Mitsubishi Car 1999-05

Removal & Installation

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  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the cotter pin, halfshaft nut and washer.
  4.  
  5. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor.
  6.  
  7. If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:
    1. Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.
    2.  
    3. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.
    4.  

  8.  
  9. Disconnect the lower ball joint and the tie rod end from the steering knuckle.
  10.  
  11. If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.
  12.  
  13. If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.
    NOTE
    Do not pull on the shaft; doing so damages the inboard joint.

  14.  

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. Insert the halfshaft into the transaxle. Be sure it is fully seated.
  4.  
  5. Pull the strut assembly out and install the other end to the hub.
  6.  
  7. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the washer so the chamfered edge faces outward. Install the nut and tighten to 145-188 ft. lbs. (200-260 Nm) Secure with a new cotter pin.
  10.  
  11. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.
  12.  
  13. Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.
  14.  
  15. If equipped with ABS, install the front wheel speed sensor.
  16.  
  17. If equipped with Active-ECS, perform the following:
    1. Install the air line with a new O-ring.
    2.  
    3. Install the actuator to the top of the strut. Connect the wiring harness.
    4.  

  18.  
  19. Install the wheel and lower the vehicle to the floor.
  20.  

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel and tire assemblies.
  4.  
  5. Remove and discard the cotter pin, then remove the driveshaft nut.
  6.  
  7. Separate the tie rod end from the steering knuckle.
  8.  
  9. Detach the stabilizer link ball joint and damper fork connection.
  10.  
  11. Remove the retainers, then remove the damper fork.
  12.  
  13. Separate the lateral lower control arm ball joint from the steering knuckle.
  14.  
  15. Disconnect the compression lower ball joint from the steering knuckle.
  16.  
  17. For FWD vehicles, remove the halfshaft from the vehicle.
  18.  
  19. For AWD vehicles, unfasten the halfshaft retaining bolt, then remove the halfshaft and inner shaft (left side) or halfshaft (right side).

    Click image to see an enlarged view

    Fig. Exploded view of the driveshaft (halfshaft) assembly-1999 Models

  20.  
  21. Remove the circlip from the end of the halfshaft.
  22.  

To install:

  1. Install the circlip on the end of the halfshaft.
  2.  
  3. Position the halfshaft assembly in the vehicle.
  4.  
  5. For AWD vehicles, install the retaining bolt, and tighten to 30 ft. lbs. (40 Nm).
  6.  
  7. Install the compression lower ball joint and lateral lower ball joint into the steering knuckle.
  8.  
  9. Install the damper fork.
  10.  
  11. Install the remaining components in the reverse order of removal. Tighten the retainers to the specifications shown in the accompanying figures.
  12.  

  1. Raise and safely support the vehicle.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft nut and washer
     
    Tie rod end from the knuckle
     
    Stabilizer link from the damper fork
     
    Compression and lateral arm ball joint studs from the knuckle
     

  4.  
  5. Mount a puller on the wheel studs and push the halfshaft through the hub assembly.
  6.  
  7. Detach the inner halfshaft from the transaxle by carefully prying the CV-joint housing out.
  8.  
  9. Pull the knuckle assembly outward and remove the halfshaft.
  10.  

To install:

  1. Place a new circlip on the inner halfshaft and install the halfshaft in the transaxle.
  2.  
  3. Push out on the knuckle assembly and install the halfshaft through the hub.
  4.  
  5. Using new nuts, install the lateral and compression arm ball joint studs in the knuckle. Tighten the nuts to 43-52 ft. lbs. (59-71 Nm). Install new cotter pins.
  6.  
  7. Install the damper fork on the knuckle. Do nut tighten the nut at this time.
  8.  
  9. Attach the stabilizer link to the damper fork. Tighten the nut to 29 ft. lbs. (39 Nm).
  10.  
  11. Install the washer and nut on the halfshaft. Prevent the hub from turning and tighten the nut to 145-188 ft. lbs. (196-255 Nm).
  12.  
  13. Install the wheel and lower the vehicle to the floor. Tighten the damper fork nut to 65 ft. lbs. (88 Nm).

    Click image to see an enlarged view

    Fig. Proper method for removing the inner halfshaft from the transaxle or differential

  14.  

