Ch 8 Suspension & Steering

WHEELS 8-2 WHEELASSEMBLY 8-2 REMOVAL& INSTALLATION 8-2 INSPECTION 8-2 WHEELLUGSTUDS 8-2 REMOVAL& INSTALLATION 8-2 FRONT SUSPENSION 8-4 MACPHERSONSTRUTANDCOIL SPRING 8-7 REMOVAL& INSTALLATION 8-7 OVERHAUL 8-7 SHOCKABSORBERANDCOIL SPRING 8-8 REMOVAL&INSTALLATION 8-8 OVERHAUL 8-9 UPPERBALLJOINT 8-9 REMOVAL& INSTALLATION 8-9 INSPECTION 8-9 UPPERCONTROLARM 8-10 REMOVAL&INSTALLATION 8-10 LOWERBALLJOINT 8-10 REMOVAL&INSTALLATION 8-10 INSPECTION 8-10 LOWERCONTROLARM 8-10 REMOVAL&INSTALLATION 8-10 SWAYBAR 8-12 REMOVAL& INSTALLATION 8-12 KNUCKLE,HUB,AND BEARING 8-13 REMOVAL& INSTALLATION 8-13 WHEELALIGNMENT 8-16 CASTER 8-16 CAMBER 8-17 TOE 8-17 REAR SUSPENSION 8-18 STRUTAND COILSPRING 8-21 REMOVAL& INSTALLATION 8-21 OVERHAUL 8-22 UPPERCONTROLARMS 8-22 REMOVAL& INSTALLATION 8-22 LOWERCONTROLARMS 8-23 REMOVAL&INSTALLATION 8-23 TRAININGARM 8-24 REMOVAL& INSTALLATION 8-24 SWAYBAR 8-25 REMOVAL&INSTALLATION 8-25 HUB & BEARINGS 8-25 ADJUSTMENT 8-25 REMOVAL& INSTALLATION 8-25 STEERING 8-27 STEERINGWHEEL 8-27 REMOVAL&INSTALLATION 8-27 COMBINATIONSWITCH 8-29 REMOVAL&INSTALLATION 8-29 WINDSHIELDWIPERSWITCH 8-29 REMOVAL&INSTALLATION 8-29 IGNITIONLOCKCYLINDER 8-29 ' REMOVAL&INSTALLATION 8-29 IGNITIONSWITCH 8-30 REMOVAL&INSTALLATION 8-30 STEERINGLINKAGE 8-30 REMOVAL&INSTALLATION 8-30 MANUALRACKAND PINIONSTEERING GEAR 8-31

REMOVAL& INSTALLATION 8-31 POWERRACKAND PINIONSTEERING GEAR 8-32 REMOVAL&INSTALLATION 8-32 POWERSTEERING PUMP 8-34 REMOVAL&INSTALLATION 8-34 SYSTEMBLEEDING 8-36 COMPONENT LOCATIONS FRONTSUSPENSION COMPONENT LOCATIONS 8-4 REARSUSPENSION COMPONENT LOCATIONS 8-18 SPECIFICATIONS CHARTS ’ TORQUESPECIFICATIONS 8-39

.

8-2 SUSPENSION ANDSTEERING

REMOVAL&INSTALLATION # See Figures 1, 2, 3, and 4 1. Parkthevehicleona levelsurface. 2. Remove thejack,tireironand,if necessary, thesparetirefromtheirstoragecompartments. 3. Checktheownersmanual, or referto Section 1 ofthismanualforthejackingpointsonyourvehicle.Then,placethejackintheproperposition, 4. If equipped withlugnuttrimcaps,remove thembyeitherunscrewing or pullingthemoffthelug nuts,asappropriate. Consulttheownersmanual, if necessary. 5. If equipped witha wheelcoveror hubcap, insertthetaperedendof thetireironinthegroove andpryoffthecover. 6. Applytheparkingbrakeandblockthediagonallyoppositewheelwitha wheelchockortwo. *Wheel chocksmay be purchasedat your local auto parts store, or a block of wood cut into wedgesmay be used. If possible,keep one or two of the chocksin your tire storage compartment,in caseany of the tires hasto be removedon the side of the road.

7. If equipped withanautomatic transmission/transaxle, placetheselectorleverin P or Park;witha manual transmission/transaxle, place theshifterin Reverse. 8. Withthetiresstill ontheground,usethetire iron/wrench to breakthelugnutsloose. *If a nut is stuck, never use heat to loosen it or damageto the wheel and bearingsmay occur. If the nutsare seized, one or two heavy hammerblows directly on the end of the bolt usually loosensthe rust. Be careful, as continuedpoundingwill likely damagethe brakedrum or rotor. 9. Usingthejack,raisethevehicleuntilthetire is clearoftheground.Supportthevehiclesafelyusingjackstands. 10. Remove thelugnuts,thenremovethetire andwheelassembly. To install: 11. Makesurethewheelandhubmatingsurfaces,aswellasthewheellugstuds,arecleanand freeof all foreignmaterial. Alwaysremoverustfrom thewheelmounting surfaceandthebrakerotoror drum.Failureto doso maycausethelugnutsto looseninservice. 12. Installthetireandwheelassembly andhandtightenthelugnuts.

b 13. Usingthetirewrench,tightenall thelugnuts, in acrisscrosspattern, untiltheyaresnug. 14. Raisethevehicleandwithdrawthejackstand, thenlowerthevehicle. 15. Usingatorquewrench,tightenthelugnutsin a crisscross patternto 65-80ft. lbs.( 90-l 10Nm). Checkyourownersmanualor referto Section1 of thismanual for thepropertightening sequence.

Do not overtightenthe lug nuts, as this may causethe wheel studsto stretch or the brake disc (rotor) to warp. 16. If soequipped, installthewheelcoveror hub cap.Makesurethevalvestemprotrudes throughthe properopeningbeforetappingthewheelcoverinto position. 17. If equipped, installthelugnuttrimcapsby pushingthemor screwing themon,asapplicable. 18. Remove thejackfromunderthevehicle,and placethejackandtireiron/wrench intheirstorage compartments. Remove thewheelchock(s). 19. If youhaveremoved a flator damaged tire, placeit inthestoragecompartment of thevehicleand takeit to yourlocalrepairstationto haveit fixedor replaced assoonaspossible.

Inspectthetiresfor lacerations, puncture marks, nailsandothersharpobjects.Repairor replaceas necessary. Alsocheckthetiresfortreadwear andair pressure asoutlinedin Section1 of thismanual. Checkthewheelassemblies for dents,cracks,rust andmetalfatigue.Repairor replace asnecessary.

REMOVAL&INSTALLATION

Fig. 3 Place the jackstandsunderthe vehicle to support the vehicle’s weight before

SUSPENSION ANDSTEERiNG8-3 PRESS RAM

PRESS STOCK

STUD

Fig. 5 View of the rotor and stud assembly 1. Raiseand supportthe appropriateend of the vehiclesafelyusingjackstands,then removethe wheel. 2. Removethe brakepads and caliper. Support the caliper aside using wire or a coat hanger. For details, pleaserefer to Section 9 of this manual. 3 Removethe outerwheelbearingandliff off the rotor. For detailson wheelbearingremoval,installationand adjustment,pleasereferto Section1 of this manual. 4. Properlysupportthe rotor using pressbars, then drive the stud out using an arbor press.

Fig. 6 Pressingthe stud from the rotor

*If a press is not available, CAREFULLY drive the old stud out usinga blunt drift. MAKESUREthe rotor is properly and evenly supportedor it may be damaged. To install: 5. Cleanthe stud hole with a wire brushand startthe newstudwith a hammerand drift pin. Do not useany lubricantor threadsealer. 6. Finish installingthe studwith the press.

*If a press is not available, start the lug studthroughthe bore in the hub, then position about4 flat washersover the studand threadthe lug nut. Holdthe hub/rotorwhile tighteningthe lug nut, andthe studshouldbe drawn into position. MAKESURETHESTUD IS FULLYSEATED,then removethe lug nut andwashers. 7. Installthe rotor and adjustthe wheelbearings 8. Installthe brakecaliperand pads. 9. Installthe wheel,then removethe jackstands and carefullylowerthe vehicle. 10. Tightenthe lug nutsto the propertorque.

tcca$Oi

Fig. 7 Use a press to install the stud into the rotor With Drum Brakes p See Figures 8, 9, and 10 1. Raisethe vehicleand safelysupportit with jackstands,then removethe wheel. 2. Removethe brakedrum. 3. If necessaryto provideclearance,removethe brakeshoes,as outlinedin Section9 of this manual. 4. Usinga largeC-clampand socket,pressthe stud from the axle flange. 5. Coatthe serratedpartof the stud with liquid soapand placeit into the hole.

To install: 6. Positionabout4 flat washersover the stud andthreadthe lug nut. Hold the flangewhile tightening the lug nut, andthe stud should be drawninto position.MAKESURETHESTUDIS FULLYSEATED, then removethe lug nut andwashers. 7. If applicable,installthe brakeshoes. 8. Installthe brakedrum. 9. Installthe wheel.then removethe iackstands and carefullylowerthe vehicle. 10. Tightenthe lug nutsto the propertorque.

NUT

AXLE SHAFT

FLAT WASHERS

C-FRAME AND CLAMP ASSEMBLY Im3goa

3g. 8 Exploded view of the drum, axle lange and stud

Fig. 9 Use a C-clamp and socket to press out the stud

Fig. 10 Force the stud onto the axle flange usingwashers and a lug nut

199340 MIRAGE FRONT SUSPENSION COMPONENT LOCATIONS

1. 2. 3. 4. 5.

Tie rod end Lower balljoint Lowercontrolarm Lowercontrolarm mountsandbushings Sway barassembly

6. 7. 8. 9.

Swaybar link Strutassembly Huband bearingassembly Halfshaftassembly

I

1994-98 GAIANT FRONT SUSPENSION COMPONENT LOCATIONS

1. 2. 3. 4. 5. 6.

Shockandspringassembly Steeringknuckleassembly Hubandbearingassembly Lowerballjoints Compressionlower controlarm Laterallower control arm

7. 8. 9. 10. 11. 12.

Lowercontrol arm mountsandbushings Steeringrackand pinion Swaybar assembly Halfshaftassembly Upperballjoint Uppercontrol arm

1999-90 GAIANT FRONT SUSPENSION COMPONENT LOCATIONS

1. 2. 3. 4.

Tie rod end Lowerballjoint Lowercontrol arm Lowercontrolarm mountsand bushings

5. 6. 7. 8.

Sway bar assembly Strutassembly Huband bearingassembly Halfshaftassembly

SUSPENSION ANDSTEERING8-7 with the mountingbolts.Tightenthe mountingbolts to 70-76 ft. Ibs. (90-105 Nm). 10. If equippedwith Active-ECS,performthe following, a. Installthe air line with a new O-ring. b Install the actuatorto the top of the strut Connectthe wiring harness. 11. Installthe brakehose bracketandthe ABS clamp,if equipped. 12. Installthe wheeland tire assembly. 13. Havea front end alignmentperformed.

Mirage # See Figure 11 1 2 3 4 5 6 7 8 9 10 11

Cotter p,n Drive shaft Washer Caliper assembly connecf~on Self-IockIng ““f Lower arm ball ,Ol”f Connectlo” cotter PI” T,e rod end connectton Drive Shaft Strut assembly connection Hub and knuckle 1

1990-92Mirage front suspensioncomponents

1, Disconnectthe negativebatterycable. 2. Raiseand safelysupportvehicle. 3. Removethe brakehoseandtube bracketretainerbolt and bracketfrom the front strut. Do not pry the brakehoseand tubeclamp awaywhenremovrng. 4. If equippedwith ABS, disconnectthe front speedsensormountingclampfrom the strut. 5. Supportthe lowerarm usmgfloor jack or equivalent Removethe lowerstrut to knucklebolts.

*Before removingthe top bolts, make matchmarkson the bodyandthe strut insulator for properreassembly.

-

6. Removethe strut uppermountingbolts. 7. Removethe strut assemblyfrom the vehicle.

To install: 8. Installthe strut to the vehicleand installthe top mountingbolts,Tightenthe mountrngbolts to 29 ft. Ibs. (40 Nm) 9. Positionthe strut on the knuckleand mstall the mountingbolts,While holdrngthe headof the lowermountingbolt, tightenthe nutsto 80-94 ft. Ibs. (110-130 Nm). 10. Installthe brakehose bracketandthe ABS clamp,if equipped 11 Installthe wheeland tire assembly 12. Havea front end alignmentperformed. 1 2 3 4 5 6 7 8 9 10 11

OVERHAUL

Cutter PI” Drtve shaft Washer Ca,,perassembly connect~o” Self-locking nut Lower arm ball ,o,nt connection cotter PI” Tie rod end connection Dwe shaft Strut assembly connection Hub and knuckie

) See Figures 12 thru 22

Diamantefront suspensioncomponents

REMOVAL&INSTALLATION Diamante,1990-93 Galant, and 1999-00 Galant 1. Disconnectthe negativebatterycable. 2. Raiseand safelysupportthe vehicle. 3. Removethe brakehoseandthe tube bracket.

to knucklebolts Usea pieceof wire to suspendthe knuckleto keepthe weightoff the brakehose. 6. If equippedwith Active ElectronrcControl Suspension(Active-ECS)performthe followrng: a. Loosenthe nut that securesthe an line to the to the too of the strut and discardthe O-ring. b. Removethe bolts that securethe actuator to the top of the strut and removethe component. Disconnectthe wiring harness.

*Before removingthe top bolts, make matchmarkson the bodyandthe strut insulator for proper reassembly.

40 not pry the brake hoseandtube clamp awav when removinoit.

7. Removethe strut uppernutsand removethe strut assemblvfrom the vehicle.

4. If equippedwith ABS,disconnectthe front speedsensormountingclampfrom the strut. 5. Supportthe lowerarm and removethe strut

8. Installthe strut to the vehicleandtightenthe uppermountingnuts to 33 ft. Ibs. (45 Nm) 9 Align the strutto the knuckleandconnect

To instalf:

1. Removethe strut assemblyfrom the vehicle,as outlinedearlier in this Section. 2. Mount the strut assemblyinto a suitable spring compressor. 3. Compressthe strut approximatelyr/a its height afterinitial contactwith the top cap.

Neverbottomthe spring or dampenerrod! 4. Removethe centernutfrom the strut and removethe uppermountingbracketand bushings. 5. Removethe coil spring.

To install: 6. Installthe compressedspring on the strut assembly. 7. Installthe upperbushingsand the mounting bracket Installthe nut andtighten it to 43 ft. Ibs. (59 Nm). 8. Removethe strut from the spring compressor. 9. Installthe strut into the vehrcle

8-8 SUSPENSION ANDSTEERING REMOVAL &INSTALLATION 199443 Galant u See Figures 23 and 24

I

I I 25 Nm 18 fths.

