Mitsubishi Car 1999-05

Overhaul 1

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These vehicles use several different types of joints. Engine size, transaxle type, whether the joint is an inboard or outboard joint, even which side of the vehicle is being serviced could make a difference in joint type. Be sure to properly identify the joint before attempting joint or boot replacement. Look for identification numbers at the large end of the boots and/or on the end of the metal retainer bands.

The 3 types of joints used are the Birfield Joint, (B.J.), the Tripod Joint (T.J.) and the Double Offset Joint (D.O.J.).


NOTE
Do not disassemble a Birfield joint. Service with a new joint or clean and repack using a new boot kit.

The distance between the large and small boot bands is important and should be checked prior to and after boot service. This is so the boot will not be installed either too loose or too tight, which could cause early wear and cracking, allowing the grease to get out and water and dirt in, leading to early joint failure.


NOTE
The driveshaft joints use special grease; do not add any grease other than that supplied with the kit.



Click image to see an enlarged view

Fig. Disassembled halfshaft assembly-2000-2005 Eclipse


NOTE
Never disassemble the BJ assembly, except when replacing the BJ boot.

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove the large and small TJ boot bands.
  4.  
  5. Remove the TJ case and inner shaft assembly.
  6.  
  7. Remove the TJ case. Remove the seal plate. Remove the inner shaft using tool MB991248. Remove the dust cover.
  8.  
  9. Remove the bracket assembly. Remove the inner and outer dust seals.
  10.  
  11. Remove the center bearing bracket (3.0L engine, right side). Use tools MB990930 and MB990938 to press the center bearing out of the center bearing bracket.
  12.  
  13. Remove the circlip. Remove the snapring. Remove the spider assembly. Wrap tape around the spline part of the BJ assembly so that the TJ boot is not damaged when it is removed. Remove the TJ boot. Remove the BJ assembly.
  14.  
  15. Remove the damper band (2.4L engine and 3.0L engine, left side). Remove the dynamic damper (2.4L engine and 3.0L engine, left side).
  16.  
  17. Remove the large and small BJ boot clamp. Remove the BJ boot.
  18.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install the dynamic damper as shown in the illustration. Measurement -A- should be 9.5 +/- 0.12 for the left side and 10.0 +/- 0.12 for the right side.
    NOTE
    There should be no grease stuck to the rubber part of the dynamic damper. The damper band and TJ boot band (small) are different in shape. Be sure not to assemble a wrong band in the wrong place.



    Click image to see an enlarged view

    Fig. Dynamic damper installation measurement-2004-2005 Eclipse

  4.  
  5. The damper band is Blue. The TJ boot band is Pink for the 3.0L engine without ABS and Brown for the 3.0L engine with ABS. Secure the damper bands.
  6.  
  7. Wrap plastic tape around the shaft spline, then install the TJ boot band (small) and the TJ boot.
  8.  
  9. To install the spider assembly, apply grease to the spider axles and rollers of the spider assembly. Do not mix old and new grease or different types of grease.
  10.  
  11. Face the chamfered portion of the spider assembly-s spline toward the halfshaft, and then install the spider assembly to the halfshaft.
  12.  
  13. On 3.0L engine, right side, use tools MB990930 and MB990938 to press the center bearing into the center bearing bracket. Pack grease in the inner and outer seal and use the special tools to press the oil seal into the center bearing bracket. The dust inner seal should take about 0.5-0.7 ounces and the outer seal should take about 0.3-0.4 ounces of grease. Apply grease to the lip of the seal, not to the outside of the lip. Use tool MB991172 to hold the center bearing inner race, and then press in the inner shaft.

    Click image to see an enlarged view

    Fig. Dust seal grease application location-2004-2005 Eclipse with center bearing halfshaft

  14.  
  15. Apply grease to the inner shaft serration and then press the inner shaft assembly to the TJ case.
  16.  
  17. Fill the TJ case with grease and insert the halfshaft. Refill the TJ case with grease. Do not mix old and new grease or different types of grease. The 2.4L engine uses 3.4 +/- 0.4 ounces of grease and the 3.0L engine uses 6.2 +/- 0.4 ounces of grease.
  18.  
  19. Position the TJ outer race so that the distance between the boot bands is 3.3 +/- 0.12 inch for the 2.4L engine and 3.5 +/- inch for the 3.0L engine.
  20.  
  21. Remove part of the TJ outer race to release the air pressure inside the boot.