  1. Raise and support the vehicle safely.
  2.  
  3. If equipped with ABS, disconnect the speed sensor connection. Remove the brake hose clip.
  4.  
  5. Remove the cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
  6.  
  7. Remove the lower ball joint cotter pin.
    NOTE
    Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  8.  
  9. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  10.  
  11. Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.
  12.  
  13. Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
    NOTE
    Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  14.  
  15. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  16.  
  17. Tighten the bolt with a wrench to disconnect the tie rod end.
  18.  
  19. Disconnect the stabilizer link connection.
    NOTE
    Do not damage the ABS rotor attached to the BJ outer race, on vehicle equipped with ABS.

  20.  
  21. Use special tools MB991354, MB990242 and MB990767 to push the halfshaft out from the hub.
    NOTE
    Do not pull on the halfshaft, doing so will damage the TJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

  22.  
  23. Insert a prybar between the transaxle case and the halfshaft to remove the halfshaft on vehicles equipped with 2.4L engine and vehicles equipped with 3.0L engine (left side shaft).
  24.  
  25. If the inner shaft and transaxle are tightly joined, tap the center bearing bracket with a plastic hammer to remove the halfshaft and inner shaft from the transaxle on vehicles with 3.0L engine (right side).
  26.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Check and adjust the front end alignment, as necessary.

    Click image to see an enlarged view

    Fig. Halfshaft and related components-2004-2005 Eclipse

  4.  

  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the cotter pin, halfshaft nut and washer.
  4.  
  5. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor.
  6.  
  7. If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:
    1. Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.
    2.  
    3. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.
    4.  

  8.  
  9. Disconnect the lower ball joint and the tie rod end from the steering knuckle.
  10.  
  11. If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.
  12.  
  13. If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.
    NOTE
    Do not pull on the shaft; doing so damages the inboard joint.

  14.  

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. Insert the halfshaft into the transaxle. Be sure it is fully seated.
  4.  
  5. Pull the strut assembly out and install the other end to the hub.
  6.  
  7. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the washer so the chamfered edge faces outward. Install the nut and tighten to 145-188 ft. lbs. (200-260 Nm). Secure with a new cotter pin.
  10.  
  11. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.
  12.  
  13. Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.
  14.  
  15. If equipped with ABS, install the front wheel speed sensor.
  16.  
  17. If equipped with Active-ECS, perform the following:
    1. Install the air line with a new O-ring.
    2.  
    3. Install the actuator to the top of the strut. Connect the wiring harness.
    4.  

  18.  
  19. Install the wheel and lower the vehicle to the floor.
  20.  

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the front under cover. Remove the side undercover. Drain the transaxle fluid.
  4.  
  5. On vehicles equipped with the 3.8L engine, disconnect the front exhaust pipe if working on the right side halfshaft.
  6.  
  7. Disconnect the speed sensor connection. Remove the wheel speed sensor. Remove the brake hose clip.
  8.  
  9. Remove the cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
  10.  
  11. Remove the lower ball joint cotter pin.
    NOTE
    Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  12.  
  13. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  14.  
  15. Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.
  16.  
  17. Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
    NOTE
    Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  18.  
  19. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  20.  
  21. Tighten the bolt with a wrench to disconnect the tie rod end.
  22.  
  23. Disconnect the stabilizer link connection.
    NOTE
    Do not strike the ABS rotor attached to the BJ or EBJ outer race, of the halfshaft against other parts when removing the halfshaft as damage to the rotors will result.

  24.  
  25. Use special tools MB991354, MB990242 and MB990767 to push the halfshaft out from the hub.
    NOTE
    Do not pull on the halfshaft, doing so will damage the TJ or PTJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

  26.  
  27. Remove the halfshaft from the hub by pulling the bottom of the brake disc towards you.
  28.  
  29. Insert a prybar between the transaxle case and the halfshaft, and than pry and remove the halfshaft from the transaxle.
    NOTE
    Insert a prybar, taking care not to damage the protrusion of the transaxle case when removing the halfshaft (left side).

  30.  
  31. If the inner shaft and transaxle are tightly joined, tap the center bearing bracket with a plastic hammer to remove the halfshaft and inner shaft from the transaxle on vehicles with 3.0L engine (right side).
  32.  