Removalsteps 1. Brake hose clamp 2. Front speed sensor 3. Bolts 4. Self-locking nut 5. Strut assembly

csution

For vehicles with ABS, be careful when handling the pole piece at the tip of the spaed sensor so as not to damage it by striking against other parts.

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Fig. 11 Front strut assemblyand related parts---Mirage

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STRUT ASSEMBLY EXPLODED VIEW

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91146p61

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91146p?Jl

Fig. 12 Install a suitable strut spring compressor onto the strut spring

Fig. 14 A special set of sockets Is available to remove the nut from the top of the strut

1a Disconnect theneaative battervcable. 2. Raiseandsafelvsu~oortvehicle. 3. Remove theappronnate wheelassembly. theswaybarlinkfromthe I 4. Disconnect ,I oamper rork. 5. Remove thedamper forklowerthrough-bolt andupperpinchbolt.Remove thedamper forkassembly. 6. Remove theshockabsorber uppernutsand removetheshockandspringassembly fromthevehicle. To install: 7. Installtheupperbracket assembly andposition it sothatthethreeboltsareinthecorrectposition. 8. Installtheupperbushing, washer,andlocknut.Tightenthelocknutto 18ft.-lbs. 9. Installtheshockabsorber andtightentheuppermounting nutsto 32ft. Ibs.(44Nm). IO. Aligntheshocktothedamper forkandinstall thedamper fork.Tightenthelowerthrough-bolt/nut to 65ft. Ibs.(88Nm)andtheupperpinchboltto 76 ft. Ibs.(103Nm). 11. Connect theswaybarlinkto thedamoer fork andtightenthelinknuttb 29ft. Ibs.(39Nm): 12. Installthewheelandtireassembly. 13. Haveafrontendalignment performed.

Fig. 15 Place the larger socket over the nut

Fig. 13 Tightendown the nuts on the top of the forcing screws on this type of spring compressor

1;ir

;;ostrut;;;

install the small soi8oet

SUSPENSION ANDSTEER'ING 8-9

91148PS7

ile looseningthe larger socket(strut

then remove the top nut from

Fig. 19 . t , and remove the washer underneath

91148ps4

1Fig. 29 Removethe strut mount and bearins assembly

1Fig. 21 Remove the upper spring seat 1 washer

Fig. 22 Removethe coil spring assembly

INSPECTION ) See Figure 25

Fig. 23 Removethe lower coil-over shock lowar mounting bolt andnut from the con-

Fig. 24 Removethe three shockabsorberto-bodyretaining nuts, the

OVERHAUL

absorber assembly. Besureto aligntheedgeof coil sorina to the steoaed Dartof thespringSeat. laSk3ll 6e d&cover, d;mpiubber,cupassembly, upper bushing, collar,andupperspringnad r--. 6. Installtheshockandspringassembly asoutlinedinthissection.

theshockandspringassembly as 1. Remove outlinedinthissection. 2. Compress thecoilspringwitha specialcompressiontool. 3. Remove theself-lockingnutandwasher.Removetheupperbushing,upperbracketassembly, the sorina oad. andthecollar. upper 4. demðeotherupperbushing,cupassembly,bumprubber,dustIcover,andthecoil spring.Carefullyremovethecoil springcompressiontool. To install: 5. Installthecompressed coilspringto theshock

REMOVAL &INSTALLATION Thp inint is an inkoral ..*.,lwwr “rf.l’ hall “m..,-.,.. .--.. ....-=.- oart r-. of. the umer .rr

controlarm.If theballjointbecomes wornor damaged,thecontrolarmmustbereplaced.

’

1. Shaketheballjointstuda fewtimes,theninstallthenutto thestudandusea preloadsocket (MB9c26 or equivalent) andaninchlb.torque wrenchto measure thebreakaway torqueof theball joint.Thereadingshouldbe3-22 inchIbs.(0.3-2.5 Nm). 2. Ifthemeasured valueis higherthanthestandard,theuppercontrolarmmustbereplaced. 3. Ifthevalueis lowerthanthestandard, check thattheballjointturnssmoothlywithoutexcessive plate.If so,theballjointis OK. 4. Also,checktheballjointdustcoverforcracks or otherdamage, if found,theuppercontrolarm mustbereplaced.

Fig. 25 Measurethe toruue of the ball joint to see if it needsto be t&laced

‘.

.

^ .s

840

”

SUSPENSION ANY ik%iiiG

REMOVAL&INSTALLATION Except199M-98 Galant Thesevehiclesusea struttypefrontsuspension, Nouooercontrolarmis used. 1994-98 Galant # See Figures 26 thru 33 1. Raiseandsafelysupportthevehicle. 2. Remove thefrontwheel. 3. Disconnect theupperarmballjointfromthe steeringknuckle. 4. Remove theupperarmshaftmounting nuts fromthebody. 5. Remove theupperarm.

6. Remove thethrough-bolts thatattachtheupperarmto theshafts To install: 7. Assemble theupperarmto theshaftsatthe properangle.Tightenthethrough-bolts andnutsto 41ft. Ibs.(57Nm).Theproperangleis84-86”.After thearmandtheshaftsareconnected attherightangle,measure dimensions A andBto insurecorrect assembly, andcomoare withthefollowingspecifications: l A O-ring:11.8in. (299.9mm) l B O-ring:9.2in. (234.0mm) 8. Installthecontrolarmass_embly to the I-.,body ..withnewself-lockingnuts.TightenIL_ one--at sea-rockrng nutsto 62ft. Ibs.(86Nm). 9. Connect theupperarmballjointto thesteeringknucklewith nut.Tightenthe I- ^_a~.newself-locking lockingnutto 20ft. Ibs.(28Nm). 10. Installthefrontwheel. I ml.,,.* ,I.+. 11. L”WCl LIIt:.,^l.:^l^ “ClIllx. 12. Havea front end ---galinnmen - t performed.

,

Thelowerballjointis anintegralpartof thelower controlarmassembly, andcannotbeservicedseparately.A wornor damaged balljointrequiresreplacementof lowercontrolarmassembly.

INSPECTION 1. Raiseandsafelysupportthevehiclesonjackstands.Allowthesuspension to hangfree. 2. Graspthetireatthetopandthebottomand movethetar 3. Obser veforanyhorizontal movement of the steeringknucklerelativetothefrontlowercontrol arm.If anymovement is detected, replacetheball joint. fromthesteer4. If theballstudis disconnected ingknuckleandanylooseness is detected, or if the hall dir! VLVV

II&WI finnnr ““y”’

u.l,,,y

REMOVAL &INSTALLATION

,-.-.

Diamante,1990-93 Galant, and 1994-00 Galant

‘YUN - ,-. 2m.lk~

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7923Fw7

1Fig. 26 Uppercontrol arm assembly-Galant

Fig. 27 Removethe nut retaining the upper 1ball joint to the steering knuckle , . .

ran ho twiatm-l #II in IIU itr UY”I\“L cnrlmt “Yll YY L..l”L””

pressure, replacetheballjoint,

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rck

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REMOVAL&INSTALLATION

““.I

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.

Fig. 28 . , . then install a suitable puller like this to separate the connection

1, Disconnect thenegative batterycable. 2. Raisethevehicleandsupportsafely,allowing wheelsandsuspension to hangfreely. 3. Remove theswaybarlinksfromthelower ..^^l-^l^-titJIILIlJI alIll. thebailjointstudfromthesteer4. Disconnect ingknuckle. 5. Remove theinnermounting framethroughboltandnut. 6. Remove therearmountbolts.Remove the clamp,if equipped. 7. Remove therearrodbushing,if servicing. To install: 8. Assemble thecontrolarmandbushing. 9. Installthecontrolarmto thevehicleandinstallthethrough-bolt. Replace the,nutandsnuatemporarily. -

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Fig. 29 A knuckle COI

SUSPENSION ANDSTEERING8-11 \

-*i7928685

Fig, 30 Removethe nuts retaining theg3’w5 upper control arm to the body . . .

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;A, -;h$re~ove

the upper co;:; 1

Fig 32 Correct angle of control arm and shaftsGa,ant

enchto remove the retain-

1. Connect theballjointstudtotheknuckle.InNm). 12. Installtheswaybarandlinks. 13. Lowerthevehicleto thefloorfor thefinal tightening of theframemountthrough-bolt. 14. Oncethefull weightof thevehicleis onthe floor,tightentheframemountthrough-bolt nutsto 75-90ft. Ibs.(102-122Nm). 15. Connect thenegative batterycable. 16. Checkthewheelalignment andadjustif necessary 1994-98 Galant ) See Figures34 thru 40 Thelowerlateralarmballjointandthecompressionarmballjointareintegralcomponents of thelateralarmandthecompression armrespectively. If the balljointsareto beserviced, thearmsmustbereplaced. 1. Raiseandsupportthevehiclesafely. 2, Disconnect bothballjointstudsfromthe steeringknuckle. 3. Toremovethelowerlateralarm,remove the crossmember brackets. 4. Remove theinnerlateralarmmounting bolts andnut. 5. Remove thearmfromthevehicle. 6. Remove thetwoboltsholdingthecompressionarm.

Fig. 37 Use a suitable prytool to separate

the lower ball joints from the

8-12 SUSPENSION ANDSTEERING REMOVAL&INSTALLATION Mirage

Compression lower an assembly removal steps 1. Connection for compression lower arm ball joint and knuckle 2. Compressron lower arm mounting bolt 3. Compression lower arm assembly

Lateral lower arm assembly removal Hcps 4. stay 5. ~mdtsoorber lower mounting 6. Connection for lateral lower ball joint and knuckle 7. Metal lower arm mounting end nut 6. Lateral low% arm assemblv

arm bolt

CSUtlOll l : Indicates parts wfdch should k temporarily tightened, and then fully tightened with fhe vehicle on the ground in the unladen wndluon. 93158p62

:ig. 39 Remove the lower control arm-to-body mounting bolts, then remove the arm from the rehicle 7. Removethe compressionarm, To install: -. .*.. a. 8. Assemoleme control armsand bushmgs. ^. Y. Installthe lateralcontrol arm to the vehicle and installthe inner mountingbolts. Installa newnut and snugtemporarily. 10. Installthe compressionarm to the vehicle. * 11. Connectthe ball joint studsto the knuckle. Install newnutsand tightento 43-51 ft. Ibs (59-71 Nm). 12. Lowerthe vehicleto the floor for the final tightening. 13. Oncethe full weightof the vehicle is on the suspension,tightenthe lateralarm rearbolt to 71-85 ft. Ibs. (98-118 Nm) and the front bolt to the damper fork to 64 ft. Ibs. (88 Nm). 14. Tightenthe boltsfor the compresslonarm to 60 ft. Ibs. (83 Nm). 15. Reinstallthe crossmemberbracketswith their mountingbolts.Tightenthe mountingboltsto 51-58 ft. Ibs. (69-78 Nm). 16. Havea front endalignmentperformed. Mirage ti See Figure 41 *The suspension components should not be tightened until the vehicle’s weight is resting on its wheels.

1. Raisethe vehicleand supportsafely. 2. Removethe wheeland tire assembly 3. Removeswaybar links or mountingnutsand boltsfrom lowercontrol arm. Removethe joint cups and bushings. 4. Disconnectthe ball joint stud from the steering knuckle. 5. Removethe inner lowerarm mountingbolt and nut. 6. Removethe rearmountboltsfrom the retaining clamp.Removethe rear retainerclamp if equipped. 7. Removethe arm from the vehicle. To install: 8. Installthe controlarm to the vehicleand install the inner mountingbolt. Install newnut and tightento 78 ft. Ibs. (108 Nm). 9. Installthe rearmountclampand bolts. Tightenthe clampmountingboltsto 65 ft. Ibs.(90 Nm). 10. Connectthe ball joint studto the knuckle.Install a newnut andtightento 43-52 ft. Ibs. (60-72 Nm). 11. Installthe sway barand links. 12. Lowerthe vehicleto the floor for the final tighteningof the innerframemountbolt. 13. Installthe wheeland tire assembly.

1. Disconnectthe negativebatterycable. 2. Raiseand safelysupportvehicle. 3. Disassemblethe links, removethe locknut, joint cup, bushing,and collar. Removethe swaybar link bolts. 4. It will be necessaryto removethe centercrossmemberin orderto removethe swaybar.Thefollowing stepsare requiredto removethe crossmember: a. Removethe front exhaustpipe b. Properlysupportthe engine,removethe engine roll stopperbolts. Removethe four center membermountingbolts and removethe center memberassembly. c. Removeboth steeringrack mounts. d. Disconnectthe lower control arm from the crossmember, e. Supportthe crossmember,removethe mountingbolts and lowerthe crossmemberfor access. 5. Removethe swaybar mountsand removethe barfrom the vehicle. To install: *Note that the bar brackets are marked left and right. 6. Positionthe swaybar in the vehicle,then install the crossmemberin the reverseorderit was removed. 7. Installthe swaybar mountbrackets,and tightenthe mountingbolts to 16 ft. Ibs. (22 Nm). 8. Connectthe swaybar links andtightenthe bolts with rubberbushings,until the amountof bolt protrusionat the end of link mountingbolt is 0.87 inches(22mm). 9. Lowerthe vehicleand connectthe negative batterycable. 1990-93 Galant FWD VEHICLE 1. Disconnectthe negativebatterycable. 2. Raiseand safelysupportvehicle. 3. Removethe front exhaustpipe and gasket from the manifoldand usingwire, tie it downand out of the way. WWhen relocating the front exhaust pipe, make sure the flexible joint is not bent more than a few degrees or damage to the pipe joint may occur. 4. Removethe centercrossmemberrearinstallation bolts. 5. Removethe swaybar link bolts. Onthe pillow-balltype, hold ball studwith a hexwrenchand removethe self-lockingnut with a box wrench. 6. Removethe swaybarbolts and mounts. 7. Removethe barfrom the vehicle,as follows: a. Pull both ends of the sway bar towardthe rear of the vehicle. b. Move the right sway bar end until the end clearsthe lowerarm. c. Removethe sway bar out the right side of the vehicle.

SUSPENSION ANDSTEERING8-13 3. Disconnectthe sway bar links by removing the self-lockingnuts. 4. Removethe sway bar mountingbracketsand bushings. 5. Removethe barfrom the vehicle. 6. Inspectall componentsfor wearor damage, and replacepartsas needed.

83Nm

W-118 Nm* 71-W ft.lbs:

To install:



69-78

7. Installthe swaybar into the vehicle. 8. Looselyinstallthe swaybar bracketson the vehicle. 9. Align the side locatingmarkingson the sway bar, so that the markingon ihe bar,extendsapproximately0.40 inches(1Omm)from the Inneredgeof the mountingbracket,on both sides. 10. With the swaybar properlyaligned,tighten the mountingbracketbolts to 28 ft. Ibs. (39 Nm). 11. Connectthe sway links to the damperfork andthe swaybar.Tightenthe locking nutsto 28 ft. Ibs (39 Nm). 12. Lowerthe vehicleand connectthe negative batterycable.