    Click image to see an enlarged view

    Fig. TJ boot band measurement-2000-2005 Eclipse

  22.  



Click image to see an enlarged view

Fig. Disassembled halfshaft assembly-Galant


NOTE
Be careful not to damage the ABS rotor, which is attached to the outer race during disassembly and reassembly. Never disassemble the BJ assembly, except when replacing the BJ boot.

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove both TJ boot bands, if equipped with the 2.4L engine. Remove both PTJ boot bands if, equipped with the 3.8L engine.
  4.  
  5. Using tool MB991248 remove the PTJ case inner shaft assembly, if equipped with the 3.8L engine.
  6.  
  7. Remove the center bearing bracket from the inner shaft using tool MB990810, if equipped with the 3.8L engine.
  8.  
  9. Remove the TJ case, if equipped with the 2.4L engine. Remove the PTJ case, if equipped with the 3.8L engine.
  10.  
  11. If equipped with the 3.8L engine (right side), remove the inner shaft, dust cover, bracket assembly, dust outer seal, dust inner seal, center bearing and center bearing bracket.
  12.  
  13. Use tools MB990938 and MB990930 to remove the center bearing from the center bearing bracket, if equipped with the 3.8L engine.
  14.  
  15. Remove the snapring. Remove the spider assembly.
  16.  
  17. Remove the TJ boot, if equipped with the 2.4L engine. Remove the PTJ boot if equipped with the 3.8L engine.
  18.  
  19. Remove the dynamic damper (left side). Remove the damper band and damper if equipped with the 2.4L engine (right side).
  20.  
  21. Remove the BJ assembly. Remove the small and large BJ boot bands. Remove the BJ boot.

    Click image to see an enlarged view

    Fig. Dynamic damper installation measurement-2004-2005 Galant and 2004-2005 Lancer

  22.  

To install:

Click image to see an enlarged view

Fig. TJ boot band measurement-2004-2005 Galant, 2004-2005 Lancer and Evolution

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install the dynamic damper as shown in the illustration. Measurement -L- should be 10.2 +/- 0.12 inch for the 2.4L engine left side and 16.0 +/- 0.12 inch for the 2.4L engine right side and 10.3 +/-0.12 inch for the 3.8L engine.
    NOTE
    There should be no grease stuck to the rubber part of the dynamic damper.

  4.  
  5. Secure the damper bands. Wrap plastic tape around the shaft spline, then install the TJ boot band (small) and the TJ boot or the PTJ boot band (small) and the PTJ boot.
  6.  
  7. To install the spider assembly, apply grease to the spider axles and rollers of the spider assembly. Do not mix old and new grease or different types of grease.
  8.  
  9. Install the spider assembly to the shaft from the direction of the spline chamfered side.
  10.  
  11. Use tools MB990930 and MB990938 to press the center bearing into the center bearing bracket. Pack grease in the inner and outer seal and use the special tools to press the oil seal into the center bearing bracket. The dust inner seal should take about 0.5-0.7 ounces and the outer seal should take about 0.3-0.4 ounces of grease. Apply grease to the lip of the seal, not to the outside of the lip. Use tool MB991172 to hold the center bearing inner race, and then press in the inner shaft.
  12.  
  13. Apply grease to the inner shaft spline and then press the inner shaft assembly to the PTJ case.
    NOTE
    When press fitting the inner shaft into the PTJ case, apply a thin coat of repair grease to the dust seal outer lip and to the outside edge of the PTJ axial component.

  14.  
  15. Use special tool MB991172 to hold the center bearing inner race, then press in the inner shaft.
  16.  
  17. Fill the TJ or PTJ case with grease and insert the halfshaft. Refill the TJ or PTJ case with grease. Do not mix old and new grease or different types of grease. If equipped with the 2.4L engine the left side uses 4.9 +/- 0.3 ounces of grease and the right side uses 4.6 +/- 0.3 ounces of grease. The 3.8L engine uses 7.8 +/- 0.3 ounces of grease.
  18.  
  19. Position the TJ or PTJ boot bands at 3.35 +/- 0.12 inch in order to adjust the amount of air inside the TJ or PTJ boot. Tighten the TJ or PTJ boot band (small) and the TJ or PTJ boot band (large) securely.
  20.  

Double Offset Joint



The Double Offset Joint (D.O.J.) is bigger than other joints and, in these applications, is normally used as an inboard joint.

