Cardan shaft (Mitsubishi Lancer 9)

Removal

Note:

• − The parts are removed in the order of numbers shown in the figure "Removing the propeller shaft".
• - When removing parts, pay attention to the following operations

Removal the propeller shaft.

a) Apply marks to the flange of the cardan shaft and the flange of the gearbox.

b) Remove the driveshaft.

Caution: Remove the propeller shaft in a straight and horizontal direction to avoid damaging the protective cover.

Note: Place the rag into the narrow part of the protective cover.

c) Install the plug to prevent dirt from entering the transfer case.

Examination

Check the driveshaft runout.

Maximum runout - 0.5 mm

Installation

Note: Installation is performed in the reverse order of removal. When installing parts, pay attention to the following operations.

1. Installing the cardan shaft.

Caution: Be careful not to damage the transfer case seal.

Align the marks on the propeller shaft flange and the gearbox flange.

Caution: Before tightening nuts and bolts, thoroughly clean the threads of fasteners from oil or grease.

Disassembly

Note:

• - Disassembly of the cardan shaft is carried out in the order of numbers indicated in the figure "Disassembly of the cardan shaft".
• - When disassembling, pay attention to the following operations.

1. Removing the retaining rings.

Before removing the retaining ring, mark the crosspiece and the cardan joint fork. Remove the retaining rings using a special tool.



2. Using a special tool, press the bearing out of the crosspiece and the cardan joint fork.

Caution: Do not knock out the bearings when removing them, as this may result in imbalance of the driveshaft,

4. Remove the flange and the fork of the intermediate cardan shaft

a) Apply marks to the intermediate cardan shaft, flange and fork,

b) Using a special tool, remove the flange and fork from the intermediate cardan shaft.



5. Using a press, remove the intermediate support.



6. Remove the hinge.



a) Detach the cover from the hinge.



b) Apply alignment marks to the outer race, separator and inner race of the joint.

c) Remove the outer race of the joint and take out the balls.

Note: Place the balls in their original positions.

d) Using the special tool, remove the retaining ring, inner race and separator.

Note: Before replacing the grease in the joint, remove the old grease and clean the outer and inner races, separator and balls of the joint.

7. Remove the rear propeller shaft joint boot.

Note: When reinstalling the boot, wrap the rear propeller shaft splines with electrical tape before removing.

Examination

1. Check the driveshaft splines for wear or damage.

2. Check the ball grooves on the outer race and inner race of the joint for uneven wear, damage or corrosion.

3. Check the surface of the balls for corrosion, wear or other damage.

4. Check the joint separator for corrosion or damage.

Assembly

- Assembly is carried out in the reverse order of disassembly. When assembling, pay attention to the following operations.

1. Installing the cardan shaft joint cover.

a) Install the clamps on the cover.

b) Wrap the splines of the driveshaft with electrical tape and install the cover.

2. Installing the hinge assembly.

a) Apply a thin layer of special consistent grease to the grooves under the balls on the outer and inner races of the joint.

Lubricant - grease from the repair kit

b) Install the separator on the inner race of the joint, aligning the installation marks, and install the two balls so that they are located in mutually opposite grooves. In this case, both balls should be installed in the same grooves in which they were installed before disassembling the joint,

c) Install the inner race and separator assembly into the outer race, aligning the installation marks of their relative positions,

d) Install the remaining balls into the grooves according to their original location.

d) Apply special consistent grease from the repair kit to the joint.

Amount of grease - 110±5 g



e) Apply a small amount of special glue to three points on the surface of the ball grooves located at equal distances from each other around the circumference of the joint, in which there are grooves for the rubber seal, and then install the rubber seal on the joint.



Glue - quick-drying glue No.1741



g) Install the joint assembly onto the rear propeller shaft, aligning the mounting bolt holes. Fit a suitable tool head to the inner race of the joint and tap with a plastic-faced hammer to ensure a tight fit.



h) Re-align the bolt holes on the hinge boot with the mounting bolts and install the protective boot onto the hinge.



i) Install the rubber flange seal.



3. Installing the protective cover clamp.

Important: position the cover clamp lock so that it is on the opposite side of the cover to the ventilation tabs of the cover. Make sure that there is no grease around the protective cover tabs.

4. Installation of intermediate supports, self-locking nut, flange and fork of the intermediate cardan shaft.

a) Install the intermediate supports as an assembly on the intermediate propeller shaft.

b) Align the previously made alignment marks on the flanges, forks and intermediate cardan shaft.

b) Press the flange, fork and intermediate supports together firmly, tightening the self-locking nuts.





6. Installing the universal joint crosspiece and universal joint crosspiece bearings.

a) Apply general purpose grease to the following parts of the universal joint and bearings.

- Crosspiece journals and oil collection grooves.

- Working edges of oil seals.

- Needle bearings.

Caution: Do not apply excessive amounts of grease, as too much grease will cause assembly difficulties and incorrect snap ring selection.

b) Using a special tool, press the bearings into the cardan joint forks in accordance with the following sequence of operations.

- Align the previously made marks of the relative position of the cardan shaft and the cardan joint fork.

- Install the appropriate mandrel on the special tool.

- Install both bearings into the cardan joint fork and press them in using a special tool.

Note:

• When installing the bearing, there must be a groove left for the retaining ring.

- The bearings will be installed in a position determined by the size of the special tool mandrel.

7. Installing the retaining ring.

a) Install retaining rings of equal thickness on both sides of the universal joint fork.

b) Using a bronze drift, press the bearing and crosspiece into the cardan joint fork on one side.

c) Measure the axial clearance of the universal joint cross bearing (between the retaining ring and the bearing) using a feeler gauge.

Nominal value - 0.02 - 0.06 mm

Caution: Always install snap rings of equal thickness on both sides of the universal joint yoke.

d) If the axial clearance exceeds the maximum permissible value, adjust it by selecting a retaining ring of suitable thickness.

Thickness of retaining ring, mm	Color label
1,02	—
1,05	Yellow
1,08	Blue
1,11	Purple
1,14	Black