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Home >> Mitsubishi >> 2002 >> Eclipse Spyder GT V6-3.0L SOHC >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Service and Repair >> Overhaul

Overhaul









DISASSEMBLY AND REASSEMBLY





LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS
>>A<< INNER SHAFT REMOVAL





1. Use special tool MB991248 or MD998801 to remove the inner shaft assembly and the seal plate from the TJ case.

NOTE: Press the seal plate to deform it, and then press out the inner shaft.





2. Use special tool MB991248 or MD998801 to remove the inner shaft from the center bearing bracket.

>>B<< CENTER BEARING REMOVAL





Use special tools MB990930 and MB990938 to press the center bearing out from the center bearing bracket.

>>C<< TJ BOOT REMOVAL





Wrap plastic tape around the spline part on the BJ assembly so that the TJ boot is not damaged when they are removed.

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








1. Install the dynamic damper in the position shown in the illustration.

CAUTION:
^ There should be no grease adhered to the rubber part of the dynamic damper.
^ The damper band and the TJ boot band (small) are different in shape. Be careful not to assemble a wrong band by identifying a color of the band.





2. Secure the damper bands.
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 uses special grease. Do not mix old and new or different types of grease.





1. Apply the repair kit grease to the spider axles and rollers of the spider assembly.
2. Face the chamfered portion of the spider assembly's spline toward the driveshaft, and then install the spider assembly to the driveshaft.

>>C<< CENTER BEARING INSTALLATION





Use special tools MB990930 and MB990938 to press the center bearing into the center bearing bracket.

>>D<< DUST SEAL INNER/DUST SEAL OUTER INSTALLATION





1. Pack multipurpose grease in the places shown in the figure.
Quantity:
14 - 20 g (0.5 - 0.7 oz) Dust seal inner>
8 - 12 g (0.3 - 0.4 oz) Dust seal outer>

CAUTION: Do not damage the rubber portion of the dust seal outer surface when packing the multipurpose grease, otherwise grease will leak.

2. Use special tools MB990890 and MB990934 to press the oil seal into the center bearing bracket.
3. Apply multipurpose grease to the lip of the dust seal.

NOTE: Do not apply the specified grease to the outside of the lip.

>>E<< INNER SHAFT INSTALLATION





Use special tool MB991172 to hold the center bearing inner race, and then press-in the inner shaft.

>>F<< TJ CASE AND INNER SHAFT ASSEMBLY INSTALLATION





1. Apply multipurpose grease to the inner shaft serration, and then press the inner shaft assembly into the TJ case.





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

2. Fill the TJ case with repair kit grease and insert the driveshaft, and then refill the TJ case with repair kit grease.
Grease quantity:
100 ± 10 g (3.5 ± 0.4 oz) <2.4L ENGINE>
105 ± 10 g (3.7 ± 0.4 oz) <3.0L ENGINE>

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

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





1. Position the TJ outer race so that the distance between the boot bands is at the standard value.
Standard value (A): 85 ± 3 mm (3.3 ± 0.12 inch)
2. Remove part of the TJ outer race to release the air pressure inside the boot.

BJ BOOT REPLACEMENT





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

NOTE: The BJ boot bands cannot be roused.

2. Remove the BJ boot.





3. Turn the adjusting bolt on the special tool MB991561 so that the size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.12 inch)
If it is larger than 2.9 mm (0.12 inch)> Tighten the adjusting bolt.
If it is smaller than 2.9 mm (0.12 inch)> Loosen the adjusting bolt.

NOTE: The value of W will change by approximately 0.7 mm (0.03 inch) for each turn of the adjusting bolt.

NOTE: The adjusting bolt should not be turned more than once.





4. Place the BJ boot band (small) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration.





CAUTION:
^ Secure the driveshaft in an upright position and clamp the part of the BJ boot band to be crimped securely in the jaws of the special tool MB991561.
^ Crimp the BJ boot band until the special tool MB991561 touches the stopper.

5. Use special tool MB991561 to crimp the BJ boot band (small),





6. Check that crimping amount (B) of the BJ boot band is at the standard value.
Standard value (B): 2.4 - 2.8 mm (0.10 - 0.11 inch)





If the crimping amount is larger than 2.8 mm (0.11 inch)> Readjust the value of (W) in step 4 according to the following formula, and then repeat the operation in step 6.
[W = 5.5 mm (0.22 inch) - B]
Example: if B = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch).
If the crimping amount is smaller than 2.4 mm (0.09 inch)> Remove the BJ boot band, readjust the value of (W) in step 4 according to the following formula, and then repeat the operations in steps 5 and 6 using a new BJ boot band.
W = 5.5 mm (0.22 inch) - B]
Example: If B = 2.3 mm (0.10 inch), then W = 3.2 mm (0.13 inch).
Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in steps 4 to 6 using a new BJ boot band.

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

8. Fill the inside of the BJ boot with the specified amount of the repair kit grease.
Grease quantity:
<2.4L ENGINE> 110 ± 10 g (3.9 ± 0.4 oz)
<3.0L ENGINE> 120 ± 10 g (4.2 ± 0.4 oz)





9. Install the BJ boot band (large) so that clearance (c) between it and the BJ housing is at the standard value.
Standard value (c): 0.1 - 1.55 mm (0.004 - 0.061 inch)





10. Follow the same procedure as in step 3 to adjust the size of the opening (W) on special tool MB991561 so that it is at the standard value.
Standard value (W): 3.2 mm (0.13 inch)





11. Place the BJ boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (D) in the illustration.
12. Use special tool MB991561 to crimp the BJ boot band (large) in the same way as in step 5.





13. Check that the crimping amount (E) of the BJ boot band is at the standard value and that the crimping amount (F) of the BJ boot band is at the limited value.
Standard value (E): 2.4 - 2.8 mm (0.10 - 0.11 inch)
Limited value (F): 9.5 mm (0.40 inch)
If the crimping amount is larger than 2.8 mm (0.11 inch)> Readjust the value of (W) in step 10 according to the following formula, and then repeat the operation in step 12.
[W = 5.8 mm (0.23 inch) - E]
Example: If E = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch).
If the crimping amount is smaller than 2.4 mm (0.09 inches) Remove the BJ boot band, readjust the value of (W) in step 10 according to the following formula, and then repeat the operations in steps 11 and 12 using a new BJ boot band.
[W = 5.8 mm (0.23 inch) - El
Example: If E = 2.3 mm (0.10 inch) then W = 3.5 mm (0.15 inch).
14. Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in steps 11 to 13 using a new BJ boot band.


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