Mitsubishi Colt Ralliart. Manual — part 256

DRIVESHAFT ASSEMBLY

FRONT AXLE

26-24

LUBRICATION POINTS

AC511692 AC

Grease: repair kit grease
Amount used: 95 ± 10 g

The driveshaft joint uses special
grease. Do not mix old and new or
different types of grease.

CAUTION

CAUTION

Grease: repair kit grease
Amount used: 150 ± 6 g

The driveshaft joint uses special
grease. Do not mix old and new or
different types of grease.

DISASSEMBLY SERVICE POINTS
<<A>> TJ CASE/SPIDER ASSEMBLY
REMOVAL

CAUTION

Do not disassemble the spider assembly.
1. Wipe off grease from the spider assembly and the

inside of the TJ case.

2. Always clean the spider assembly when the

grease contains water or foreign material.

<<B>> TJ BOOT REMOVAL

1. Wipe off grease from the shaft spline.
2. When reusing the TJ boot, wrap plastic tape

around the shaft spline to avoid damaging the
boot.

Main

Index

Group

TOC

DRIVESHAFT ASSEMBLY

FRONT AXLE

26-25

REASSEMBLY SERVICE POINTS
>>A<< DYNAMIC DAMPER/DAMPER
BAND/TJ BOOT INSTALLATION

CAUTION

There should be no grease adhered to the rubber
part of the dynamic damper.

AC208295

AD

A

1. For vehicles with 4A9, Install the dynamic damper

in the position shown in the figure.

A:

220

± 3 mm (LH)

380.5

± 3 mm (RH)

AC311709 AB

Dynamic
damper

MB991248
or
MD998801

Driveshaft

AC511676 AC

A

2. For vehicles with 4G1, press-fit the dynamic

damper by using special tool inner shaft remover
(MB991248 or MD998801) in the position shown
in the figure.

A: 231

± 3 mm

3. Wrap plastic tape around the shaft spline, and

then install the TJ boot band (small) and TJ boot.

>>B<< SPIDER ASSEMBLY
INSTALLATION

CAUTION

• The driveshaft joint use special grease. Do

not mix old and new or different types of
grease.

• If the spider assembly has been cleaned, take

special care to apply the specified grease.

1. Apply the specified grease furnished in the repair

kit to the spider assembly between the spider axle
and the roller.

Specified grease: Repair kit grease

AC102654AC

Chamfered
side

2. Install the spider assembly to the shaft from the

direction of the spline chamfered side.

>>C<< TJ CASE INSTALLATION

CAUTION

The driveshaft joint use special grease. Do not
mix old and new or different types of grease.

AC102656 AC

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

Specified grease: Repair kit grease
Amount to use : 100

± 10 g <4A9>

(inside of joint : 65

± 5 g, inside of boot : 35 ± 5

g)

Amount to use : 150

± 6 g <4G1>

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

Main

Index

Group

TOC

DRIVESHAFT ASSEMBLY

FRONT AXLE

26-26

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

<4A9>

AC102657AB

A

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 (small), TJ boot
band (large) securely.

Standard value: 80

± 3 mm

<4G1>

AC102657

A

AC

1. 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 (small)
securely.

Standard value (A): 80

± 3 mm

2. Install the TJ boot band (large) by following the

next steps.

AC314219

AD

Protrusion part

MB992194

(1) Use specila tool boot band clipping tool

(MB992194) to catch the protrusion part of the
TJ boot band (large) and tighten it firmly.

AC314220

AB

(2) After having tightened securely the protrusion

part of the TJ boot band (large), hook the end
of the TJ boot band (large) as shown in the
illustration.

EBJ BOOT (RESIN BOOT)
REPLACEMENT

M1261007500012

AC102658

1. Remove the boot bands (large and small).

NOTE: The boot bands cannot be re-used.

2. Remove the EBJ boot.
3. Wrap a plastic tape around the shaft spline, and

assemble the boot band and EBJ boot.

AC102660

W

MB991561

Stopper

Adjusting bolt

AC

4. Turn the adjusting bolt on special tool boot band

crimping tool (MB991561) so that the size of the
opening (W) is at the standard value.

Standard value (W): 3.9 mm

<If it is larger than 3.9 mm> Tighten the adjust-

ing bolt.

<If it is smaller than 3.9 mm> Loosen the

adjusting bolt.

Main

Index

Group

TOC

DRIVESHAFT ASSEMBLY

FRONT AXLE

26-27

NOTE: The value of W will change by approxi-
mately 0.7 mm for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned
more than once.

CAUTION

• Secure the driveshaft in an upright position

and clamp part of the boot band to be crimped
securely in the jaws of special tool.

•

AC102663 AB

MB991561

Crimp the boot band until special tool
touches the stopper.

5. Use the special tool to crimp the boot band

(small).

AC102662

A

AB

6. Check that the crimping amount (A) of the boot

band is at the standard value.

Standard value (A): 1.2

− 4.5 mm

<If the crimping amount is larger than 4.5 mm

>

Readjust the value of (W) in step 4 according to

the following formula, and then repeat the
operation in step 5.

<If the crimping amount is smaller than 1.2

mm >

Remove the EBJ boot band, readjust the value

of (W) in step 4, and then repeat the opera-
tions in steps 4 and 5 using a new EBJ boot
band.

7. Check that the boot band is not sticking out past

the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 5 to 6, using a new boot band.

CAUTION

The driveshaft joint uses special grease. Do not
mix old and new or different types of grease.
8. Fill the inside of the boot with the specified

amount of the specified grease.
Specified grease: Repair kit grease
Amount to use : 70

± 10 g

(Inside of joint : 35

± 5 g, inside of boot : 35 ± 5

g)

AC102664 AB

9. Install the BJ boot big end on the BJ case groove.
10.Follow the same procedure as in step 4 to adjust

the size of the opening (W) on the special tool so
that it is at the standard value.

Standard value (W): 3.9 mm

11.Use the special tool to crimp the EBJ boot band

(large) in the same way as in step 6.

AC102666

B

AB

12.Check that the crimping amount (B) of the boot

band is at the standard value.

Standard value (B): 1.2

− 4.5 mm

<If the crimping amount is larger than 4.5 mm

>

Readjust the value of (W) in step 10, and then

repeat the operation in step 11.

<If the crimping amount is smaller than 1.2

mm >

Remove the EBJ boot band, readjust the value

of (W) in step 10, and then repeat the opera-
tions in steps 11 using a new BJ boot band.

Main

Index

Group

TOC