Nm

Diamante

Lateral lower steps 4. stay

Compression lower arm assembly removal steps 1. Connection for compression lower arm ball joint and knuckle 2. Comoression lower arm mouniina

bon’

3. Compression

lower

tmn assembly

6. CMlnection for lateral lower ball joint and knuckle 7. lateral lower arm mounting andnllt 0. hleral lower am7 assembly

arm assembly

removal

arm boll

To install:

CWtlOtl l : Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition 7923PGB8

Fig. 40 Explodedview of the lower control arms-Galant 8. Inspectall bushingsfor wearand deterioration and replaceas required. 9. Checkthe swaybarfor damage,and replace as required.

To install: 10. Installthe swaybar into the vehicle. 11. Installthe swaybar bracketson the vehicle, following anyside locatingmarkingson the brackets. Temporarilytightenthe swaybar bracket.Align the bushingend with the markedpart of the swaybarand thenfully tightenthe swaybar bracket. 12. If equippedwith the pillow-ball type mounting, installthe sway bar links and link mountingnuts. Usinga wrench,securethe ball studsat both endsof the sway bar link while tighteningthe mountingnuts. Tightenthe nuts on the swaybar bolt so that the distanceof bolt protrusionabovethe top of the nut is 0.63-0.70 in. (1&18mm). 13. Installthe front exhaustpipe with newgasket in place.Tightennewself-lockingnutsto 29 ft. Ibs. (40 Nm). 14. Connectthe negativebatterycable. A WD VEHICLE

I

1. Disconnectthe negativebatterycable. 2. Removethe front exhaustpipe. 3. Removethe centergussetand transferassembly. 4. Usinga wrenchto securethe ball studs at bothendsof the sway bar link, removethe swaybar link mountingnuts. Removethe swaybar link.

1. Disconnectthe negativebatterycable. 2. Raisethe vehicleand supportsafely. 3. Removethe front exhaustpipe and engine undercover. 4. Removethe left and right framemembers. 5. Removethe sway bar link. 6. Removethe sway bar bracketsand remove the swaybarfrom the vehicle.

5. Removethe swaybar bracketinstallationbolt and the swaybar bracketand bushing. 6. Disconnectthe swaybar couplingat the right lower controlarm. Pull out the left side swaybar edge,pulling it out betweenthe driveshaftandthe lowerarm. Pull out the right side barbelowthe lower arm.

7. Notethatthe bar bracketsare markedleft and right. Lubricateall rubberpartsand installthe bushings,the swaybarand brackets. 8. Installthe swaybar link. 9. Installthe framemembers. 10. Installthe engineundercoverandexhaust pipe. 11. Connectthe negativebatterycable.

REMOVAL& INSTALLATION

To install: 7. Installthe bar into the vehiclein the same manneras removal. 8. Temporarilytightenthe swaybar bracket. Align the bushingend with the markedpart of the swaybarand thenfully tightenthe stabilizerbar bracket. 9. Installand tightenthe swaybar bracketbolt. 10. Installthe swaybar links and link mounting nuts Usinga wrench,securethe ball studsat both endsof the swaybar link while tighteningthe mounting nuts.Tightenthe nutson the swaybar bolt so that the distanceof bolt protrusionabovethe top of the nut is 0.63 to 0.70 in. (16 to 18mm). 11. Installthe transferassemblyand gusset. 12. Installthe left crossmember.Tightenthe rear mountingboltsto 58 ft Ibs.(80 Nm) and the front mountingboltsto 72 ft. Ibs.(100 Nm).

1994-90 Galant # See Figures42, 43, and 44 1. Disconnectthe negativebatterycable. 2. Raiseand safelysupportthe vehicle

Diamante,Mirage, 1996-93 Galant, and 1999-00 Galant ) See Figures45, 46, and 47 1. Disconnectthe negativebatterycable. 2. Raisethe vehicleand supportsafely.Remove the halfshaftnut. 3. If equippedwith ABS,removethe front wheel speedsensor 4. If equippedwith Active ElectronicControl Suspension(Active-ECS),disconnectthe heightsen-. sor from the lowercontrolarm. 5. Removethe caliperassemblyand brakepads. Suspendthe caliperwith a wire 6. Usinga suitableball joint separatortool, disconnectthe ball joint and tie rod endfrom the steering knuckle. 7. Removethe halfshaftfrom the hub. 8. Unboltthe lowerend of the strut and remove the hub and steeringknuckleassemblyfrom the vehicle. 9 Removethe hub, bearingsand racesas follows.

.

8-14 SUSPENSION ANDSTEERING *Do not use a hammerto accomplishthis or the bearingwill be damaged.

108 N

?afu

--?8-98Nm 58-72ft.b.

Remrnmlstsps 1. Lower arrn ball joint connection 2. Self-locking nut 3. Stabilizer rubber 4. Stabilizer bar 5. Collar 8. Lower arm front bushing connection

7. Support bracket 8. Lower arm assembly Caution *: lndkates parts which should be temporarily tightened, and then fully tightensd with the vehicle on the ground in the unladen condition.

a. Remove theoil sealfromtheaxlesideof theknuckleusinga smallpryingtool. b. Remove thewheelbearinginnerracefrorr thefronthubusinga puller. . -Be careful that the front hub does not fall whenthe inner race is removed. c. Remove thesnapringfromtheaxleside01 theknuckle.Remove thebearingfromthe knuckleUI;rnga purrer. ** d. Onee thebearingis removed, thebearing outerracecanberemoved bytappingoutwith-a brassdriftpinanda hammer. To install: 10. Installthehub,bearings, andracesasfollows: a. Fillthewheelbearingwithmultipurpose grease. Applya thincoatingof multipurpose greas +L”S?kle andbearinacontactsurfaces. L” +hn u lC N IUI b. Pre:is thewheelbearingintotheknuckle usingana#ppropriate pressingtool.Oncethe bearingis installed,installtheinnerraceusing theproperdrivingtool. c. Drivietheoil sealintotheknuckleusing thepropersizedriver.Drivesealintoknuckleun til it is flushwiththeknuckleendsurface. d. UsingpressingtoolMB990998 or equivalent,mountthefronthubassembly intothe knuckle.Tightenthenutof thepressingtoolto

:tg. 41 Lower control arm assemblyand related components-Mirage

1Fig ing’nuts . . . the sway bar ,,,,link self-lock42 Remove Q3158p60 1 1:;izi I

I

. ..t$i yovy

the sway ba~~~~~1.

I’

r

urn

7923PGC1

Fig, 45 Front wheel bearing assembly exploded View-Mirage and Diamante

9315Bp63 / Fig. 44 The sway bar mountingbracket and bushingsare retained by 2 bolts

the

nut

7923PGC2

79wGc3

Fig. 46 Use of presstool for hub removal-Mirage and Diamante

Fig. 47 Removinginner race from hub-Mlrage and Diamante

SUSPENSION ANDSTEERING845 144-188 ft. Ibs. (200-260 Nm). Rotatethe hub to seat the bearing. e. Mount the knuckleassemblyin a vise. Checkthe hub assemblyturning torque and endplay as follows: l Using a torquewrenchand socket MB990998 or equivalent,turn the hub in the knuckleassembly.Note the readingon the torque wrenchand compareto the desired readingof 16 inch Ibs. (1.8 Nm) or less.This is knownas the breakawaytorque. l Checkfor roughnesswhenturning the bearing. 0 Mount a dial indicatoron the hub so the pointercontactsthe machinedsurfaceon the hub. l Checkthe end-play. l Comparethe readingto the limit of 0.002 in. (0.05mm). f. If the startingtorque or the hub end-play are not within specificationswhile the nut is tightenedto 144-188 ft. Ibs. (200-260 Nm), the bearing,hub or knucklehave probablynot been installedcorrectly.Repeatthe disassemblyand ‘assemblyprocedureand recheckstartingtorque and end-play. 11. Installthe huband knuckleassemblyonto the vehicle.Installthe lowerball joint stud into the steer-

ing knuckleand installa new nut.Tightento 52 ft. Ibs. (72 Nm). 12. Installthe halfshaftinto the hub/knuckleassembly. 13. Installthetwo front strutlowermountingbolts andtightento 80-94 ft. Ibs.(110-130 Nm) on Mirage or 65-76 ft. Ibs.(90-105 Nm) on Diamantemodels. 14. Installthe tie rod end andtightenthe nutto 25 ft. lbs. (34 Nm) for Mirageand 21 ft. Ibs. (29 Nm) ‘on Diamantemodels 15. Installthe brakedisc and caliperassembly. 16. If equippedwith Active-ECS,connectthe heightsensorand tightenthe mountingbolt to 15 ft. Ibs. (20 Nm). 17. Installthe front speedsensor,if removed. 18. Installthe washerand new locknutto the end of the halfshaft.Tightenthe locknutsnuglyto 144-188 ft. Ibs. (200-260 Nm). 19. Installthe tire and wheelassemblyonto the vehicle. 20. Lowerthe vehicleto the ground.

1994-98 Galant + See Figures48 thru 58 1. Raisethe vehicleand supportsafely. 2. Removethe appropriatewheelassembly.

Fig. 48 Removethe cotter pm axle lshaRBmV * from the“57pa3~ ~Fig.4g~..thenloosehtheaxlattut~~;.~ the vehicle is still on the ground

3. Removethe cotterpin, halfshaftnut and washer. 4. If equippedwith ABS,removethe Vehicle SpeedSensor(VSS). 5. Removethe caliperand brakepads.Support the caliperout of the way using wire. 6. Removethe brakerotorfrom the hubassembly. 7. Disconnectthe upperball joint from the steeringknuckleand pull the knuckleoutward. 8. Fromthe backof the knuckle,removethe ‘four bolts securingthe hubto the knuckle. 9. Removethe hub and bearingassemblyfrom the knuckle.

*The hub assemblyis not serviceableand shouldnot be disassembled. To install: 10. Install the hub to the steering knuckle and tighten the mounting bolts to 65 ft. Ibs. (88 Nm). 11. Connectthe upperball joint to the steering ‘knuckleandtightenthe self-lockingnut to 21 ft. Ibs. (28Nm). 12. Installthe axlewasherand nut. Tightenthe nut to 145-188 ft. Ibs. (200-260 Nm). 13. Positionthe rotor on the hub. 14. Installthe caliper holderand the brake ” caliper.

Fig. 50 Using a suitable punch and hammer, gently tap the halfshaft out of the

8116 SUSPENSION ANDSTEERING

Fig. 54 To remove the hub and bearing assembly, unfastenthe four retaining bolts . . .

Fig. 55 . . . then remove the hub and bearing assembly from the knuckle

Fig, 56 If replacing the steering knuckle, you must remove the retaining bolt and transfer the brake dust shield . . . 15. Ifequipped withABS,installtheVSS. 16. Installthewheelassembly andlowerthevehicle.

If thetiresarewornunevenly, if thevehicleis not stableonthehighwayor if thehandlingseemsuneveninspiriteddriving,thewheelalignment should bechecked. If analignment problemis suspected, firstcheckfor improper tireinflationandotherpossiblecauses. Thesecanbewornsuspension or steeringcomponents, accidentdamage or evenunmatched tires.If anywornor damaged components arefound,theymustbereplaced beforethewheels canbeproperlyaligned.Wheelalignment requires veryexpensive equipment andinvolvesminuteadjustments whichmustbeaccurate; it shouldonlybe performed bya trainedtechnician. Takeyourvehicle to a properlyequipped shop. Followingisa description of thealignment angles whichareadjustable onmostvehiclesandhowthey affectvehiclehandling. Although theseanglescan applyto boththefrontandrearwheels,usuallyonly thefrontsuspension is adjustable.

2. Drive shafl nut 3. Frc-rc,speed fiensor cvehides 4. Caliper

asWmbly

with

5.BrakediW &collnectionfciflJpperarm 7. Front hub assembly cauuen nlcrfonthubaMmbly~natbrrliurr#n61ed.

SUSPENSION ANDSTEERING8-17 CASTER ) See Figure 59 Looking at a vehicle from the side, caster angle describes the steering axis rather than a wheel angle. The steering knuckle is attached to a control arm or strut at the top and a control arm at the bottom. The wheel pivots around the line between these points to steer the vehicle. When the upper point is tilted back, this is described as positive caster. Having a positive caster tends to make the wheels self-centering, increasing directional stability. Excessive positive caster makes the wheels hard to steer, while an uneven caster will cause a pull to one side. OVerlOading the vehicle or sagging rear springs will affect caster, as will raising the rear of the vehicle. If the rear of the vehicle is lower than normal, the caster becomes more positive.

FRONT <

CASTER IS POSITIVE WHEN THE La ILOWER BALL JOINT) IS AHEAD OR PULLING THE SPINDLE.

LOAD IS PULLING

THE WHEEL. TCCABgOl

Fig. 59 Caster affects straight-line stability. Caster wheels used on shopping carts, for example, employ positive caster

CAMBER # See Figure 60 Looking from the front of the vehicle, camber is the inward or outward tilt of the top of wheels. When the tops of the wheels are tilted in, this is negative camber; if they are tilted out, it is positive. In a turn, a slight amount of negative camber helps maximize contact of the tire with the road. However, too much negative camber compromises straight-line stability, increases bump steer and torque steer.

D

TOE ) See Figure 61 Looking down at the wheels from above the vehicle, toe angle is the distance between the front of the wheels, relative to the distance between the back of the wheels. If the wheels are closer at the front, they are said to be toed-in or to have negative toe. A small amount of negative toe enhances directional stability and provides a smoother ride on the highway.

A A CYLINDER WILL ROLL STRAIGHT AHEAD B A CONE WILL ROLL IN A CIRCLE TOWARD THE SMALL END C TIRE CONTACTS THE ROAD SURFACE D POSITIVE CAMBER ANGLE E VERTICAL TCCABgOi

:ig. 60 Camberinfluences tire contactwith the road

Fig. 61 With toe-in, the distance betweenthe wheels is closer at the front than at the rear

1993-90 MIRAGE REAR SUSPENSION COMPONENT LOCATIONS 1. Hub and bearing assembly 2. Lower control arm 3. Control link

4. Trailing arm 5. Strut assembly

1994-98 GALANT REAR SUSPENSION COMPONENT LOCATIONS

1. Huband bearingassembly 2. Toe controlarm 3. Lowercontrolarm

4. Trailingarm 5. Hubandbearinaassemblv

II

199940 GALANT REAR SUSPENSION COMPONENT LOCATIONS

1. 2. 3. 4.

