Rear Axle - Evolution: Removal & Installation Mitsubishi Lancer IX

HUB BOLT REPLACEMENT

Required Special Tools

1. MB990767: End Yoke Holder
2. MB991618: Hub Bolt Remover

Scheme 49

1. Remove the brake caliper and brake disc.
2. Use special tools MB990767 and MB991618 to remove the hub bolts. NOTE: To retain a space for removing the hub bolts, remove near the retainer spring mounting position.
3. Install the plain washer to the new hub bolt, and install the bolt with a nut.

Scheme 50

DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT

1. Remove the drive shaft from the differential carrier. (Refer to «DRIVE SHAFT ASSEMBLY»(ref-183221-S14434931802005081200000) ).
2. Remove the differential carrier oil seal.
3. Use special tools MB990938 and MB991115 to press-fit a new oil seal.
4. Apply multi-purpose grease to the oil seal lip and drive shaft oil seal seating area.
5. Replace the drive shaft circlip with a new one, and install the drive shaft to the differential carrier. (Refer to «DRIVE SHAFT ASSEMBLY»(ref-183221-S14434931802005081200000) ).

Scheme 51

REMOVAL AND INSTALLATION

Scheme 52

Scheme 53

Required Special Tool

1. MB990767: End Yoke Holder
2. MB990241: Axle Shaft Puller
3. MB991354: Puller Body
4. MB990211: Slide Hammer

<< A >> DRIVE SHAFT NUT REMOVAL

Use special tool MB990767 to fix the hub and remove the drive shaft nut.

Scheme 54

<< B >> CALIPER ASSEMBLY REMOVAL

Secure the removed caliper assembly with wire, etc.

<< C >> REAR WHEEL HUB REMOVAL

If the rear wheel hub is seized, remove the rear wheel hub as follows.

1. Remove the knuckle with rear wheel hub and fix them with a vise. (Refer to «KNUCKLE»(ref-183221-S27181948522005081200000) ).
2. Use special tools MB990244 (MB990241), MB991354 and MB990211 to pull out the rear wheel hub from the knuckle.

Scheme 55

>>A<< WASHER/DRIVE SHAFT NUT INSTALLATION

1. Be sure to install the drive shaft washer in the specified direction.
2. Using special tool MB990767, tighten the drive shaft nut to the specified torque. Tightening torque: 225 +/- 25 N.m (166 +/- 18 ft-lb)

Scheme 56

Scheme 57

Required Special Tool

1. MB991897: Ball Joint Remover

<< A >> SELF LOCKING NUT (TRAILING ARM, TOE CONTROL ARM AND UPPER ARM CONNECTION) REMOVAL

Note. When adjusting the arms in parallel, turn the knob in the direction shown in the figure.

Scheme 58

Scheme 59

Required Special Tool

1. MB990767: End Yoke Holder
2. MB991354: Puller Body
3. MB990241: Axle Shaft Puller
4. MB991017: Front Hub Remover and Installer
5. MB990998: Front Hub Remover and Installer
6. MB991897: Ball Joint Remover

Use special tool MB990767 to fix the hub and remove the drive shaft nut.

Scheme 60

Secure the removed caliper assembly with wire, etc.

<< C >> SELF LOCKING NUT (TRAILING ARM, TOE CONTROL ARM AND UPPER ARM CONNECTION) REMOVAL

Scheme 61

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

Scheme 62

Scheme 63

1. Use special tools MB990242, MB990244, MB991354 and MB990767 to push out the drive shaft from the hub. CAUTION: Do not pull on the drive shaft; doing so will damage the TJ; be sure to use special tools MB991721, MB991833 and MB991961. When pulling the drive shaft out from the differential carrier, be careful that the spline part of the drive shaft does not damage the oil seal.
2. Remove the drive shaft from the differential carrier by using a pry bar.

Scheme 64

Scheme 65

>> A << DRIVE SHAFT INSTALLATION

>> B << WASHER/DRIVE SHAFT NUT INSTALLATION

1. Assemble the drive shaft washer in the illustrated direction.
2. Tighten the drive shaft nut to the specified torque with special tool MB990767. Tightening torque: 225 +/- 25 N.m (166 +/- 18 ft-lb)

Scheme 66

<< A >> TJ CASE/SPIDER ASSEMBLY REMOVAL

1. Wipe off grease from the TJ case and spider assembly.
2. If there is water or foreign material in the wiped grease, be sure to clean the spider assembly.