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Side cutter pliers can be used to cut the metal retaining bands. Remove the boot from the joint outer race.
  4.  
  5. Locate and remove the large circlip at the base of the joint. Remove the outer race (the body of the joint).
  6.  
  7. Remove the small snapring and take off the inner race, cage and balls as an assembly. Clean the inner race, cage and balls without disassembling.
  8.  
  9. If the boot is to be reused, wipe the grease from the splines and wrap the splines in vinyl tape before sliding the boot from the shaft.
  10.  
  11. Remove the inner (D.O.J.) boot from the shaft. If the outer (B.J.) boot is to be replaced, remove the boot retainer rings and slide the boot down and off of the shaft at this time.
  12.  

To install:

  1. Be sure to tape the shaft splines before installing the boots. Fill the inside of the boot with the specified grease. Often the grease supplied in the replacement parts kit is meant to be divided in half, with half being used to lubricate the joint and half being used inside the boot.
  2.  
  3. Install the cage onto the halfshaft so the small diameter side of the cage is installed first. With a brass drift pin, tap lightly and evenly around the inner race to install the race until it comes into contact with the rib of the shaft. Apply the specified grease to the inner race and cage and fit them together. Insert the balls into the cage.
  4.  
  5. Install the outer race (the body of the joint) after filling with the specified grease. The outer race should be filled with this grease.
  6.  
  7. Tighten the boot bands securely. Make sure the distance between the boot bands is correct.
  8.  
  9. Install the halfshaft to the vehicle.
  10.  

The Double Offset Joint (D.O.J.) is bigger than other joints and, in these applications, is normally used as an inboard joint.

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Side cutter pliers can be used to cut the metal retaining bands. Remove the boot from the joint outer race.
  4.  
  5. Locate and remove the large circlip at the base of the joint. Remove the outer race (the body of the joint).
  6.  
  7. Remove the small snapring and take off the inner race, cage and balls as an assembly. Clean the inner race, cage and balls without disassembling.
  8.  
  9. If the boot is to be reused, wipe the grease from the splines and wrap the splines in vinyl tape before sliding the boot from the shaft.
  10.  
  11. Remove the inner (D.O.J.) boot from the shaft. If the outer (B.J.) boot is to be replaced, remove the boot retainer rings and slide the boot down and off of the shaft at this time.
  12.  

To install:

  1. Be sure to tape the shaft splines before installing the boots. Fill the inside of the boot with the specified grease. Often the grease supplied in the replacement parts kit is meant to be divided in half, with half being used to lubricate the joint and half being used inside the boot.
  2.  
  3. Install the cage onto the halfshaft so the small diameter side of the cage is installed first. With a brass drift pin, tap lightly and evenly around the inner race to install the race until it comes into contact with the rib of the shaft. Apply the specified grease to the inner race and cage and fit them together. Insert the balls into the cage.
  4.  
  5. Install the outer race (the body of the joint) after filling with the specified grease. The outer race should be filled with this grease.
  6.  
  7. Tighten the boot bands securely. Make sure the distance between the boot bands is correct.
  8.  
  9. Install the halfshaft to the vehicle.
  10.  

Evolution





Click image to see an enlarged view

Fig. Disassembled halfshaft assembly-Evolution


NOTE
Be careful not to damage the ABS rotor, which is attached to the outer race during disassembly and reassembly. Never disassemble the EBJ assembly, except when replacing the EBJ boot.

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove the large and small TJ boot bands.
  4.  
  5. Remove the TJ case. Remove the snapring.
  6.  
  7. Remove the spider assembly. Remove the TJ boot.
  8.  
  9. Remove the EBJ assembly. Remove the small and large EBJ boot bands. Remove the EBJ boot.
  10.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Wrap plastic tape around the shaft spline, then install the EBJ boot band (small) and the EBJ boot.
  4.  
  5. To install the spider assembly, apply grease to the spider axles and rollers of the spider assembly. Do not mix old and new grease or different types of grease.
  6.  
  7. Install the spider assembly to the shaft from the direction of the spline chamfered side.
  8.  
  9. Fill the TJ case with grease and insert the halfshaft. Refill the TJ case with grease. Do not mix old and new grease or different types of grease. Uses 5.1 +/- 0.3 ounces of grease.
  10.  
  11. Position the TJ boot bands at 3.35 +/- 0.12 inch in order to adjust the amount of air inside the TJ boot. Tighten the TJ boot band (small) and the TJ boot band (large) securely.
  12.  

 
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