Home ReviewsRefund
Home/Mitsubishi/Lancer/Mitsubishi Lancer IX (2000-2007)/Repair manual/Suspension Front/Front Suspension - Evolution: Removal & Installation
Contents Wiring diagrams Section: Suspension Front All sections

Front Suspension - Evolution: Removal & Installation Mitsubishi Lancer IX

Suspension Front 18 illustrations ~1065 words

Removal

CAUTIONDO NOT strike the ABS rotors installed to the Eight Ball Fixed Joint (EBJ) outer race of axle shaft against other parts when removing or installing the axle shaft. Otherwise, the ABS rotors will be damaged.
CAUTIONBe careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing work.
CAUTIONDuring maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. If there is brake fluid on the caliper, wipe it off quickly.
  1. Remove front under cover and side under cover.
  2. Remove cotter pin. (Scheme 35)
  3. Using End Yoke Holder (MB990767), fix the hub and remove the axle shaft nut. (Scheme 36)
  4. Remove washer. (Scheme 35)
  5. Disconnect front ABS sensor.
  6. Remove caliper assembly. See «FRONT BRAKE CALIPER»(ref-163016-S12518411572004061600000) under REMOVAL & INSTALLATION in DISC - EVOLUTION article under BRAKES.
  7. Remove brake disc. See «FRONT BRAKE ROTOR»(ref-163016-S28422814082004061600000) under REMOVAL & INSTALLATION in DISC - EVOLUTION article under BRAKES.
  8. Remove dust cover. (Scheme 35)
  9. Disconnect lower arm from knuckle.
  10. Disconnect tie rod end ball joint from knuckle assembly. Install Ball joint Remover (MB991897) as shown in illustration. (Scheme 37) Turn the bolt and knob as necessary to make the jaws of Ball Joint Remover (MB991897) parallel. (Scheme 38) Tighten the bolt by hand and confirm that the jaws are still parallel. Tighten the bolt with a wrench to disconnect the ball joint.
  11. Using Axle Shaft Puller (MB990241), Puller Shaft (MB990242), Puller Bar (MB990244), Puller Body (MB991454) and End Yoke Holder (MB990767), push out the axle shaft from the hub and knuckle. (Scheme 39) Remove the hub by pulling the top of the hub and knuckle towards you. (Scheme 40)
  12. Remove strut-to-hub and knuckle mounting bolt. (Scheme 35)
  13. Remove hub and knuckle assembly.

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Installation

  1. Install hub and knuckle assembly. (Scheme 35)
  2. Install strut-to-hub and knuckle bolt.
  3. Reconnect tie rod end and knuckle.
  4. Reconnect lower ball joint to knuckle.
  5. Install dust cover.
  6. Install brake disc. See «FRONT BRAKE ROTOR»(ref-163016-S28422814082004061600000) under REMOVAL & INSTALLATION in DISC - EVOLUTION article under BRAKES.
  7. Install caliper assembly. See «FRONT BRAKE CALIPER»(ref-163016-S12518411572004061600000) under REMOVAL & INSTALLATION in DISC - EVOLUTION article under BRAKES.
  8. Reconnect front ABS sensor. (Scheme 35)
  9. Be sure to install the axle shaft washer as shown in illustration. (Scheme 41) Using End Yoke Holder (MB990767), tighten the axle shaft nut to specification. See «TORQUE SPECIFICATIONS»(ref-170069-S16787094772004122900000).
  10. Install cotter pin. (Scheme 35)
  11. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-170069-S16787094772004122900000).
  12. Check ball joint dust cover. See «BALL JOINT DUST COVER»(ref-170069-S06765848022004122900000) under ADJUSTMENTS & INSPECTION.
  13. Install front under cover and side under cover.

Scheme 41

Scheme 41
Scheme 41

Removal & Installation

Note. If the dust cover is damaged accidentally during service work, replace the dust cover.

  1. Remove the dust cover.
  2. Apply multi-purpose grease to the lip and inside of the dust cover.
  3. Using Ball Joint Remover and Installer (MB990800), press the dust cover until it contacts the lower arm assembly. (Scheme 42)
  4. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.

Scheme 42

Scheme 42
Scheme 42
  1. Remove the caliper assembly and suspend it with wire so that is does not fall.
  2. Remove the brake disc.
  3. Using End Yoke Holder (MB990767) and Hub Bolt Remover (MB991618), remove the hub bolts. (Scheme 43)
  4. Install the plain washer to the new hub bolt, and install the bolt with a nut. (Scheme 44)
  5. Install the caliper assembly and tighten the caliper assembly mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170069-S16787094772004122900000).