<< B >> TJ BOOT/EBJ BOOT REMOVAL

1. Wipe off grease from the shaft spline part.
2. Wrap plastic tape around the spline part on the TJ side of the drive shaft so that TJ and EBJ boots are not damaged when they are removed.

Scheme 67

>> A << EBJ BOOT/TJ BOOT INSTALLATION

Wrap plastic tape around the spline part on the TJ side of the drive shaft, and then install EBJ and TJ boots.

>> B << SPIDER ASSEMBLY/TJ CASE INSTALLATION

After applying the specified grease to the TJ case, insert the driveshaft and apply grease one more time.

1. Specified grease: Repair kit grease
2. Use amount: 135 +/- 10 g (4.8 +/- 0.4 oz.)

Note. The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

Scheme 68

>> C << TJ BOOT BAND (SMALL)/TJ BOOT BAND (LARGE) INSTALLATION

Set the TJ boot bands at the specified distance in order to adjust the amount of air inside the TJ boot, and then tighten the TJ boot band (large) and TJ boot band (small) securely.

1. Standard value (A): 90 +/- 3 mm (3.5 +/- 0.1 inches)

Scheme 69

Scheme 70

<< B >> REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY REMOVAL

1. Using a jack, support the differential carrier from its underside.
2. Remove the rear crossmember mounting bolts and remove the differential carrier, where it is attached to the rear crossmember, from the vehicle.

>> A << REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY INSTALLATION

Tighten the rear crossmember mounting bolts in the numerical order shown.

Note. To ensure both good installation accuracy and ease of installation, the rear crossmember mounting holes have different diameters between front and rear. This is the reason for specifying the tightening sequence of the mounting bolts.

Scheme 71

Scheme 72

>> B << PROPELLER SHAFT INSTALLATION

Align the mating marks of differential companion flange and propeller shaft assembly.

DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT

Required Special Tools

1. MB990641: Lower Arm Bush (A) Remover and Installer
2. MB991439: Bush Remover and Installer

<< A >> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL SIDE BEARING SPACER/DIFFERENTIAL SIDE BEARING OUTER RACE REMOVAL

Use the wooden handle of a hammer to remove the differential case assembly, differential side bearing spacers and differential side bearing outer races.

Note. Keep the right and left side bearings and side bearing spacers separate, so that they do not become mixed during reassembly.

Scheme 73

<< B >> DIFFERENTIAL SIDE BEARING INNER RACE REMOVAL

Use special tools MB990810 and MB990811 to pull out the side bearing inner races.

Note. There are two notches provided (at the differential case side) for the claw part of the special tools; use special tool MB990810 at that position.

Scheme 74

<< C >> DRIVE GEAR REMOVAL

1. Make the mating marks to the differential case and the drive gear.
2. Loosen the drive gear attaching bolts in a diagonal sequence to remove the drive gear.

Scheme 75

<< D >> SELF-LOCKING NUT REMOVAL

Use special tool MB990850 to hold the companion flange, and then remove the companion flange self-locking nut.

Scheme 76

<< E >> DRIVE PINION ASSEMBLY/COMPANION FLANGE REMOVAL

1. Make mating marks on the drive pinion and companion flange.
2. Use special tool MB990810 to pull out the companion flange.

Scheme 77

<< F >> DRIVE PINION REAR BEARING INNER RACE REMOVAL

Use special tool MD998801 to pull out the drive pinion rear bearing inner race.

Scheme 78

<< G >> OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE REMOVAL

Use special tool MB990939 to remove the oil seal, drive pinion front bearing inner race, and drive pinion front bearing outer race.

Scheme 79

<< H >> DRIVE PINION REAR BEARING OUTER RACE REMOVAL

Use special tool MB990939 to remove the drive pinion rear bearing outer race.

Scheme 80

Scheme 81

Required Special Tools

1. MB990938: Bar
2. MB991115: Oil Seal Installer
3. MB990936: Installer Adapter
4. MB990934: Installer Adapter
5. MB990901: Drive Pinion Setting Gauge Set
6. MB991378: Drive Pinion Setting Gauge Set
7. MB990326: Preload Socket
8. MB990685: Torque Wrench
9. MB990728: Bearing Installer
10. MB990850: End Yoke Holder
11. MB990727: Oil Seal Installer
12. MB990810: Side Bearing Puller
13. MB990811: Side Bearing Cup
14. MB991367: Special Spanner
15. MB991385: Pin

Scheme 82

>> G << DIFFERENTIAL SIDE BEARING INNER RACE INSTALLATION

Use special tool MB990728 to press-fit the differential side bearing inner races into the differential case.