Trailingarm Huband bearingassembly Lowercontrol arm Strutassembly

5. 6. 7. 8.

Sway bar Sway bar link Steeringknuckle Toe controlarm

.

SUSPENSION ANDSTEERING8-21 axle weight must be supported separately, requiring the use of two separate lifting devices. 1. Disconnectthe negativebatterycable. 2. Raiseand supportvehiclechassis. 3. Raiseand supporttorsion axle andarm assemblyslightly. Makesurethe jack doesnot contact the lateralrod. *Always use a wooden block between the jack receptacle and the axle beam. Place the jack at the center of the axle beam. 1nents Q3158!@3 1990-92 Mirage rear suspension compo-

93158QM

1990-93 Galant rear suspension compoInents

4. Removethe trunk interiortrim to gain access to the top mountingnuts. 5. If equippedwith Active-ECS,performthe followingsteps: a. Labeland disconnectthe air tubesfrom the shockabsorber. *Immediately plug or cap the lines with tape or similar product to prevent the entry of dirt into the system. Do NOT bend or crimp the air tubes. Plug or cover the air ports on the joint and actuator.

1992-96 Diamante w/out 4 wheel steering rear suspension components

1997-00 Diamante rear suspension corn 1ponents %”

REMOVAL & INSTALLATION Diamante 1. Disconnectthe negativebatterycable. ! 2. Raiseand properlysupportvehicle. 3. Removeboth rearwheels. 4. Supportthe lowercontrol arm with a jack. 5. Matchmarkthe positioningof the upper spring plateto the vehiclefor reinstallationpurposes. 6. If equippedwith Active ElectronicControl Suspension(Active-ECS),performthe following: a. Loosenthe nut that securesthe air line to

1992-96 Diamante with 4 wheel steering rear suspension components the to the top of the strut and discardthe O-ring. b. Removethe bolts that securethe actuator to the top of the strut and removethe component Disconnectthe wiring harness. 7. Removethe shockabsorberlowermounting bolt and removethe two nutsthat securethe shock upperplateto the vehicle. 8. Lowerthe supportjackand removethe shock from the vehicle. To install: 9. Positionthe uooersprina elateand installthe strut. Usethe support’jackto as% with installation. 10. Tightenthe upperstrut mountingnuts to 33 ft. Ibs. (45 Nm). 11. Tightenthe lowerstrut mountingbolt to 71 ft. Ibs. (98 Nm). 12. If equippedwith Active-ECSperformthe following: a. Usinga new O-ring, tighten the nut that securesthe air line to the to the top of the strut to 84 inch Ibs. (9 Nm). b. Install the actuatorto the top of the shock absorberand securewith mountingbolts. Connect the wiring harness. 13. Removethe supportjack, install wheelsand lowervehicle. 14. Connectthe negativebatterycable. 1990-93 Galant FWD MODELS *The strut assembly Is a load bearing component, therefore the vehicle chassis and

b. Removethe O-ring and bushing. c. Removethe actuatorassembly. 6. Removethe top capand uppershockmounting nuts. 7. Removethe strut lowermountingbolt and removethe assemblyfrom the vehicle. To install: 8. Positionthe strut assemblyso that the lower mountingbolt can be installedand lightly tightened. 9. Usethe jack to raise or lowerthe axleassembly so thatthe top strut platestudsaligns throughthe body.Raisethe jackto hold the strut assemblyin position 10. Installthe top platenuts on the studs.Tighten the uppershockmountingnutsto 29 It. Ibs. (40 Nm). 11. With the car on the ground,tightenthe lower mountingbolt to 72 ft. Ibs. (100 Nm). 12. If equippedwith Active-ECS,assemblethe actuatorcomponentsin the following order: a. Install the adapterto the mountingbracket. b. Using new O-rings,connectthe air line to the actuator,Tightenthe locknutsto 6 ft Ibs. (9 Nm). c. Swabthe air connectorswith a solution of soapywater.Startthe engine,cycle the suspension controls and observethe joints for any sign of air leaks. 13. Installtop capand interiortrim. AWD MODELS 1. Disconnectthe negativebatterycable. 2. Raiseand supportvehiclechassis. 3. Raiseand supporttrailing arm assembly slightly. 4. Removethe trunk interiortrim to gain access to the top mountingnuts. 5. Removethe top capand uppershockmounting nuts. 6. Removethe braketube bracketbolt. 7. Removethe shock lowermountingbolt and removethe assemblyfrom the vehicle. To install: 8. Positionthe strut assemblyso that the lower mountingbolt can be installedand lightly tightened. 9. Usea jack to raiseor lowerthe trailing arm, so that the top strut platestudsaligns throughthe

8-22 SUSPENSION ANDSTEERING

, I semblyslightly. 3. Inorderto gainaccessto thetopmounting nuts,remove therearseatasfollows: a. Whilepullingtherearseatstopperoutward,lift thelowercushionupward.Remove the lowercushion. b. Remove theseatbackmounting bolts. c. Lifttheseatbackupwardandremovethe seat. 4. Remove theshockuppermounting nuts. 5. Remove theshocklowermounting boltand removetheassembly fromthevehicle. To install: 6. Positiontheshockassembly sothatthe lowermounting boltcanbeinstalledandlightly tightened. 7. Usea jackto raiseor lowerthelowercontrol arm,sothatthetopshockplatestudsalignthrough thebody.Raisethejackto holdtheshockassembly inposition.

r

I--

lb

8 In&dl the tnn nlato nl Itc: nn thp dl~rk nnri “,

,,,“Lu,l

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.

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tightenthemounting nutsto 32ft. Ibs.(44Nm). 9. Withthevehicleontheground,tightenthe lowermounting boltto 71ft. Ibs.(98Nm). 10. Installtherearseatbackandcushion. Miraae I

1. Remove thetrunkinteriortrimto aainaccess to thetopmounting nuts. 2. Remove thetopcapanduppershockmountingnuts. 3. Raiseandsupport vehiclechassis. 4. Supportthetrailingarmassembly witha iack 5_. Matchmark thF! unner snrino elate to .._._....._......_ -TT- _r u r _.- .- thevehiclechassisfor reassembly andremovetheupper spring ^ plate ^ mounting .. nuts. .a .I II. I b. nemove tnestrutlowermolInrmgDOII anaremovetheassembly fromthevehicle 9. To install: 7. Positionthestrutassembly sothatthelower mountino boltcanbeinstalledandliahtlvtiahtened. 8. t&ea jackto raiseor lowerthk&le&sembly sothatthetopshockplatestudsalignsthrough body.Raisethejackto holdthestrutassembly in position. 9. Installthetopplatenutsandtightenthemto 20ft. Ibs.(27Nm).

I

1. cap a. ““QJ1vw ;. ~~;~~inp 6: Spring pad

ii ZPb 10: Dust cbver

2Q*,A,ll)rrr Beif-lockingnut

11. 12. 13.

A

Bump rubber Coil spring Shock absorber assembly

7. Upper bushing B

mounting boltto 65ft. Ibs.(90Nm). 11. Installthetopcapandinteriortrim.

I Fig. 64 Explodedview of the rear shock absorber assembly-Galant and Mirage OVERHAUL Mirage and 1996-00 Galant 1. Remove theshockandspringassembly from thevehicle.Refertotheprocedure above. 2. Usea coilspringcompressor andcompress thecoilspring. 3. Remove theshockcap. ”,. \w.;,n .,,,,,- hrrh~inn ,,-,-,**J+I-...l” n;r+nn r .I._.*rnr( .-_, rnmn,rc, .-...-.- thn ...self-lockingnut. 5. Remove theupperbracketassembly and springpad. 6. Remove thecollar,upperbushing, cupassembly,bumprubberanddustcover. 7. Remove thecoilspringfromtheshock.

I -t

TmFliBl

I----.

Too Install: A*. .* I 0. ,,ngnmeenaof thecoilspringwiththe stepped partof thespringseatandinstallthecompressed cnil _..snrinn -r,.. J nn _ the _shock _ __ 9. Installthedustcover,bumprubber,cupassembly,upperbushing, collar,upperspringpadand bracket assembly ontheshock. 10. Installtheupperbushingandwasheronthe pistonrod. 11. Installa newself-locking nutonthepiston roa.temporarily tightenthenut. 12. Remove thespringcompressor fromthe spring.Tightentheself-locking nutto 16ft. Ibs.(25 Nm). 13. Installtheshockcap. 14. Installtheshockandspringassembly into the v&i&a

Rnfnr tn the nmrd~w~

ahnrm

SUSPENSION ANDSTEERING8-23 i-l

12. Checkrearwheelalignment andadjustif necessary.

REMOVALANDINSTALLATION 1990-93 Galant

1

1. Disconnect theneoative battetvcable. 2. Raiseandsafelysipportvehicle. 3. Remove thetireandwheelassembly. 4. Supporttherearlowercontrolarm. 5. Remove thebrakelineclampbolt. 6. Remove thenutandseparate theupperball joint,usingtoolMB9f35or equivalent, fromtherear trailingarm/steering knuckle. *It is importantto use proper methodof joint separationwhen reusingjoint. Damage can result from unapprovedmethods,resulting in possiblejoint failure. 7. Matchmark the - eccentric ..._...-nn -..the ...-IInner -rr-. installationboltandremovefromthecontrolarm. 8. Remove theupperarmfromthevehicle. To install: 9. Installthearmtothevehicleandinstallthe upperarminstallation bolt.Alignthematchmarks andtightenthenutsnuglyonly. 10. Installtheupperarmballjointto therear spindleassembly andinstallnewnut.Tightento 52 ft. Ibs.(72Mm). 11. Installthetireandwheelassembly. 12. Lowerthevehicleuntilthesuspension supportsitsweight. 13. Tightentheupperarminstallation boltto 116 ft. Ibs.(160Nmj. 14.‘Checktherearwheelalignment.

1990-93 Galant

!4315ap22

Fig. 65 Remove the through-bolt securing the upper arm to the knuckle

md . . .

1994-98 Galant ti See Figures 65, 66, and 67 1b Raiseandsafelysupportthevehicle. 2. Remove thewheelandtireassembly. 3. Remove thethrough-bolt securingtheupper armto theknuckle. 4. Remove thefourboltssecuringtheupper armto thebody. 5. Remove theuooerarmassemhlv 6. Remove thethrough-bolts andnutsandremovetheupperarmto bodybrackets, To install: 7. Installtheupperarmto bodybrackets to the upperarm.Tightentheboltsandnutsto 41ft. Ibs. (57Nm). 8. Installtheupperarmto thevehicleand tightenthefourboltsto28ft. Ibs.(39Nm). 9. Installthethrough-bolt securing
Diamante 1, Raiseandproperlysupportvehicle. 2. Remove appropriate wheelassembly. 3. Disconnect theswaybarandremovethestrut assembly.

REMOVALAND INSTALLATION

4. Supportthetrailingarmassembly andremove nutconnecting thecontrolarm .* theSelf-locking totnetramngarm. 5. Usinga jointseparation tool,disconnect the upperballjointfromthetrailingary. 6. Disconnect thecontrolarmfromthesubframeandremove theassembly. To install: 7. Installthecontrolarmtothesubframe and liahtlvtiahtenthemounting bolt. 8’. eonnectthe&irolarmto thetrailinaarm andtightentheself-lockingnutto 54-61ft. Ibs. (75-89Nm). 9. Installthestrutassembly andconnectthe swaybar. 10. Installwheelandlowervehicle. 11. Withfull weightofvehicleontheground, tightenthecontrolarmto subframe boltto 54-61ft. Ibs.(75-89Nm).

1

1. Disconnect thenegative batterycable. 2. Raisethevehicleandsupportsafely. 3. Remove swaybarlinksor mounting nutsand boltsfromlowercontrolarm.Remove thejointcups andbushings, if equipped. 4. Disconnect theballjointstudfromthesteeringknuckle, usingtoolMB9f35or equivalent. *It is importantto use proper methodwhen separatingjoints. Damageto joint could occur, resultingin possiblefailure. 5. Remove theinnerlowerarmmounting bolts andnut. 6. Remove therearmountbolts.Remove the rearretainerclampif equipped. 7. Remove thearmfromthevehicle. 8. Remove therearrodbushing,if serviceis required. To install: 9. Assemble thecontrolarmandbushing.Installthecontrolarmto thevehicleandinstalltheinnermounting bolts.Installnewnutandsnugtemnnrarilv f.r”‘Y”‘,. 10. Installtherearmountclamp,boltsandreplacement nuts.Tightentheclampmounting nutsto 34ft. Ibs.(47Nm).Temporarily tightentheclamp mounting bolt.Oncetheweightof thevehicleis on thesuspension, theboltwill betightened to 72ft. Ibs.(100Nm). 11. Connect theballjointstudtotheknuckle.Installa newnutandtightento43-52ft. Ibs.(60-72 Nm). 12. Installtheswavbarandlinks. 13. Lowerthevehicletothefloorforthefinal torquingof theinnerframemountbolt. 14. Oncethefull weightof thevehicleis onthe suspension, tightentheinnerlowerarmmounting boltnutsto87ft. Ibs.(120Nm).Tightentheinner clampmounting boltto 72ft. Ibs.(100Nm). 15. InSpetall suspension bolts,makingsure theyall havebeenfullytightened. 16. Connect thenegative batterycable. 199440 Gafant

\

LOWERCONTROL ARM + See Figures68 and 69 1. Raiseandsupportthevehiclesafely. 2. Remove theappropriate wheelassembly. 3. If equipped withABS,disconnect thespeed sensorharnessbrackets fromthelowercontrolarm. 4. Disconnect thestabilizerbarlinkfromthe lowercontrolarm. 5. Remove thethrough-bolt, connecting the knuckleassembly to thelowercontrolarm. fi V.

Romn\fn +hn mwntinn

IIVIII”“~

OK,

ill”

-......

J

hnlt cnnnwtinn

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--....--....

J

the .,,”

lowercontrolarmto thesuspension crossmember. 7. Remove thelowercontrolarmfromthevehicle.

8-24 SUSPENSION ANDSTEERING 8. Connect theECSheightsensorrodto the lowerarm,if equipped. 9. Installwheelandlowervehicle. IO. Withthefull weightofthevehicleonthe ground,tightenthecontrolarmto rearcrossmember boltto 54-61ft. Ibs.(75-89Nm). 11, Checkrearwheelalignment andadjustif necessary

REMOVAL & INSTALLATION 9315t$M

Fig. 68 Removethe through-boltconnecting the knuckle assembly to the lower control 1arm

Fig, 89 Removethe mountingbolt connect-/

93158p26

Fig. 70 Disconnectthe ball joint stud from the steering knuckle

1996-93 Galant 1, Raiseandsafelysupportthevehiclesecurely onjackstands. 2. Remove thewheelandtireassembly. 3. Remove thebrakedrumor rotor. 4. Remove thehubandbearingassembly. 5. Supporttherearaxleusinga jackor other suitabledevice. 6. Remove thelowershockabsorber-to-trailing armconnection. 7. Remove thetrailingarm-to-axle connection.

