Mitsubishi Lancer Evolution IX. Manual — part 306

DRIVESHAFT ASSEMBLY

FRONT AXLE

26-17

• Check the boots for deterioration, damage or

cracking.

EBJ BOOT (RESIN BOOT)
REPLACEMENT

M1261005200435

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.

AC102659

4. Align the centre groove on the EBJ boot small end

with the shaft groove.

AC102660

W

MB991561

Stopper

Adjusting bolt

AC

5. 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): 2.9 mm

<If it is larger than 2.9 mm> Tighten the adjust-

ing bolt.

<If it is smaller than 2.9 mm> Loosen the

adjusting bolt.

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.

AC102661AC

Boot

A

Boot band
(small)

B

Projection

6. Position the EBJ boot band (small) so that there is

even clearance at either end (A and B).

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 AC

MB991561

Crimp the boot band until special tool
touches the stopper.

7. Use the special tool to crimp the boot band

(small).

AC102662

C

AD

8. Check that the crimping amount (C) of the boot

band is at the standard value.

Standard value (C): 2.4

− 2.8 mm

DRIVESHAFT ASSEMBLY

FRONT AXLE

26-18

<If the crimping amount is larger than

2.8 mm >

Readjust the value of (W) in step 5 according to

the following formula, and then repeat the
operation in step 7.

W = 5.5 mm

− C

Example: If C = 2.9 mm, then W = 2.6 mm.

<If the crimping amount is smaller than 2.4

mm >

Remove the EBJ boot band, readjust the value

of (W) in step 5 according to the following
formula, and then repeat the operations in
steps 6 and 7 using a new EBJ boot band.

W = 5.5 mm

− C

Example: If C = 2.3 mm, then W = 3.2 mm.

9. 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 6 to 8, using a new boot band.

CAUTION

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

amount of the specified grease.
Specified grease: Repair kit grease
Amount to use: 100

± 10 g

AC102664 AC

11.Align the centre groove on the EBJ boot big end

with the EBJ case groove.

12.Follow the same procedure as in step 5 to adjust

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

Standard value (W): 3.2 mm

AC102665 AC

Boot

Projection

Boot band
(large)

D

E

13.Position the EBJ boot band (large) so that there is

even clearance at either end (D and E).

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

(large) in the same way as in step 7.

AC102666

F

AD

15.Check that the crimping amount (F) of the boot

band is at the standard value.

Standard value (F): 2.4

− 2.8 mm

<If the crimping amount is larger than 2.8 mm

>

Readjust the value of (W) in step 12 according

to the following formula, and then repeat the
operation in step 14.

W = 5.8 mm

− F

Example: If F = 2.9 mm, then W = 2.9 mm.

<If the crimping amount is smaller than 2.4

mm >

Remove the EBJ boot band, readjust the value

of (W) in step 12 according to the following
formula, and then repeat the operations in
steps 13 and 14 using a new EBJ boot band.

W = 5.8 mm

− F

Example: If F = 2.3 mm, then W = 3.5 mm.

16.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 13 to 15, using a new boot band.

27-1

GROUP 27

REAR AXLE

CONTENTS

GENERAL INFORMATION . . . . . . . .

27-2

SERVICE SPECIFICATIONS. . . . . . .

27-3

LUBRICANTS . . . . . . . . . . . . . . . . . .

27-3

SEALANT. . . . . . . . . . . . . . . . . . . . . .

27-3

SPECIAL TOOLS. . . . . . . . . . . . . . . .

27-4

TROUBLESHOOTING . . . . . . . . . . . .

27-7

TROUBLESHOOTING STRATEGY . . . . . .

27-7

DIAGNOSIS FUNCTION. . . . . . . . . . . . . . .

27-7

DIAGNOSIS CODE CHART . . . . . . . . . . . .

27-9

DIAGNOSTIC TROUBLE CODE

PROCEDURES. . . . . . . . . . . . . . . . . . . . . .

27-11

SYMPTOM CHART. . . . . . . . . . . . . . . . . . .

27-23

INSPECTION PROCEDURE FOR TROUBLE
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . .

27-24

DATA LIST REFERENCE TABLE . . . . . . .

27-25

ACTUATOR TEST REFERENCE TABLE. .

27-25

CHECK AT 4WD-ECU TERMINAL . . . . . . .

27-25

ON-VEHICLE SERVICE. . . . . . . . . . .

27-26

REAR AXLE TOTAL BACKLASH CHECK .

27-26

GEAR OIL LEVEL CHECK . . . . . . . . . . . . .

27-26

GEAR OIL REPLACEMENT . . . . . . . . . . . .

27-27

FLUID LEVEL CHECK . . . . . . . . . . . . . . . .

27-27

AYC BLEEDING . . . . . . . . . . . . . . . . . . . . .

27-28

AYC OPERATION CHECK . . . . . . . . . . . . .

27-29

OIL PRESSURE CHECK . . . . . . . . . . . . . .

27-29

WHEEL BEARING AXIAL PLAY CHECK . .

27-30

HUB BOLT REPLACEMENT. . . . . . . . . . . .

27-30

DIFFERENTIAL CARRIER OIL SEAL

REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

27-31

REMEDY FOR A DISCHARGED BATTERY

27-31

REAR AXLE HUB ASSEMBLY . . . . .

27-32

REMOVAL AND INSTALLATION . . . . . . . .

27-32

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27-33

KNUCKLE . . . . . . . . . . . . . . . . . . . . . .

27-35

REMOVAL AND INSTALLATION . . . . . . . .

27-35

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27-36

DRIVESHAFT ASSEMBLY. . . . . . . . .

27-36

REMOVAL AND INSTALLATION . . . . . . . .

27-36

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27-39

DISASSEMBLY AND REASSEMBLY . . . . .

27-40

DIFFERENTIAL CARRIER

ASSEMBLY. . . . . . . . . . . . . . . . . . . . .

27-43

REMOVAL AND INSTALLATION . . . . . . . .

27-43

DIFFERENTIAL SUPPORT MEMBER

BUSHING REPLACEMENT . . . . . . . . . . . .

27-45

DISASSEMBLY AND REASSEMBLY . . . . .

27-46

REMOVAL AND INSTALLATION . . . . . . . .

27-49

HYDRAULIC UNIT DISPOSAL . . . . . . . . . .

27-50

GENERAL INFORMATION

REAR AXLE

27-2

GENERAL INFORMATION

M1271000100382

The rear axle consists of rear wheel hub assembly,
knuckles and driveshafts, and has the following fea-
tures:

• The wheel bearing is a unit ball bearing (dou-

ble-row angular contact ball bearing) for reduced
friction.

• The driveshaft has EBJ-TJ constant velocity

joints.

• ABS rotor for detecting the wheel speed is

press-fitted to the EBJ.

• For environmental protection, lead-free grease is

used on the joints.

Active Yaw Control (AYC) is adopted to improve the
turning performance. AYC incorporates the torque
transfer differential and the hydraulic unit.
EBJ:Eight Ball Fixed Joint; The use of the

smaller-sized eight balls inside the joint achieves
weight saving and compact size compared with a
BJ (Birfield Joint).

TJ: Tripod Joint

SPECIFICATIONS

Item

Specification

Wheel bearing

Type

Unit ball bearing (Double-row angular
contact ball bearing)

Bearing (OD x ID) mm

70

× 40

Driveshaft

Type

Outer

EBJ

Inner

TJ

Length (joint to joint)

×

diameter mm

Left

428.5

× 25

Right

448.5

× 25

CONSTRUCTION DIAGRAM

AC310259

Rear hub

BJ

TJ

Driveshaft

Differential carrier

AB

ABS rotor