To install:

Click image to see an enlarged view

Fig. Halfshaft and related components-2004-2005 Galant

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Check and adjust the front end alignment, as necessary.
  4.  

  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the cotter pin, halfshaft nut and washer.
  4.  
  5. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor.
  6.  
  7. If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:
    1. Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.
    2.  
    3. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.
    4.  

  8.  
  9. Disconnect the lower ball joint and the tie rod end from the steering knuckle.
  10.  
  11. If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.
  12.  
  13. If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.
    NOTE
    Do not pull on the shaft; doing so damages the inboard joint.



    Click image to see an enlarged view

    Fig. Halfshaft and related components-Lancer

  14.  

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. Insert the halfshaft into the transaxle. Be sure it is fully seated.
  4.  
  5. Pull the strut assembly out and install the other end to the hub.
  6.  
  7. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the washer so the chamfered edge faces outward. Install the nut and tighten to 181 ft. lbs. (245 Nm). Secure with a new cotter pin.
  10.  
  11. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.
  12.  
  13. Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.
  14.  
  15. If equipped with ABS, install the front wheel speed sensor.
  16.  
  17. If equipped with Active-ECS, perform the following:
    1. Install the air line with a new O-ring.
    2.  
    3. Install the actuator to the top of the strut. Connect the wiring harness.
    4.  

  18.  
  19. Install the wheel and lower the vehicle to the floor.
  20.  

  1. Raise and support the vehicle safely.
  2.  
  3. If equipped with ABS, disconnect the speed sensor connection. Remove the ABS sensor and bracket. Remove the brake hose clip.
  4.  
  5. Remove the stabilizer bar locknut, rubber insulator and collar.
  6.  
  7. Remove the cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
  8.  
  9. Remove the lower ball joint cotter pin.
    NOTE
    Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  10.  
  11. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  12.  
  13. Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.
  14.  
  15. Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
    NOTE
    Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  16.  
  17. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  18.  
  19. Tighten the bolt with a wrench to disconnect the tie rod end.
    NOTE
    Do not damage the ABS rotor attached to the BJ outer race, on vehicle equipped with ABS.

  20.  
  21. Use special tools MB990241 and MB990767 (vehicles without center bearing) or tools MB991354, MB990242 and MB990244 (vehicles equipped with center bearing) to push the halfshaft out from the hub and knuckle.
  22.  
  23. Remove the halfshaft from the hub by pulling the bottom of the brake disc toward you, and than remove the hub retaining bolts.
    NOTE
    Do not pull on the halfshaft, doing so will damage the TJ or ETJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

  24.  
  25. Insert a prybar between the transaxle case and the halfshaft, and then pry the halfshaft from the transaxle.
  26.  
  27. If the inner shaft and transaxle are tightly joined, tap the center bearing bracket with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.
  28.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Check and adjust the front end alignment, as necessary.

    Click image to see an enlarged view

    Fig. Halfshaft and related components-2004-2005 Lancer

  4.  

  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the cotter pin, halfshaft nut and washer.
  4.  
  5. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor.
  6.  
  7. If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:
    1. Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.
    2.  
    3. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.
    4.  

  8.  
  9. Disconnect the lower ball joint and the tie rod end from the steering knuckle.
  10.  
  11. If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.
  12.  
  13. If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.
    NOTE
    Do not pull on the shaft; doing so damages the inboard joint.

  14.  

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. Insert the halfshaft into the transaxle. Be sure it is fully seated.
  4.  
  5. Pull the strut assembly out and install the other end to the hub.
  6.  
  7. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the washer so the chamfered edge faces outward. Install the nut and tighten to 145-188 ft. lbs. (200-260 Nm). Secure with a new cotter pin.
  10.  
  11. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.
  12.  
  13. Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.
  14.  
  15. If equipped with ABS, install the front wheel speed sensor.
  16.  
  17. If equipped with Active-ECS, perform the following:
    1. Install the air line with a new O-ring.
    2.  
    3. Install the actuator to the top of the strut. Connect the wiring harness.
    4.  

  18.  
  19. Install the wheel and lower the vehicle to the floor.
  20.  

