSTALLATION

Align the stabilizer bar identification mark with the right end of the bushing.

Scheme 30

>> B << SELF-LOCKING NUT INSTALLATION

Tighten the self-locking nut until its producing length meets the standard value.

1. Standard value (A): 22 +/- 1.5 mm (0.87 +/- 0.06 inch)

Scheme 31

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

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See also:
• AIR BAG SAFETY PRECAUTIONS
• DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING