Mitsubishi Car 1999-05

Overhaul 2

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Except Double Offset Joint



  1. Disconnect the negative battery cable. Remove the halfshaft.
  2.  
  3. Use side cutter pliers to remove the metal retaining bands from the boot(s) that will be removed. Slide the boot from the T.J. case.
  4.  
  5. Remove the snapring and the tripod joint spider assembly from the halfshaft. Do not disassemble the spider and use care in handling.
  6.  
  7. If the boot is be reused, wrap vinyl tape around the spline part of the shaft so the boot(s) will not be damaged when removed. Remove the dynamic damper, if used, and the boots from the shaft.
  8.  

To install:

  1. Double check that the correct replacement parts are being installed. Wrap vinyl tape around the splines to protect the boot and install the boots and damper, if used, in the correct order.
  2.  
  3. Install the joint spider assembly to the shaft and install the snapring.
  4.  
  5. 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. Keep grease off the rubber part of the dynamic damper (if used).
  6.  
  7. Secure the boot bands with the halfshaft in a horizontal position. Make sure distance between boot bands is correct.
  8.  
  9. Install the halfshaft to the vehicle and reconnect the negative battery cable.
  10.  



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Fig. Check the CV-boot for wear



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Fig. Removing the outer band from the CV-boot



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Fig. Removing the inner band from the CV-boot



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Fig. Removing the CV-boot from the joint housing



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Fig. Clean the CV-joint housing prior to removing boot



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Fig. Removing the CV-joint housing assembly



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Fig. Removing the CV-joint



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Fig. Inspecting the CV-joint housing



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Fig. Removing the CV-joint outer snapring



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Fig. Checking the CV-joint snapring for wear



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Fig. CV-joint snapring (typical)



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Fig. Removing the CV-joint assembly



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Fig. Removing the CV-joint inner snapring



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Fig. Installing the CV-joint assembly (typical)

  1. Disconnect the negative battery cable. Remove the halfshaft.
  2.  
  3. Use side cutter pliers to remove the metal retaining bands from the boot(s) that will be removed. Slide the boot from the T.J. case.
  4.  
  5. Remove the snapring and the tripod joint spider assembly from the halfshaft. Do not disassemble the spider and use care in handling.
  6.  
  7. If the boot is be reused, wrap vinyl tape around the spline part of the shaft so the boot(s) will not be damaged when removed. Remove the dynamic damper, if used, and the boots from the shaft.
  8.  

To install:

  1. Double check that the correct replacement parts are being installed. Wrap vinyl tape around the splines to protect the boot and install the boots and damper, if used, in the correct order.
  2.  
  3. Install the joint spider assembly to the shaft and install the snapring.
  4.  
  5. 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. Keep grease off the rubber part of the dynamic damper (if used).
  6.  
  7. Secure the boot bands with the halfshaft in a horizontal position. Make sure distance between boot bands is correct.
  8.  
  9. Install the halfshaft to the vehicle and reconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Check the CV-boot for wear



    Click image to see an enlarged view

    Fig. Removing the outer band from the CV-boot



    Click image to see an enlarged view

    Fig. Removing the inner band from the CV-boot



    Click image to see an enlarged view

    Fig. Removing the CV-boot from the joint housing



    Click image to see an enlarged view

    Fig. Clean the CV-joint housing prior to removing boot



    Click image to see an enlarged view

    Fig. Removing the CV-joint housing assembly



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    Fig. Removing the CV-joint



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    Fig. Inspecting the CV-joint housing



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    Fig. Removing the CV-joint outer snapring



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    Fig. Checking the CV-joint snapring for wear



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    Fig. CV-joint snapring (typical)



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    Fig. Removing the CV-joint assembly



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    Fig. Removing the CV-joint inner snapring



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    Fig. Installing the CV-joint assembly (typical)

  10.  

With Center Bearing





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Fig. Disassembled halfshaft assembly-Lancer with center bearing


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 ETJ boot bands. Remove the ETJ case and inner shaft assembly.
  4.  
  5. Use special tool MB991248 to remove the inner shaft assembly from the ETJ case.
  6.  
  7. Use tool MB990810 to remove the center bearing bracket from the inner shaft.
  8.  
  9. Remove the dust cover. Remove the bracket assembly.
  10.  
  11. Remove the inner and outer dust seal. Remove the center bearing from the center bearing bracket using tools MB990938 and MB990930. Remove the center bearing bracket.
  12.  
  13. Remove the circlip. Remove the snapring. Remove the spider assembly.
  14.  
  15. Remove the damper band. Remove the dynamic damper.
  16.  
  17. Remove the EBJ assembly. Remove the EBJ small and large boot bands. Remove the EBJ 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 -L- should be 9.1 +/- 0.12 inch.
    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 EBJ boot band (small) and the EBJ 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.
  12.  
  13. Use special tools MB990890, MB990938 and MB990934 to press the dust seals into the center bearing bracket until they are flush with each other. Apply grease to the lip of each dust seal.
  14.  
  15. Use tool MB991172 to hold the center bearing inner race, and then press in the inner shaft.
  16.  
  17. Apply grease to the inner shaft spline and then press the inner shaft assembly to the EBJ case.
    NOTE
    When press fitting the inner shaft into the EBJ case, apply a thin coat of repair grease to the dust seal outer lip and to the outside edge of the EBJ axial component.

  18.  
  19. Use special tool MB998369 and press in the seal plate.
  20.  
  21. Fill the EBJ case with grease and insert the halfshaft. Refill the EBJ case with grease. Do not mix old and new grease or different types of grease. Left side uses 4.6 +/- 0.3 ounces of grease and right side uses 4.2 +/- 0.3 ounces of grease.
  22.  
  23. Position the EBJ boot bands at 3.15 +/- 0.12 inch in order to adjust the amount of air inside the EBJ boot. Tighten the EBJ boot band (small) and the EBJ boot band (large) securely.
  24.  

 
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