Fig. 71 Removethe mountingbolt connect1ing the toe lower control arm to the SW (80-100Nm). 12. Remove theaxlesuooortdevice.

Dolt.

9; Connect theknuckleto thelowercontrolarm andlightlytightenthethrough-bolt. 10. Connect thestabilizerbarlinkto thecontrol armandtightenthenutto 28ft. Ibs.(39Nm). 11. Installthewheelsandlowerthevehicleto the floor. 12. Oncethefull weightofthevehicleis onthe suspension, tightenthelowerarmmounting boltnuts to 71ft. Ibs.(98Nm). 13. Checkrearwheelalignment andadjustif necessary. TOELOWERCONTROL ARhl ti See Figures 70 and 71 Thelowerballjointis integralwiththelowertoe controlarm.Theyareremoved andreplaced asan assembly. 1. Raiseandsupportthevehiclesafely. 2. Remove theappropriate wheelassembly. 3. Matchmark thecontrolarmadjusting boltto aidin reassembly. 4. Usingjointseparator MB991113, disconnect theballjointstudfromthesteeringknuckle. 5. Remove themounting boltsconnecting the lowercontrolarmto thesuspension crossmember.

9. Withthefull weigh ground,tightenthecontrol %--56ft. ibs.( 10. Check reman0aajusrII necessay. Diamante 1, Raiseandproperlysupporl vehicleRemove appropriate whleelassembly. 2. Matchn narkthecamber aldiustina , _ bolttoaid in reassembly. 3. Onvehiclesequipped withActiveSusoenr sion,disconnect theECSheightsensorrodfrom lowerarm. 4. Supporttrailingarmassembly andremove theself-locking nutconnecting thelowerarmto the trailingarm. 5. Disconnect thelowerarmattherearsubframe.Remove thearmassembly. To install: 6. Connect thecontrolarmto therearcrossmember. Alionmatchmarks andliahtlvtiohten. 7. Connect thecontrolarmtothetrailingarm andtightentheself-locking nutto 54-PI I eIL IY.J. rho (75-89Nm).

onjackstands. 2. Remove thewheelandtireassembly. 3. Remove thebrakedrumor rotor. 4. Remove thehubandbearingassembly. 5. Supporttherearaxleusingajackor other suitabledevice. 6. Remove thelowercontrolarm-to-trailing arm connection. 7. Remove theupperlink-to-trailing armconnection. 8. Remove thetrailingarm-to-body mounting through-bolt andremovethetrailingarm. To install: 9. Installthetrailingarmandinstallthetrailing arm-to-body mounting through-bolt. Tightenthebolt to 72-87ft. Ibs.(100-120Nm). 10. Installtheupperlink-to-trailing armconnection.Tightentheboltto 65ft. Ibs.(90Nm). 11. Installthelowercontrolarm-to-trailing arm connection. Tightentheboltto 65ft. Ibs.(90Nm). 12. Remove theaxlesupportdevice. 13. Install1hehubandbearingassembly. 14 Install . _ 1.hebrakedrumor rotor. 15. Installthewheelandtireassembly. 16. Lowerthevehicle.

SUSPENSION ANDSTEERING8-25 1994-00 Galantand 1997-00 Diamante

4. Remove theretainerboltsandthestabilizer ..Darbrackets. Hemove thebushing. 7er hnr 5. HoldthestabilL_. __.with . . FI _ wmnph ..._..“...Remnun ..I..._._ theself-locking nut. 6. Oncethestabilizerbarnutis removed, removethejointcupsandstabilizerrubberbushing. 7. Holdthestabilizerlinkwitha wrenchandremovetheself-lockingnuts.Remove thestabilizer link. 8. Lowerthejacksupporting therearaxle n~~““yll-““!~ (1II” fWll”“C LllG llcllllll$j a,,,,. slightly.Maintaina slightgapbetween therearsusTo install: pensionandthf?bodyof thevehicle. 6. Installthetrailingarmandinstallthetrailing 9. Remow ! thestabilizerbar. _)----- wear .-- ana .-J aerenoJAI.... arm-to-body mounting through-bolt. Tightenthebolt 10. InspectIL_ LIIBL__ uarI__ 101uamage, to 99-114ft. Ibs.(137-157Nm). rationandreplaceasrequired. -Fe c--a-... 7. Installthetrailingarm-to-knuckle connection. I 0 Insran: Tightentheboltto 85-99ft. Ibs.(118-137Nm). 11, Installthestabilizerbarintothevehicle.Raise nemovemeaxlesupponaewce. therearaxleandsuspension intoplace. 9. Installthewheelandtireassembly. 12. InstallthestabilizerlinkintothestabilizerbaIr 10. Lowerthevehicle. anfi indc4ll ockingnut.Tightenthenutto 33ft. Ibs.(45Nm). 1992-96 biamante 13. InstalltheiointClrnC __-_2nd _.._?$bilizer __ rubberto thelink.Ins’talla rkW self~locking nut ontothelink. 1. Raise and safely support the vehicle securely Mlhiln hnlrii, ..I., lll~llGllUlulng thestabi” ” ’ oall ’ ’ studs nzernnK witha onIacKsranos. wrench,tightentheself,-lockingnutsotheprotrusion 2. Remove thewheelandtireassembly of thestabilizerlinkisvwithin0.354-0.433 3, Remove thn hralm rntnr in. (9-llmm). 4. Remove1 ihehubandbearingassembly. 14. Installthecente I stabilizerbarbushings, 5. Supporttherearaxleusinga jackor other thnhnk In -IAu brackets andbolts.Tiqt>+nn suitabledevice. 6. Remove thelowershockabsorber-to-trailing Nm). , , 15. Installtheparking I oraxecat*alearid rearspeed armconnection. sensor installation bolt. 7. Remove thestabilizerbarlink-to-trailing arm 16. Installthecrossmember bracket andtighten connection. theboltto 61ft. Ibs.(8!i Nm).Tightenthecrossmem8. Remove thetierodend-to-trailing armconberbracketmounting nlAto 94ft. Ibs.(130Nm). nection. 17. Installtherubbe !rinsulators andnewseif9. Remove thelowercontrolarm-to-trailing arm lockingnutsontothecro:ismemoer ’ brackets. Tighten connection. thenutsto 80-94fl. Ibs.([110-130Nm). 10. Remove thetrailingarm-to-body mounting 18. Lowerthevehicle. through-bolt andremove thetrailingarm. To install: Diamante and 1994-98 Gal&i t 11. Installthetrailingarmandinstallthetrailina arm-to-body mounting through-bolt. Tightenthebolt ) See Figure 72 to 101-116ft. Ibs.(140-160Nm). 12. Installthetrailingarm-to-lower controlarm 1. Disconnect theInegative battery(sble. ;“I,-. connection. Tightentheboltto 101-116ft. Ibs. 2. Raiseandsafely I supportthevbhlblG. (140-160Nm). 3. Disconnect theIstabilizer linksbyremoving 13. Installthetie rodend-to-trailing armconnec- theself-lockingnuts. tion.Tightenthenutto 21ft. Ibs.(29Nm). 4. Remove thestatAlizerbarmounting brackets 14. Installthestabilizerbarlink-to-trailing arm andbushings. connection. Tightenthenutto 29ft. Ibs.(40Nm). 5. Remove thebarfromthevehicle. 15. Installthelowershockabsorber-to-trailing 6. Inspect all comrlonentsforwearor damage, arm connection. Tighten the bolt to 65 ft. Ibs. (90 and replace parts asneeded. . Nrn). To install: 16. Remove theaxlesupportdevice. 7 InstA ._._. the ..._dnhili -.--.. lzerbarintothevehicle. 17. Installthehubandbkaringassembly, 18. Installthebrakerotor. 19. Installthewheelandtireassembly. 20. Lowerthevehicle. 1. Raiseandsafelysupportthevehiclesecurely onjackstands. 2. Remove thewheelandtireassembly. 3. Supporttherearaxleusinga jackor other suitabledevice. 4. Remove thetrailingarm-to-knuckle connection, 5. Remove thetrailingarm-to-body mounting

REMOVALANDINSTALLATION 1990-93 Gaiant 1. Raiseandsupportthevehiclesafely. 2. Placea jackundertherearaxleandsuspenSianassembly. 3. Remove theself-locking nutsandcrossmemberbracket.

8, Loosely in”,“,,+I?,, r+&,il;7nr kn-h.~r.l,,d” -.. 1 IIIJMII UK 3La”III‘w “ill “lduKm “II thevehicle. (1 th “. ,Alinn ,,LY,, ,,iesidelocatingmarkings onthestabilizerbar,sothatthemarkingonthebarextends approximately 0.39inches(1Omm) fromtheouteredge of themounting bracket,onbothsides. 10. Withthestabilizerbarproperlyaligned, tightenthemounting bracketboltsto 28ft. Ibs.(39 Nm). 11. Connect thestabilizerlinksto thedamper fork andihestabilizerbar.Tightenthelockingnutsto 28 ft. Ibs.(38Nm). 8..12. Lower Ia thevehicleandconnectthenegative mery came.

ADJUSTMENT Mirage *Never disassemblethe rear hub bearing. Thewheel bearingis serviced by replacementof the hub. 1. Raiseandsafelysupportthevehicle.

2. Remove therearwheel.

3. Remove thecaliperandbrakediscof brake drum. 4. Remove thedustcabandtightentheflange *lb+to 130ft. Ibs.(180Nm). 5. Usinga dialindicator, measure wheelbearingend-play.Themaximum limitfor end-playis o.oc-rzumcnes(u.usmm). ‘^ -6. Usinga springscaleanda ropewrapped arolmdthebolts,measure therotaryslidingresistance of thebearing/hub. Themaximum limitfor resiskmceis 4 Ibs.(19N). 7. If anyof thereadings exceed thespecifications,replacement of thehubis required. 8. Installthedustcap. 9. Installthebrakediscandcaliper,or brake drum. 10. Installtherearwheelassembly andlowerthe vehicletothefloor. * ll”,

1990-93 Galant *Vehicles equippedwith rear disc brakes use a sealed huband bearingassembly, which requiresno adjustment.Drumbrake modelsare adjustedusingthe following pro-

cedure.

1. Raisethevehicleandsupportit safely. 2. Remove thewheelandtireassemblies. 3. Ifequipped withreardiscbrakes,removethe caliperassembly. 4. Remove thegreasecapandthehubnut. 5. Tightenthewheelbearingnutto 20ft. Ibs.(27 Nm)whilerotatir10tne ” mum/hub. ” 6. Backoffthieadjusting nutto removethepreloadandthentightenit to 7 ft. Ibs.(10Nm). 7. Installthenutlockanda newcotterpin. 8. If brakecaliperwasremoved, reinstall. 9. Installthewheelandlowerthevehicle. Diamanteand lQQ44 Galant

93158P61

Fig. 72 Removethe self-locking nuts from the stabilizer bar link a

Measure thewheelbearingend-playusinga dial indicator.Theend-playshouldbe0.002inches (0.05mm) or lesswiththewheelbearinglocknut

SUSPENSION ANDSTEERING8-25 8. Looselyinstallthe stabilizerbar bracketson the vehicle. 9. Align the side locatingmarkingson the stabilizer bar,so thatthe markingon the bar extendsapproximately0.39 inches(1Omm)from the outeredge of the mountingbracket,on bothsides. 10. With the stabilizerbarproperlyaligned, tightenthe mountingbracketbolts to 28 ft. Ibs. (39 Nm). 11. Connectthe stabilizerlinks to the damperfork andjhe stabilizerbar.Tightenthe locking nutsto 28 ft. Ibs. (38 Nm). 12. Lowerthe vehicleandconnectthe negative batterycable.

1994-00 Galant and 1997-00 Diamante 1, Raiseand safelysupportthe vehiclesecurely on jackstands. 2. Removethe wheelandtire assembly. 3. Supportthe rearaxle using a jack or other suitabledevice. 4. Removethe trailing arm-to-knuckleconnection. 5. Removethe trailing arm-to-bodymounting through-boltand removethe trailing arm.

To install: 6. Installthe trailing arm and installthe trailing arm-to-bodymountingthrough-bolt.Tightenthe bolt to 99-114 ft. lbs. (137-157 Nm). 7. Installthe trailing arm-to-knuckleconnection. Tightenthe bolt to 85-99 ft. Ibs. (118-137 Nm). 8. Removethe axle supportdevice. 9. install the wheeland tire assembly. 10. Lowerthe vehicle.

ADJUSTMENT

1992-96 Diamante 1. Raiseand safelysupportthe vehiclesecurely on jackstands. 2. Removethe wheelandtire assembly. 3. Removethe brakerotor. 4. Removethe huband bearingassembly. 5. Supportthe rearaxle using a jack or other suitabledevice. 6. Removethe lowershockabsorber-to-trailing arm connection. 7. Removethe stabilizerbar link-to-trailingarm connection. 8. Removethe tie rod end-to-trailingarm connection. 9. Removethe lowercontrol arm-to-trailingarm connection. 10. Removethe trailing arm-to-bodymounting through-boltand removethe trailing arm.

To install: 11, Installthe trailing arm and install the trailing arm-to-bodymountingthrough-bolt.Tightenthe bolt to lOl-116ft. Ibs.(14C-160 Nm). 12. Installthe trailing arm-to-lowercontrol arm connection.Tightenthe bolt to 101-116 ft. Ibs. (140-l 60 Nm). 13. Installthe tie rod end-to-trailingarm connection. Tightenthe nut to 21 ft. Ibs. (29 Nm). 14. Installthe stabilizerbar link-to-trailina arm connection.Tightenthe nut to 29 ft. Ibs. (40 im). 15. Installthe lowershockabsorber-to-trailing arm connection.Tightenthe bolt to 65 ft. Ibs. (90 Nm). 16. Removethe axle supportdevice. 17. Installthe huband bearingassembly. 18. Installthe brakerotor. 19. Installthe wheelandtire assembly. 20. Lowerthe vehicle.

REMOVALANDINSTALLATION

1990-93 Galant *Vehicles equippedwith rear disc brakes use a sealed huband bearingassembly, which requiresno adjustment.Drumbrake modelsare adjustedusingthe following procedure. 1. Raisethe vehicleand supportit safely. 2. Removethe wheelandtire assemblies. 3. If equippedwith reardisc brakes,removethe caliperassembly. 4. Removethe greasecapand the hub nut. 5. Tightenthe wheelbearingnutto 20 ft. Ibs. (27 Nm) while rotatingthe drum/hub. 6. Backoff the adjustingnutto removethe preload and thentighten it to 7 ft. Ibs. (10 Nm). 7. Installthe nut lock anda newcotterpin. 8. If brakecaliperwas removed,reinstall. 9. Installthe wheeland lowerthe vehicle.