Scheme 83

<< A >> SCREW REMOVAL

1. Check out the alignment marks.
2. Loosen a uniform amount little by little the screws securing differential case A to B.
3. Separate differential case B from differential case A and remove their components.
4. Keep the removed spring plates, friction plates, and friction discs organized in order of removal and for right and left use.

Scheme 84

Scheme 85

>> A << DIFFERENTIAL CASE B INSTALLATION

Before starting the assembly procedure, perform the following steps to adjust dimensional differences (clutch plate friction force) in the axial direction of the components inside the differential case and axial clearance of the differential side gear.

Scheme 86

Scheme 87

1. Place friction discs (two each) and friction plates (three each) one on top of another as illustrated and, using a micrometer, measure the thickness of each of the right and left assemblies. Select different discs and plates so that the difference between the right and left assemblies falls within the specified range. Standard value: 0 - 0.05 mm (0 - 0.002 inch) NOTE: If a new part is used, note that the friction disc comes in two thickness: 1.6 mm (0.063 inch) and 1.7 mm (0.067 inch).
2. Measure the thickness of each of the right and left spring plates.
3. Assemble the pressure ring internal parts (pinion shaft and pressure ring), friction plates, and friction discs and, using a micrometer, measure the overall width. NOTE: When taking measurements, press the assembly from both sides so that the pinion shaft makes a positive contact with the groove in the pressure ring.
4. Find value (A) which is the thickness measured in step (3) added to the thickness of two spring plates.
5. Find dimension (B) between the spring plate facing surfaces when differential case A and B are assembled together. B = C + D - E
6. If the clearance between the spring plate and differential case (B - A) is outside the specified range, change the friction discs and make adjustments. Standard value: 0.06 - 0.25 mm (0.002 - 0.010 inch)
7. Coat each part with the specified gear oil and mount it in the specified direction and order into differential case B. Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX, or equivalent NOTE: Apply a careful coat of gear oil to the contacting and sliding surfaces.

Scheme 88

Scheme 89

1. Align the alignment mark on differential case A with that on differential case B.
2. Tighten the screws connecting differential case A and B a uniform amount little by little in the diagonal order. NOTE: If tightening the screws does not bring the two cases properly together, spring plates are not probably assembled properly. Reassemble from the start.

Scheme 90

Scheme 91

1. Use special tools MB990989 and MB990990 to check for differential torque. Standard value: NOTE: Before measuring the differential torque, first turn the gears so they snug each other, then take measurements during rotation.
2. If the measurement falls outside the specified range, disassemble the differential case assembly and repair or replace defective parts.

Scheme 92

1. Clean the disassembled parts with cleaning oil and dry them with compressed air.
2. Check each plate, disc, and pressure ring for the following: A: Friction and sliding surfaces of friction discs, friction plates, and spring plates. Replace a defective part with heat discoloration and excessive wear with a new one, as it degrades locking performance. NOTE: If the inner periphery of the friction face shows traces of harsh contact, it is because of the spring tension of each plate, disc and other part. Do not confuse this with abnormal wear. B: Inner periphery and outer periphery protrusions of friction discs, friction plates, and spring plates. Replace a cracked or damaged part with a new one. C: Friction and sliding surfaces between pressure rings and friction discs. Grind a dented or scratched part with oil stone and then lap and correct with a compound on a surface plate. NOTE: If the inner periphery of the friction face shows traces of harsh contact, it is because of the spring tension of each plate, disc and other part. Do not confuse this with abnormal wear.
3. Check the following parts for contact and siding surfaces (D to M) and correct burrs and dents with oil stone. D: Sliding surfaces of side gear and case E: Contacting surfaces of differential case and spring plate F: Contacting surfaces of pressure ring and differential case inner face G: Sliding surfaces of pressure ring hole and side gear H: Protrusions on outer periphery of pressure ring I: Pressure ring inner surface and differential pinion gear spherical surface J: Pressure ring V-groove and pinion shaft V K: Sliding surfaces of pinion shaft and differential pinion gear hole L: Side gear grooves on outer periphery M: Slits in inner periphery of differential

Scheme 93