Front





Click image to see an enlarged view

Fig. Front halfshafts and related components

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise the vehicle and support safely. Remove the lower ball joint and the tie rod end from the steering knuckle.
  6.  
  7. Remove the cotter pin, halfshaft nut and the washer.
  8.  
  9. On vehicles with an inner shaft, remove the center support bearing bracket bolts and washers.
  10.  
  11. On vehicles with an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Then, tap the shaft union at the joint case with a plastic hammer to remove the halfshaft shaft and inner shaft from the transaxle.

    Click image to see an enlarged view

    Fig. Front halfshaft removal

  12.  
  13. On vehicles without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle. Do not pull on the shaft.
  14.  

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. Insert the halfshaft into the transaxle.
  4.  
  5. Pull the strut assembly out and install the other end to the hub.
  6.  
  7. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the washer so the chamfered edge faces outward. Tighten the nut to 188 ft. lbs. (260 Nm).
  10.  
  11. Install the tie rod end and ball joint.
  12.  
  13. Install the wheel and lower the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the front suspension components

  14.  

Lancer Evolution



Front
  1. Raise and support the vehicle safely.
  2.  
  3. Remove the under cover. Remove the side cover. Drain the transaxle fluid. Drain the transfer case.
  4.  
  5. Remove the cotter pin. Install tool MB990767 to the hub and remove the driveshaft nut. Remove the washer.
  6.  
  7. Disconnect the speed sensor connection. Remove the ABS sensor and bracket. Remove the brake hose clip.
  8.  
  9. Remove the stabilizer bar locknut.
  10.  
  11. Remove the lower ball joint cotter pin.
    NOTE
    Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  12.  
  13. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  14.  
  15. Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.
  16.  
  17. Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.
    NOTE
    Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

  18.  
  19. Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.
    NOTE
    When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

  20.  
  21. Tighten the bolt with a wrench to disconnect the tie rod end.
    NOTE
    Do not strike the ABS rotor attached to the EBJ outer race, of the halfshaft against other parts when removing the halfshaft as damage to the rotors will result.

  22.  
  23. Use special tools MB990241 (MB990242 and MB990244), MB991354 and MB990767 to push the halfshaft out from the hub.
  24.  
  25. Remove the halfshaft from the hub by pulling the bottom of the brake disc toward you, and than remove the hub retaining bolts.
    NOTE
    Do not pull on the halfshaft, doing so will damage the TJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

  26.  
  27. Insert a prybar between the transaxle case and the halfshaft, and then pry and remove the driveshaft from the transaxle.
  28.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Check and adjust the front end alignment, as necessary.

    Click image to see an enlarged view

    Fig. Halfshaft and related components-Evolution

  4.  

Rear
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the rear wheel.
  6.  
  7. Remove the rear wheel speed sensor.
  8.  
  9. Remove the caliper and rotor.
  10.  
  11. Remove the brake hydraulic line from the wheel cylinder.
  12.  
  13. Remove the parking brake cable from the rear brakes.
  14.  
  15. Remove the lower end of the shock absorber from the knuckle.
  16.  
  17. Remove the trailing and lower arms from the knuckle.
  18.  
  19. Remove the toe control arm ball joint from the knuckle.
  20.  
  21. Prevent the hub assembly from turning by using a tool such as MB990767 and remove the halfshaft nut and washer.
  22.  
  23. Remove the differential mount support.
  24.  


WARNING
Do not pull on the halfshaft to remove it from the differential. Damage to the inner CV-joint will occur.

  1. Push the lower part of the knuckle outward and pry the inner halfshaft out of the differential.
  2.  
  3. Push the outer end of the halfshaft through the hub/knuckle and remove it.
  4.  

To install:

  1. Install the outer end of the halfshaft through the hub/knuckle.
  2.  
  3. Place a new circlip on the inner halfshaft and install the halfshaft in the differential.
  4.  
  5. Install the differential mount support.
  6.  
  7. Install the washer and a new nut on the end of the halfshaft. Tighten the nut to 145-188 ft. lbs. (196-255 Nm).
  8.  
  9. Install the toe control arm to the knuckle. Tighten the new nut to 20 ft. lbs. (28 Nm).
  10.  
  11. Install the lower and trailing arms to the knuckle. Do not tighten the fasteners at this time.
  12.  
  13. Install the shock absorber. Tighten the bolt to 71 ft. lbs. (98 Nm).
  14.  
  15. Assemble the brake components.
  16.  
  17. Install the rear wheel speed sensor.
  18.  
  19. Install the rear wheel and lower the vehicle to the floor. Tighten the lower arm nut to 71 ft. lbs. (98 Nm) and the trailing arm nut to 85-99 ft. lbs. (118-137 Nm).
  20.  