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44
CAUTIONDuring maintenance, take care not to contact the parts or tools to the caliper because the paint of the caliper will be scratched. If there is brake fluid on the caliper, wipe it off quickly.
  1. Remove stabilizer link nut. (Scheme 45)
  2. Disconnect lower arm from knuckle.
  3. Separate lower arm from crossmember.
  4. Lift the transmission with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly.
  5. Remove stabilizer bracket.
  6. Remove lower arm assembly.
  7. To install, reverse removal procedures. Install bolts and nuts and loosely tighten. Lower vehicle, then tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-170069-S16787094772004122900000). Check ball joint dust cover. See «BALL JOINT DUST COVER»(ref-170069-S06765848022004122900000) under ADJUSTMENTS & INSPECTION. Check and adjust wheel alignment if necessary. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 45

Scheme 45
Scheme 45
  1. Using Bar (MB990651), Base (MB991576) and Bushing Remover and Installer Base (MB991816), drive out the bushing. (Scheme 46)
  2. Set the bushing to the lower arm assembly as shown in illustration. (Scheme 47)
  3. Using Bar (MB990651), Base (MB991576) and Bushing Remover and Installer Base (MB991816), press in the bushing until its outer tube is flush with the lower arm assembly surface. (Scheme 46)

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47
WARNINGVehicles are equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see AIR BAG SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
CAUTIONDuring maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. If there is brake fluid on the caliper, wipe it off quickly.
  1. Remove steering wheel, driver's air bag module and clock spring. See «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(ref-160459-S18313971602004021000000) under REMOVAL & INSTALLATION in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
  2. Remove front axle crossmember bar. (Scheme 48)
  3. Remove front exhaust pipe.
  4. Remove stabilizer link. (Scheme 49)
  5. Remove stabilizer bar bracket.
  6. Disconnect lower arm from knuckle.
  7. Disconnect tie rod end ball joint from knuckle assembly. Install Ball joint Remover (MB991897) as shown in illustration. (Scheme 37) Turn the bolt and knob as necessary to make the jaws of Ball Joint Remover (MB991897) parallel. (Scheme 38) Tighten the bolt by hand and confirm that the jaws are still parallel. Tighten the bolt with a wrench to disconnect the ball joint.
  8. Remove steering shaft cover. (Scheme 49)
  9. Remove steering gear and joint connecting bolt.
  10. Remove rear roll stopper connecting bolt.
  11. Using a transmission jack to hold the crossmember, remove the crossmember mounting nuts and bolts. (Scheme 50) Lower the crossmember until the fixture, bushing, and stabilizer bar can be removed.

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50
WARNINGVehicles are equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see AIR BAG SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
  1. Align the stabilizer bar identification mark with the right end of the bushing (LH). (Scheme 51)
  2. Install crossmember mounting nuts and bolts. (Scheme 50)
  3. Install rear roll stopper connecting bolt. (Scheme 49)
  4. Install steering gear and joint connecting bolt.
  5. Install steering shaft cover.
  6. Reconnect tie rod end to knuckle.
  7. Reconnect lower arm to knuckle.
  8. Install stabilizer bar bracket.
  9. Install stabilizer link.
  10. Install front exhaust pipe.
  11. Install front axle crossmember bar. (Scheme 48)
  12. Install steering wheel, driver's air bag module and clock spring. See «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(ref-160459-S18313971602004021000000) under REMOVAL & INSTALLATION in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
  13. Install bolts and nuts and loosely tighten. Lower vehicle, then tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-170069-S16787094772004122900000).
  14. Check ball joint dust cover. See «BALL JOINT DUST COVER»(ref-170069-S06765848022004122900000) under ADJUSTMENTS & INSPECTION.
  15. Check steering wheel position with wheel straight ahead.
  16. Check and adjust wheel alignment if necessary. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 51

Scheme 51
Scheme 51
  1. Remove from wheel sensor harness bracket. (Scheme 52)
  2. Remove brake hose bracket.
  3. Disconnect strut from knuckle.
  4. Remove strut mounting nuts.
  5. Remove strut assembly.
  6. To install, reverse removal procedures. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-170069-S16787094772004122900000). Check and adjust wheel alignment if necessary. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 52

Scheme 52
Scheme 52

More articles — Front Suspension - Evolution