'

1990-93 Galant 1. Raiseand supportthe vehiclesafely. 2. Placea jack underthe rearaxleand suspension assembly. 3. Removethe self-lockingnuts andcrossmemher bracket. -. d.---

Diamanteand 1994-00 Galant Fig. 72 Removethe self-locking nuts from the stabilizer bar link

Measurethe wheelbearingend-playusing a dial indicator.The end-playshould be0.002 inches (0.05mm)or lesswith the wheelbearinglocknut _

8-26 SUSPENSION ANDSTEERING torquedto specifications.Thewheelbearingsare sealedunits and are not adjustable.If defective,replacementis the only option.

REMOVAL&INSTALLATION Mirage 7996-92MODELS 1. Raisethe vehicleand supportsafely. 2. Removethe tire andwheelassembly. 3. If equippedwith reardisc brakes,removethe caliperfrom the disc and removethe brakedisc. 4. Removethe dust capand bearingnut. Do not usean air gun to removethe nut. 5. Removethe outerwheelbearing. 6. Removethe drum and/or axle hub with the inner wheelbearingandthe greaseseal. 7. Removethe greasesealand removethe inner bearing.

To install: 8. Lubricatethe inner bearingand installto the drum or hub. 9. Installa newgreaseseal. 10. To determineif the self-lockingnut is reusable: a. Screw in the self-locking nut until about 0.07-0.11 in. (2-3mm) of thread is visible under the nut. b. Measurethe torque requiredto turn the self-locking nut counterclockwise. c. The lowestallowabletorque is 48 inch Ibs. (6 Nm). If the measuredtorque is lessthan the specification,replacethe nut. 11. Installthe drum and/or hubto the vehicle. 12. Lubricateand installthe outerwheelbearing to the spindle. 13. Tightenthe self-lockingnut to 108-145 ft. Ibs. (150-200 Nm). 14. Set up a dial indicatorand measurethe endplay while movingthe hub or drum in and out. If the endplayexceeds0.008 in. (0.002mm) retorquethe nut. If still beyondthe limit, replacethe bearings. 15. Installthe greasecapandwheelassembly.

1990-93 Galant DRUM BRAKE VEHICLES 1. Raisethe vehicleand supportit safely. 2. Removethe wheelandtire assemblies. 3. Removethe greasecap and the hub nut. 4. Removethe brakedrum.The outerbearing will fall out while the drum is comingoff. Do not drop it. Removethe hub and rotor assembly. 5. Pry out and discardthe oil seal. 6. Removethe inner bearing.

*Check the bearingraces. If any scoring, heat checkingor damageis noted,they should be replaced.Whenbearingor races needreplacement,replacethem as a set.

Be sure to pumpthe brakepedal until it’s firm, before movingvehicle.

7. If the bearingsand racesare to be replaced, drive out the racewith a brassdrift.

1994-00 Galant

To install: 8. Beforeinstallingnewraces,coatthemwith wheelbearinggrease.Drive into placewith proper sizedriver. Makesurethey are fully seated. 9. Thoroughlypackthe bearingsand lubricate the hubswith wheelbearinggrease.Installthe inner bearingand coatthe lip and rim of the greaseseal with grease.Drive the sealinto placewith a sealdriver. 10. Installthe drum assemblyon the axle. 11, Lubricateand installthe outerwheelbearing, washerand nut. To properlyadjustthe wheelbearing preload: a. Tightenthe wheel bearingnut to 20 ft. Ibs. (27 Nm) while rotatingthe drum. b. Backoff the adjustingnut to removethe preload,then tighten it to 7 ft. Ibs. (10 Nm). c. Install the nut lock and a new cotter pin. 12. Installthe wheeland lowerthe vehicle. O/SC BRAKE VEHICLES 1. Raisethe vehicleand supportsafely. 2. Removethe tire andwheelassembly. 3. Removethe bolt(s) holdingthe speedsensor bracketto the knuckleand removethe assemblyfrom the vehicle.

7993-60 MODELS

*Never disassemblethe rear hub bearing. The wheel bearingis serviced by replacement of the hub. 1. If equippedwith ABS,removethe wheel speedsensor. 2. Raiseand safelysupportthe vehicle. 3. Removethe rearwheel. 4. Removethe caliperand brakedisc or brake drum. 5. Removethe dustcapand flangenut. 6. Removethe rearhub assembly.

To install: 7. Installthe rearhub assemblyusing a new flangenut.Tightenthe flangenut to 130 ft. Ibs.(180 Nm). 8. install the dust cap. 9. Installthe wheelspeedsensorif removed. The air gap should be0.012-0.035 in. (0.3-0.9mm). 10. Installthe brakedisc and caliper,or brake drum. 11. Installthe rearwheelassemblyand lowerthe vehicleto the floor.

10. Installthe hub and bearingassemblyto the axle shaft. 11, Installthe tonguedwasherand a newlocking nut.Tightenthe locknutto 144-188 ft. Ibs. (200-260 Nm). Oncethe locknuthas beenproperlytorqued, crimp the nut flangeover the slot in the spindle,and installthe greasecap. 12. Installthe brakecaliperand rotor. 13. Installthe speedsensorandtightenthe mountingbolt to 8 ft. Ibs. (11 Nm). 14. Installthe tire andwheelassembly.

The speedsensorhas a pole piece projecting from it. This exposedtip mustbe protected from impactor scratches.Do not allow the oole oiece to contactthe toothedwheel durin0 removal or installation.

DRUM BRAKE VEHICLES

) See Figure 73, 74, 75 1. Raisethe vehicleand supportsafely. 2. Removethe appropriatewheelassembly. 3. If equippedwith ABS, removethe vehicle speedsensor. 4. Removethe brakedrum from the hub assembly. 5. Fromthe backof the knuckle,removethe four bolts securingthe hubto the knuckle. 6. Removethe hub and bearingassemblyfrom the knuckle.

*The hub assemblyis not serviceableand shouldnot be disassembled. 7. If replacingthe hub, usespecialsocket MB991248and a pressto removethe wheelsensor rotor from the hub.

To install: 8. Pressthe wheelsensorrotor ontothe hub. 9. Installthe hub to the knuckleand tightenthe mountingbolts to 54-65 ft. Ibs.(74-88 Nm). 10. Installthe brakedrum on the hub. 11. If equippedwith ABS, installthe vehicle speedsensor. 12. Installthe wheelassemblyand lowerthe vehicle. O/SC BRAKE VEHICLES 1. Removethe cotter pin, halfshaftnut and washer. 2. Raisethe vehicleand supportsafely.

4. Removethe caliperfrom the brakedisc and suspendwith a wire. 5. Removethe brakerotor. 6. Removethe greasecap, locking nut and tonguedwasher. 7. Removethe rearhuband bearingassembly.

*The rear hubassemblycan not be disassembled.If bearingreplacementis required, replacethe assemblyas a unit. 8. If replacingthe hubassembly,removethe two bolts securingthe speedsensorring to the hub.

To install: 9. Installthe speedsensorto the hub and bearing assembly.Tightenthe mountingbolts to 8 ft. Ibs. (11 Nm).

Fig. 73 The huband bearingassemblyis retained to the knuckleby four bolts

SUSPENSION ANDSTEERING8-27 16. If equippedwith ABS,install the vehicle speedsensor. 17. Installthe wheelassemblyand lowerthe vehicle.

Diamante *The hub assemblyis not repairable; if defective, replacementis the only option. If the hub is removedfor any reasonit mustbe replaced.

7923PGC7

Fig. 74 Use a press to remove the speed sensor rotor from the hub-Galant dhk4w

1. Raiseand supportvehiclesafely. 2. Removethe both of the rearwheels. 3. Removethe caliperand the brakedisc. Sup/ port the caliperwith wire to preventstressto the brakehose. 4. If equippedwith ABS,removethe bolt holding the speedsensorto the trailing arm and remove the sensor.

*The speedsensorhas a pole piece projecting from it. This exposedtip mustbe protectedfrom impactor scratches.Do not allow the pole pieceto contactthe toothed wheel duringremoval or installation.

with drum,brqb

5. Removethe greasecap, self-lockingnut and tonguedwasher.

*Do not use an air gunto removethe hub locknut. 6. Removethe rear hubassemblyfrom the spindle. 7. Removethe bolts that securethe ABSsensor ring to the huband removethe ring from the hub.

To install:

7923PGCE

Fig. 75 Explodedview of the rear hub/bearingassemblyand related components=Galant 3. Removethe appropriatewheelassembly. 4. If equippedwith ABS,removethe vehicle speedsensor. 5. Removethe caliperand brakepads,Support the caliperout of the way using wire. 6. Removethe brakerotor from the hub assemhl\r

WY.

7. Removethe parkingbrakeshoesas follows: a. Removethe uppershoeto anchorsprings. b. Removethe lower shoeto shoe spring. c. Removethe brakeshoe hold-downsprings. d. Disconnectthe parking brakecablefrom the actuatinglever. 8. Fromthe backof the knuckle,removethe four bolts securingthe hubto the knuckle. 9. Removethe hub and bearingassemblyfrom the knuckle.

*The hub assemblyis not serviceableand shouldnot be disassembled. 10. If replacingthe hub,use specialsocket MB991248and a pressto removethe wheelsensor rotor from the hub.

To install: Il. Pressthe wheelsensorrotor ontothe hub. 12. Installthe hubto the knuckleandtightenthe mountingbolts to 54-65 ft. tbs. (74-88 Nm). 13. Installthe parkingbrakeshoes, 14. Positionthe rotor on the hub. Installa couple of lug nutsand lightly tightento hold rotor on hub. 15. Installthe caliperholderand placebrakepads in holder.Slide caliperover brakepadsand install guide pins. Oncecaliperis secured,lug nutscan be removed.

8. Securethe sensorring to the hub assembly and tightenthe mountingbolts. 9. Installthe hubassembly,tonguedwasher and a newself-lockingnut.Tightenthe nut to 166 ft. Ibs. (230 Nm),align with the indentationin the spindle, and crimp. IO. Usinga ropearoundthe hub bolts and a spring balance,measurethe resistancenecessaryto rotatethe hub. If the resistanceexceeds7 ft. Ibs. (IO Nm), loosenand retightenthe locknut.If the resistancestill exceedsthe specification,the hub must be replaced. 11. Usinga dial indicator,measurethe hub endplay.Theendplayshould be 0.002 inches(0.05mm) or less. 12. Installthe brakerotor and caliperassembly. 13. Installthe speedsensorto the knuckle.

*Route the speedsensorcable correctly. Improperinstallation may causecable damage andsystemfailure. Usethe white stripe on the outer insulationto keepthe sensor harnessproperly positioned. 14. Usea brassor othernon-magneticfeeler gaugeto checkthe air gap betweenthe tip of the pole pieceand the toothedwheel.Correctgap is 0.008-0.028 in (0.2-0.7mm). Tightenthe sensor bracketnut with the sensorlocatedso the gap is the sameat severalpoints on the toothedwheel.If the gap is incorrect,it is likely that the toothedwheelis worn or improperlyinstalled. 15. Bleedthe brakesystemand installthe rear wheels.

... ,.x..-~* .-....,, _s_s”.,.._”

8-28 SUSPENSION ANDSTEERING 1994-00 Mirage and Galant

REMOVAL&INSTALLATION 199%93 Mirage 1. Disconnect thenegative batterycable. 2. Remove thehornpadfromthesteeringwheel, bypullingthelowerendof thepadupward.Detach hbinbutin connector. 3. steering nut:I <. . Remove .. .‘ wheelretaining . a. .a 4. Matcnmarlc mesteeringwneelto mesnan. 5. Usea steeringwheelpullerto remove the steeringwheel.

Do not hammeron steeringwheel to remove it. The collapsible columnmechanismmay ha rlsmwmd.

To install: 6. Lineupthematchmarks andinstallthesteeringwheeltotheshaft. 7. Tiflhtenthesteeringwheelattaching nutto 29 ft. Ibs.(40Nm). 8. Reconnect thehornconnector andinstallthe hornpad. 9. Connect theneaative battetvcable.

Fig. 76 Theair bagis retained by two 8 located in access holes on the back wheel. Remove the covers to access the screws

then detachthe connectorand ove the air bag module from the vehi-

b See Figures76 thru 85

f

I If aquippedwith an air bag, be sure to dlsarm it hnfnra --.-.- sfarfinn ---.-...= rmairs .-r-.‘- on -.. the _..-vehicle. ._.. - Failure to do so could result in severe personal injury and damageto vehicle. 1. the system asoutlinedinSection 6. ^z. Disarm m *I SRS Remove me coversandtheairbagmodule .,A +L. m++-,g w,,eel, mounting nutfrombehill”~IK~(G~G!I *. I 3. Todetachtheconnector of theclocKsprmfl fromtheair bagmodule,presstheair bag’slocktowardthemoduleto spreadthelockopen.While holdinglockin thisposition,usea smalltippedpryingtoolto gentlyprytheconnector fromthemodule. 4. Remove theair bagmoduleandstorein a clean,dryplacewiththepadcoverfacingup. 5. Matchmark thesteeringwheelto theshaft. 6. Remove thesteeringwheelretainingnutand usea steeringwheelpullerto remove thewheel.Do notusea hammer, orthecollapsible mechanism in thecolumncouldbedamaged. To install: 7. Confirmthatthefrontwheelsareina straightaheadposition.Centertheclocksprinfl byaligning

Fig. 77 Theretaining screws usually require a Torx@drive tool to remove them

Fig. 80 To preventpersonalinjury, ALWAYS carry a live air bag facing away from you in

theNEUTRAL markontheclockspring withthematingmarkonthecasing.Then,installthesteering wheelandtightenthenewretainingnutto 29ft. Ibs. (40Nm). 8. Installtheair bagmodule. 9. Connect thenegative batterycable,turnthekey to theONposition;theSRSwarninglightshouldilluminatefor sevenseconds andgoout. 1990-93 Galant 1. Disconnect thenegative batterycable. 2. Remove thehornoadfromthesteerino d wheel asfollows:- - - - r a. For1990-91modelsonly,thehornpadis removedby pushingthepadupward,to release thepadfromtheretainingclips.Detachhornbuttonconnector andremovethepad. b. For1992-93modelsonly,removethe screwfromthebottomof thepadandpushthe padupward,to releasethepadfromtheretaining clips.Detachhornbuttonconnector andremove thepad. 3. Remove steeringwheelretainingnut. 4. Matchmark thesteeringwheeltotheshaft. 5. Usea steeringwheelpullerto remove the steeringwheel.