Manual Transaxle





Click image to see an enlarged view

Fig. Remove the cotter pin from the axle shaft . . .



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Fig. . . . then loosen the axle nut while the vehicle is still on the ground



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Fig. Use a suitable wrench to loosen . . .



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Fig. . . . the nuts from the lower ball joint-to-steering knuckle junctions



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Fig. Remove the lower coil-over shock lower mounting bolt and nut from the control arm



Click image to see an enlarged view

Fig. Use a suitable prytool to separate . . .



Click image to see an enlarged view

Fig. . . . the lower ball joints from the steering knuckle



Click image to see an enlarged view

Fig. Use a suitable prytool to release the inner CV-joint retaining ring from the transaxle by gently prying outward



Click image to see an enlarged view

Fig. Remove the inner joint from the transaxle until the spline completely clears the transaxle



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Fig. Using a suitable punch and hammer, gently tap the halfshaft out of the steering knuckle . . .



Click image to see an enlarged view

Fig. . . . then slide the halfshaft out of the knuckle



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Fig. Remove the halfshaft from the vehicle



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Fig. Always replace the circlip on the inner joint before installing the shaft into the transaxle

  1. While the vehicle is still on the ground, remove the cotter pin, and loosen the axle nut.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. If equipped with ABS, remove the front wheel speed sensor.
  6.  
  7. If equipped with Active Electronic Control Suspension (Active-ECS), perform the following:
  8.  

  1. Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.
  2.  
  3. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.
  4.  

  1. Disconnect the lower ball joint and the tie rod end from the steering knuckle.
  2.  
  3. Remove the axle nut and the washer.
  4.  
  5. If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.
  6.  
  7. If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.
  8.  


NOTE
Do not pull on the shaft; doing so damages the inboard joint.

To install:

  1. Replace the circlips on the ends of the halfshafts.
  2.  
  3. Insert the halfshaft into the transaxle. Be sure it is fully seated.
  4.  
  5. Pull the strut assembly out and install the other end to the hub.
  6.  
  7. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the washer on the axle shaft so the chamfered edge faces outward. Install the axle nut, but do not tighten it fully at this time.
  10.  
  11. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.
  12.  
  13. Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.
  14.  
  15. If equipped with ABS, install the front wheel speed sensor.
  16.  
  17. If equipped with Active-ECS, perform the following:
  18.  

  1. Install the air line with a new O-ring.
  2.  
  3. Install the actuator to the top of the strut. Connect the wiring harness.
  4.  

  1. Install the wheel and lower the vehicle to the floor.
  2.  
  3. Tighten the axle nut to 145-188 ft. lbs. (200-260 Nm) and secure with a new cotter pin.
  4.  

Rear




NOTE
On vehicles with Limited Slip Differential, the right and left halfshafts are not the same. If both halfshafts are to be removed, mark them for proper installation.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Raise the vehicle and support it safely.
  4.  
  5. Matchmark the halfshaft and the companion flange.
  6.  
  7. Remove the bolts that attach the rear halfshaft to the companion flange.
  8.  
  9. Use a prybar to pry the inner shaft out of the differential case.
  10.  
  11. Remove the rear halfshaft from the vehicle.
  12.  

To install:

  1. Install a new circlip on the halfshaft and install it into the differential. Be sure it is fully seated.
  2.  
  3. Align the matchmarks and attach the halfshaft to the companion flange. Tighten the fasteners to 40-47 ft. lbs. (55-65 Nm).
  4.  
  5. Lower the vehicle and connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Rear halfshaft removal-AWD



    Click image to see an enlarged view

    Fig. Proper method for disconnecting ball joint studs and tie rod ends

  6.  

 
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