Fig. 78 After the air baa retainino screws \ are removed,graspthe airbag andiarefully pull it from the steering wheel . . .

fig. 81 To preventpersonalInjury, ALWAYS place a live airbag with the cover facing up

SUSPENSION ANDSTEERING8-29 i ’

I

Do not hamme!r on steeringwheel to remove i4 l-ha nnlhnr ,,. , II= ,,,,,,Jfble columnmechanismmay be damaged.

REMOVALANDINSTALLATION

To install: 6. Lineupthematchmarks andinstallthesteering\n/heelto theshaft. 7. Tightenthesteeringwheelattachingnutto 25-33ft. Ibs.(35-45Mm). 8. Attachthehornconnector andinstallthehorn pad. 9. Connect thenegative batterycable.

Theair bagsystem(SRSor SIR)mustbe disarmedbefore removingthe steeringwheel. Failure to do so may causeaccidentaldeployment,propertydamageor personalinMY. 1 .

Diamante

Be sure to disarmthe SRS(air bagI) system, beforestarting repairs OIn the vehicle. Failure to do so could result in plersonalinjury or death. DONOTperform;anywork on the vehicle until after 90 secondshas passed.The aiir bag systemis designedto retain enough short term voltage to makeair bag deploymentpossible; I .. 1. ^ DisarmtheSRSsystemasoutlinedin Secnonb. 2. Remove theair bagmodulemounting nut frombehindthesteeringwheel. 3. Matchmark thesteeringwheel. 4. Detachtheconnector of theclockspring from theairbaqmodule,presstheair baa’slocktowards themodubto spreadthelockopen:While holding lockin thisposition,usea smalltippedpryingtoolto gentlyprytheconnector fromthemodule. ..#5. ,I Store I theairI bag . moduleina clean,dryplace wlrnmepaacoverracmgup. 6. Remove thesteeringwheelretainingnlut. 7. Matchmark thesteeringwheeltotheslIaft. 8. Usea steeringwheelpullerto remove the wheel.

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rJhle

_““._.

2. If equipped, disabletheair bagsystem. 3. Remove thesteeringwheelasoutlinedearlier in thissection. 4. ForDiamante models,remove thehoodlock releasehandle. 5. Remove thekneeprotectorpanelunderthe steeringcolumn,thentheupperandlowercolumn covers. 6. ForDiamante models,remove thelapcooler andfootblowerductworkasnecessary. Carefullydetachthecombination switchconnecto&. 7. ForMiragemodels, detachall connectors, remove thewiringclipandremovethecolumnswitch assembly. 8. ForGalantmodels,if equipped, remove the fourscrewsretaining thecruisecontrolslipringto theswitch. 9. ForGalantmodels,remove thetworetaining screwsfromthecombination switchandremove the switchfromthecolumn. Tn- install: ..- _-.._ 10. Installtheswitchassembly andsecureall harness connectors withclipsif needed. Makesure thewiresarenotpinchedoroutof place. 11. Installthecolumncoversandkneeprotector andall connectors. 12. If removed, installthefootblowerductwork anfl -..- tan .-r cnnler --- ” 13. Confirmthatthefrontwheelsareina straight-ahead position. 14. Installthesteering wheel,asoutlinedearlier in thir

Do not use a hammeror the ~r”---‘~‘wImpl*

Fig. 84 . . . then tighteNW down the puller rinntlv iem until the wheel is suffL,,,,, lVvoV

93158p12

Fig. 85 Lift the steering wheel straight off of the steering column and remove the wheel

To install: 0 frnnt ,?A in , .I. Pnnfirm ““llllllll that u,a,thn,110 ll”lll whnalc I.ll~rJlJCnIj 111 a straight-ahead position.Centertheclockspring by aligningtheNEUTRAL markontheclockspring with thematingmarkonthecasing. 10. Lineupandinstallthesteeringwheel. 11. Tightentheretainingnutasfollows: \ l On1992-93Diamante models,tightenthe retammg Inutto 29ft. Ibs.(40Nm) l On1994-00Diamante models,tightenthe retainingIiut to 33ft. Ibs.(45Nm) 12. lnstal IItheairbagmoduleandtightenther& tainingnuts1:o48inchIbs.(5 Nm). wt rahle rhwk 13. Conn “...the ...” rwnative .‘“J...*.”hatim ‘&.“WSJ Y..“.”ami . ..rn” VII”“.. theSRSwarninglightoperation.

15. Connect thenegative batterycable,turnthe keytotheONposition,theSRSwarninglightshould illuminate for sevenseconds andgoout.If thewarninglightis notfunctioning properly,refertoSRS s’ystemcllagnosls. .’ 16. Checkall functionsof thecombination switch for properoperation.

REMOVAL&INSTALLATION *On vehicles not coveredhere, the windshield wiper switch is incorporatedinto the combinationswitch and is not separatelyserl viceable. Refer to the procedureabove. Diamante 1. Disconnect thenegative batterycable. 2. If equipped withanair bag,disarmasfolI” .L lows: a. Positionthefrontwheelsin thestraight aheadpositionandplacethekeyin theLOCK

8-30 SUSPENSION ANDSTEERING position. Removethe key from the ignition lock cylinder. b. Disconnectthe negativebatterycableand insulatethe cable end with high-qualityelectrical tape or similar non-conductivewrapping. c. Wait at least1 minute beforeworking on the vehicle.The air bag systemis designedto retain enoughvoltageto deploythe air bag for a short period of time evenafterthe batteryhas beendisconnected. 3. Removethe steeringwheel.as outlinedearlier in this section. 4. Removethe hood lock releasehandle. 5. Removethe switchesfrom the kneeprotector belowthe steeringcolumn,and removethe exposed retainingscrews.Thenremovethe kneeprotector. 6. Removethe columncovers. 7. Removenecessaryduct work and detachthe windshieldwiper switchconnectors. + 8. Removethe retainingscrewsand removethe windshieldwiper switchassemblyfrom the steering column.

To install: 9. Installthe wiper switchto the steeringcolumn and connectthe connectors. IO. Installany removedductwork. 11. Installthe columncovers. 12. Installthe kneeprotectorand switches. 13. Installthe hood releasehandle. 14. Confirmthatthe front wheelsare in a straight aheadposition. Installthe steeringwheel,as outlined earlier in this section. 15. Connectthe negativebatterycableandcheck the windshieldwiper and washerfor properoperation

REMOVAL &INSTALLATION

The air bagsystem(SRSor SIR)mustbe disarmedbefore removingthe steeringwheel. Failure to do so may causeaccidentaldeployment,propertydamageor personalinjury. 1. If equipped,properlydisarmthe air bagsystern: 2. Disconnectthe negativebatterycable. 3. Removethe hood lock releaseleverfrom the lower panel. 4. Removethe lowerinstrumentpanelkneeprotector. 5. Removethe ductworkwith the lowerknee paneland removethe steeringwheelassembly.

Usepropersteeringwheel puller equipment when removingthe steeringwheel. The use of a hammerfor removal could damagethe collapsible mechanismwithin the column. 6. Removethe lowerand uppersteeringcolumn covers. 7. For Diamantemodels,removethe lap cooler and foot showerductwork. 8. If necessary,removethe clip that holdsthe wiring harnessagainstthe steeringcolumn.

9. Detachall necessaryconnectors. 10. For Galantand Diamantemodels,removethe retainingscrews,then removethe entirecolumn switch/clockspringassemblyfrom the left side of the steeringcolumn. 11. For Diarnantemodels,removethe mounting screwsfrom the ignition switchand pull the switch from the interlockcylinder. 12. Insertthe key into the steeringlock cylinder and turn to the ACCposition. 13. With a small, pointedtool, pushthe lock pin of the steeringlock cylinder inwardand pull the lock cylinderout. 14. Removethe key reminderswitch,if equipped.

To install: 15. For Mirage, installthe lock cylinderin the lock cylinder bracket.Make surethe cylinderoperatesproperlybeforebreakingoff the headsof the specialbolts, if the bracketwas replaced. 16. For Galantand Diarnantemodels,installthe lock cylinder into the interlockhousing.Besurethe lock pin snapsinto place.Installthe ignition switch into the interlockhousing.Align the keywayof the ignition switchwith the lock cylinderand securewith the mountingscrews. 17. For Galantand Diamantemodels,installthe columnswitch/clockspringassemblyto the and connectthe harness. 18. installthe key reminderswitch,if equipped. 19. Attachthe harnessconnectionsand install the wiring clip. 20. If removed,installthe lap cooler and foot showerductwork. 21. Installthe steeringcolumn upperand lower covers. 22. If necessary,installthe kneeprotectorand the steeringwheel. 23. Installthe hood lock releaselever. 24. Connectthe negativebatterycable,enablethe air bagsystem,and checkthe ignition switchand lockfor properoperation.

REMOVALANDINSTALLATION Mirage and Galant I. Disconnectthe negativebatterycable.If equipped,disarmthe air bagsystem. 2. Removethe hood lock releaseleverfrom the lower panel. 3. Removethe lowerinstrumentpanelkneeprotector. 4. Removethe ductworkwith the lowerknee paneland removethe steeringwheelassembly.

*Use propersteeringwheel puller equipmentwhen removingthe steeringwheel. The use of a hammerfor removalcould damage the collapsible mechanismwithin the column. 5. Removethe lowersteeringcolumncover. 6. Removethe uppersteeringcolumncover. 7. Removethe clip that holdsthe wiring harness againstthe steeringcolumn. 8. For Galantmodels,insertthe key into the steeringlock cylinderand turn to the ACC position. 9. For Galantmodels,using a small pointed tool, pushthe lock pin of the steeringlock cylinder inwardand pull the lock cylinderout.

IO. For Galantmodels,removethe keyreminder switch,if equipped. 11. Unplugthe ignition switch harnessconnector. Removethe ignition switch mountingscrewsand pull the switchfrom the steeringlock cylinder.

*Vehicles equippedwith automatic transaxle havesafety-locksystemsandwill have a key interlock cable installed in a slide lever on the side of the key cyfinder. Carefully unhookthe interlock cable from the lock cylinder while withdrawingthe cylinder from the lock housing. To install: *To removethe steerlng lock, use a hacksaw or equivalentto cut the special bolts throughthe bracket.The bracketand bolts mustbe replacedwith new ones. 12. With the ignition key removed,installthe slide leverand the interlockcableto the steeringlock cylinder.Apply greaseto the interlockcableand install the cylinder into the lock housing.Checkfor normaloperationof the interlocksystem. 13. Installthe ignition switch into the rearof the lock cylinder housing.Besureto align the keywayof the ignition switchwith interlockcylinder. 14. Attachthe harnessconnectionsand install the wiring clip. 15. Installthe steeringcolumnupperand lower covers. 16. Installthe kneeprotector. 17. Connectthe negativebatterycable,enablethe air bagsystem(if equipped)and checkthe ignition switchand lock for properoperation.

Diamante

WorkMUSTNOTbe started until at least 90 secondsafter the ignition switch is turnedto the LOCKposition andthe negativebattery cable is disconnectedfrom the battery. This will allow time for the air bagsystembackup power supplyto depleteits stored energy preventingaccidentalair bagdeployment which could result in unnecessaryair bag systemrepairs and/orpersonalinjury. I. Disconnectthe negativebatterycable. 2. Disarmthe air bagsystem,as outlinedin Section6. 3. Removethe steeringwheel,as outlinedearlier in this section. 4. Removethe hood lock releasehandle. 5. Removethe switchesfrom the kneeprotector belowthe steeringcolumnand removethe exposed retainingscrews.Thenremovethe kneeprotector. 6. Removethe steeringcolumnupperand lower covers.Usecareremovingthe coversto prevent breakageof alignmenttabs. 7. Removelap coolerandfoot showerduct work. Detachthe ignition switch harnessconnectors. 8. Removemountingscrewsfrom the ignition switchand pull switchfrom interlockcylinder.

To install: 9. Install ignition switch into interlockhousing. Align keywayof ignition switchwith lock cylinderand securewith mountingscrews. IO. Connectthe ignition switchelectricalharness Plug.

I

SUSPENSION ANDSTEERING8-31 11. Installlapcoolerandfootshowerductwork. 12. Installtheupperandlowersteeringcolumn covers. 13. Installthekneeprotector andswitches. 14. Installthehoodreleasehandle. 15. Installthesteeringwheel,asoutlinedearlier inthissection. 16. Connect thenegative batterycableandcheck all functionsof column-mounted switches andtheignitionswitchfor properoperation,

REMOVAL&INSTALLATION Tie Rod Ends u See Figures 86 thru 94

1.’ Disconnect thenegative batterycable. 2. Remove thewheelandtireassembly. 3. Remove thecotterpinandthecastellated nut fromtheoutertierodend.Discardthecotterpin. 4. Separate theoutertie rodendfromthesteeringknuckleusinganappropriate tie rodendremover. 5. Marktheoutertierodjamnutononeside witha reference linefor installation. 6. Holdtheoutertie rodendwitha wrenchand loosenthetie rodendjamnut. 7. BackthetierodendjamnutoffONEFULL TURNONLY. 8. Remove theoutertierodendfromtheinner tie rodspindle. To install: 9. Cleanthethreadsontheinnertie rodspindle (frontwheelspindleconnecting rod). 10. Threadthenewoutertierodendontotheinnertie roduntilit bottomsonthejamnut.

11. Backthetierodandjamnutoutonefull turn untilthereference lineis inthesamepositionasbefore. 12. Placetheoutertie rodendstudintothesteeringknuckle.Setthefrontwheelsina straightahead position. 13. Connect theoutertierodendto thesteering knuckleandinstallthecastlenut.Tightenthenutto 25ft. Ibs.(34Nm)onMiragemodelsand21ft. Ibs. (29Nm)ontheGalantandDiamante models. 14. Continue to tightenthecastellated nutuntila newcotterpincanbeinserted throughtheholeinthe stud.Installa newcotterpin. 15. If required, repeattheprocedure fortheoppositeside, 16. Reinstall thewheelandtirea&embly.Tighten thelugnutsto 65-80ft. Ibs.(90-l 10Nm). 17. Reconnect thenegative batterycable. 18. Tightenthetierodendjamnutto 30ft. Ibs.

Fig. 88 A special puller is recommendedfor removing the tie rod end from the steering knucklewithout damagingthe tie rod end

Fig. 89 Remove the Be rod end from the steering knuckle * g3’5a~51

Fig. 91 Use two wrenches, one to hold the inner tie rod, and one to loosen the jam nut

93158p29

Fig. 92 Backthe jam nut off ONETURNOMLY .*m

Fig. 98 . . . then unthreadthe tie rod end from the inner tie rod

Fig. 94 Removethe tie rod end from the vehicle

.

8132 SUSPENSION ANDSTEERING (42 Nm) on Mirageand 36-39 ft. tbs. (49-53 Nm) on Galantand Diamantemodels. 19. Havethe front end alignmentchecked,and adjustedif necessary.

Inner Tie Rods 1. Raisethe front of the vehicleand supportit on jackstands. 2. Removethe wheel. 3. Removethe cotterpin andthe outertie rod ball joint stud nut. Notethe position of the steering linkage. 4. Wire brushthe threadson the tie rod shaft and lubricatewith penetratingoil. 5. Usinga suitableball joint separatortool, removethe tie rod ball joint from the steeringknuckle. 6. Loosenthe locknutand removethe tie rod endfrom the tie rod. Countthe numberof complete turns it takesto completelyremoveit. 7. Removethe tie rod-to-steeringgear locknut. 8. Removethe clampsthat securethe flexible boot to the steeringgear. 9. Slide the boot from the innertie rod and removethe boot. IO. Bendthe lock platetabs from the innertie rod end nut.

11. Loosenthe innertie rod end nut from the steeringgearand removethe innertie rod end.

To install: 12. Usinga newlock plate,installthe tie rod end andtightenthe tie rod to 65 ft. Ibs. (90 Nm). 13. Bendthe tabs of the new lock plateto secure the inner tie rod end. 14. Slide the boot ontothe steeringgearand secure it with newclamps. 15. Installthe outertie rod end to the steering gearlocknut. 16. Installthe outertie rod end,turning it in exactly as manyturns as it wasto removethe old one. Make sure it is correctlypositionedin relationshipto the steeringlinkage. 17. Connectthe outertie rod end to the steering knuckleand installthe castlenut.Tightenthe nut to 25 ft. Ibs. (34 Nm,) on the Mirage and 21 ft. Ibs. (29 Nm) on the Galantand Diamantemodels. 18. Installa newcotterpin to the castlenut. 19. Tightenthe tie rod end locking nut to 30 ft. Ibs. (42 Nm) on the Mirage and 36-39 ft. Ibs. (49-53 Nm) on the Galantand Diamantemodels. 20. Installthe wheeland tire assembly. 21. Lowerthe vehicle. 22. Havea front end alignmentperformed.

REMOVAL &INSTALLATION Mirage ) See Figure 95 *Prior to removal of the steeringrack, center the front wheels and removethe ignition key. Failure to do so may damagethe SRS clockspringand render SRSsysteminoperative. Be sure to properly disarmthe air bag system. 1. Disconnectthe batterynegativecable. 2. Raisethe vehicleand supportsafelyand removethe wheels. 3. Disconnectthe HeatedOxygen(HOzS)sensor and removethe front exhaustpipe. 4. Properlysupportthe engine.Removeboth roll stoppermountingbolts and the four centermember installationbolts. 5. Removethe centermember.

18 Nm 13 ft.lbs. 4.9 Nm 3.6 ft.lbs. 15 - 33 Nm / 11 - 25 ft.lbs. 7

03

L 69 Nm 51 ftlbs.

1. Steering shaft assembly and gear box connecting bolt 2. Band 3. Cotter pin I 4. Tie-rod end and knuckle connection Fig. 95 Explodedview of the manualsteering gear mounting-Mlrage

11 - 25 ft.lbs.

5. Cylinder clamp 6. Gear housing clamp 7. Gear box assembly 8. Steering cover assembly

SUSPENSION ANDSTEERING8-33 *Matchmark the pinion input shaft of the rack to the lower steering columnjoint for installation purposes. 6. Removethe pinch bolt holdingthe lower steeringcolumnjoint to the rackand pinion input shaft. 7. Removethe cotterpins and disconnectthe tie rod endsfrom the steeringknuckle. 8. Removethe rackand pinion steeringassembly and its rubbermountsfrom the right side of the vehicle.

To install: 9. Align the matchmarksof the inputshaftand install the rackto the vehicle. 10. Securethe rackusingthe retainerclampsand bolts.Tightenthe bolts to 51 ft. Ibs. (70 Nm). 11. Tightenthe steeringcolumnpinch bolt to 13 ft. Ibs. (18 Nm). 12. Installthe centermember. 13. Installthe front exhaustpipe. 14. Connectthe HO$ sensor. 15. Connectthe tie rod endsto the steering knucklesandtightenthe castlenutsto 25 ft. Ibs. (34 Nm). Installnewcotterpins. 16. Installthe wheelsand connectthe negative batterycable. 17. Havea front endalignmentperformed.

REMOVAL&INSTALLATION Diamante FRONT

*Prior to removal of the steering gear box, centerthe front wheels and removethe ignition key. Failure to do so may damagethe SRSclock spring and renderSRSsysteminoperative. 1. Disconnectthe negativebatterycable. 2. Disconnectthe front exhaustpipe. 3. If equippedwith AWD, removethe transfer caseassembly. 4. Removethe bolt holdingthe lowersteering columnjoint to the rackand pinion inputshaft. 5. Removethe cotterpins and disconnectthe tie rod ends. 6. Removethe leftand right framemembers. 7. Removethe stabilizerbar bracket. 8. If equippedwith four-wheelsteering,disconnectthe lines going to the rearpump. 9. Removethe rackand pinion steeringassembly and its rubbermounts.Move the rackto the right to removeit from the crossmember.

To install:

IO. Installthe rackandmountingbolts.Tighten the bolts to 51 ft. Ibs.(70 Nm).Wheninstallingthe rubberrackmounts,align the projectionof the mountingrubberwith the indentationin the cross: member.Installthe pinch bolt. 11. Connectthe pressureand returnlines to the rackand to the rearpump,if equipped. 12. Installthe framemembersand tightenthe bolts to 43-51 ft. Ibs. (60-70 Nm). 13. Connectthe tie rods and install newcotter pins.

14. Installthe transfercaseandfront exhaust pipe. 15. Refillthe reservoirand bleedthe system. 16. Havea front end alignmentperformed. REAR 1. Disconnectthe negativebatterycable. 2. Raisethe vehicleand supportsafely. 3. Drainthe powersteeringfluid. 4. Removethe main mufflerassembly. 5. Removethe rearshockabsorberlower mountingbolts. 6. Usingthe properequipment,supportthe weightof the reardifferential.Removethe 2 small crossmemberbrackets. 7. Removethe largeself-lockingcrossmember mountingnutson the differentialside. 8. Removethe oil line clamp bolts. 9. Removethe pressuretubes. IO. Hold the tie rod endsstationaryand remove the tie rod end nuts.Removethe tie rod endsfrom the trailing arms. 11. Removethe mountingbolts and removethe rearsteeringgear.

To install: 12. Securethe unit to the crossmember.Move the powercylinderpiston rod over its full stroketo determineits neutralposition. 13. Align the tie rod endswith the holes in the trailing armsand installthe nuts.Adjustthe lengthof the tie rods with the nuts if necessary.The difference in lengthbetweenthe 2 tie rod endsshouldnot exceed0.04 in. (1mm).The nuts’torquespecificationis 42 ft. Ibs. (58 Nm). 14. Replacethe O-ringsand installthe pressure tubes.Clampin place. 15. Installthe largeself-lockingcrossmember mountingnutson the differentialside.Tightento 80-94 ft. Ibs. (110-130 Nm). 16. Removethe supportequipment. 17. Installthe 2 small crossmemberbrackets. 18. Installthe shockmountingbolts. 19. Installthe mufflerassembly. 20. Refillthe reservoirand bleedthe system. 21. Havea front endalignmentperformed. _

Galant 1990-93 MODELS 1. Disconnectthe negativebatterycable. 2. Drainthe powersteeringfluid. 3. Raisethe vehicleand supportsafely. 4. Removethe bolt holding lowersteeringcolumn joint to the rackand pinion input shaft. 5. Removethe transfercase,if equipped. 6. Removethe cotterpins and using the proper tools, separatethe tie rod endsfrom the steering knuckle. 7. Locatethe triangularbracenearthe stabilizer bar bracketson the crossmemberand removeboth the braceand the stabilizerbar bracket. 8. Supportthe centercrossmember. 9. Removethe through-boltfrom the roundroll stopperand removethe rearbolts from the center crossmember. 10. Disconnectthe front exhaustpipe, if equippedwith FWD. 11. Disconnectthe powersteeringfluid pressure pipe and returnhosefrom the rackfittings. Plugthe fittings to preventexcessfluid leakage.

12. Lowerthe crossmemberslightly. 13. Removethe rackand pinion steeringassembly and its rubbermounts.Move the rackto the right to removefrom the crossmember.Tilt the assembly downwardand removefrom the left side of the vehicle. Usecautionto avoid damagingthe boots.

To install:

14. Installthe rackand installthe mountingbolts. Tightenthe mountingbolts to 43-58 ft. Ibs. (60-80 Nm).Wheninstallingthe rubberrackmounts,align the projectionof the mountingrubberwith the indentation in the crossmember. 15. Connectthe powersteeringfluid lines to the rack. 16. Connectthe exhaustpipe, if removed. 17. Raisethe crossmemberinto position.Install the centermembermountingbolts andtightento 72 ft. Ibs. (100 Nm). Installthe roll stopperbolt and new nut.Tightennut to 47 ft. Ibs. (65 Nm). 18. Installthe stabilizerbar bracketsand brace. 19. Connectthe tie rod endsand tightennutsto 25 ft. Ibs. (34 Nm). 20. Installthe transfercase,if removed.Check and fill fluid. 21. Refillthe reservoirwith powersteeringfluid and bleedthe system. 22. Havea front end alignmentperformed. 1994-M MODELS

+ See Figure 96

Prior to removal of the steering gear box, centerthe front wheels and removethe ignition key. Failure to do so may damagethe SRSclock springand renderSRSsysteminoperative. 1. Disconnectthe negativebatterycable. 2. Raiseand properlysupportthe vehicle. 3. Removeboth front wheelassemblies. 4. Removethe bolt holding lowersteeringcolumn joint to the rackand pinion input shaft. 5. Removethe stabilizerbar. 6. Removethe cotterpins, and using joint separator MB991113 or equivalent,disconnectthe tie rod endsfrom the steeringknuckle. 7. Onvehiclesequippedwith ElectronicControl Powersteering(EPS),detachthe wiring harnessfrom the solenoidconnector. 8. Locatethe two triangularbracesnearthe crossmemberand removeboth. 9. Supportthe centercrossmember.Removethe through-boltfrom the front round roll stopperand remove the bolts securingthe centercrossmember. 10. Removethe centercrossmember. Il. Properlysupportthe engineand removethe rear roll stopperthrough-bolt. 12. Disconnectthe powersteeringfluid pressure pipe and returnhosefrom the rackfittings. Plugthe fittings to preventexcessivefluid leakage. 13. Removethe clamp boltsand the two bolts securing the rackassemblyto the chassis. 14. Removethe rackand pinion steeringassembly and its rubbermounts.

*When removingthe rack and pinion assembly,tilt the assemblyto the vehicle side of the compressionlower arm and remove from the left side of the vehicle.

,

8-34 SUSPENSION ANDSTEERING' 7

43 Nm*

24-33 18-24

18 Nm

Nm ttlbs.

.

15 Nm

11 ftlbs.

6

57 Nm 42 ft.lbs.

\1- 69

Nm 51 ft.lbs.

’

78-86 58-65

\

24-33 Nm 18-24 ft.1 bs.

Nm ft.lbs. 69-78 51-58

1. Joint assembly and gear box connecting bolt 2. Cotter pin 3. Connection for tie rod end and knuckle 4. Stay 5. Center member assembly 6. Clamp 7. Bott

Nm ftlbs.

I

8. Gear box assembly

Caution The fasteners marked * should be temporarily tightened before they are finally tightened once the total weight of the engine has been placed on the vehicle body. 7923PGAl

Fig. 96 Exploded view of the power steering gear removal procedure- -Galant To install: 15. Centerthe rackassemblyand insertthe pinion into the steeringcolumnshaft. 16. Installthe rackand mountingbolts.Tighten the mountingbolts to 51 ft. Ibs. (69 Nm). 17. Installthe pinch bolt and tightenthe bolt to 13 ft. Ibs. (18 Nm). 18. Connectthe powersteeringfluid lines to the rackandtightenthe pressurehosefitting to 11 ft. Ibs. (15 Nm). Securethe returnhosewith the clamp. 19. Raisethe engineinto position. 20. Installthe rear roll stopperthrough-boltand I tightento 32 ft. Ibs. (43 Nm). 21. Raisethe crossmemberinto position.Install _the centermembermountingbolts;tightenthe front bolts to 58-65 ft. Ibs. (78-88 Nm) and the rear bolt to 51-58 ft. Ibs. (69-78 Nm). 22. Installthe front roll stopperbolt andtighten the nut to 32 ft. Ibs. (43 Nm). 23. Installthe two triangularbracesand tighten the mountingboltsto 50-56 ft. Ibs. (69-78 Nm).

24. Installthe stabilizerbar. 25. Connectthe tie rod endsandtightenthe nuts to 20 ft. Ibs. (27 Nm). 26. Onvehiclesequippedwith EPS,connectthe wiring harnessto the solenoidconnector. 27. Installthe wheelassembliesand lowerthe vehicle. 28. Refillthe reservoirwith powersteeringfluid and bleedthe system. 29. Havea front end alignmentperformed. Mirage 1990-92 MODELS I. Disconnectthe batterynegativecable. 2. Raisethe vehicleand supportsafely. 3. Removethe pinch bolt holdingthe lower steeringcolumnjoint to the rackand pinion input shaft.

4. Removethe cotterpins and disconnectthe tie rod endsfrom the steering’knuckle. 5. Disconnectthe powersteeringfluid pressure pipe and returnhosefrom the rackfittings. 6. Removethe rackand pinion steeringassembly and its rubbermounts. To install: 7. Installthe steeringgearinto the vehicleand secureusingthe retainerclampsand bolts. 8. Connectthe powersteeringfluid linesto the rackfittings. 9. Installthe stabilizerbarand reartransaxle bracket. 10. Connectthe tie rod endsto the steering knuckles. ll= Connectthe negativebatterycable. 12. Refill the reservoirand bleedthe system. 13. Havea front end alignmentperformed.

SUSPENSION ANDSTEERING8-35

1. Steering shaft assembly and gear box connecting bolt 2. Band 3. Cotter pin 4. Tie-rod end and knuckle connection 5. Return tube connection

6. 7. 8. 9.

Pressure tube connection Cylinder clamp Gear housing clamp Gear box assembly 10. Steering cover assembly 7923PGAl

FiD=97 Explodedview of the power steering gear assembly-Mirage To install:

1993-90 MODELS

) See Figure 97 *Prior to removal of the steering gear box, centerthe front wheels and removethe ignition key. Failure to do so may damagethe SRSclockspringand renderSRSsysteminoperative. ,mr;iin thepower steeringsystem. 2. Disconnectthe batterynegativecable.Raise the vehicleand supportsafely. 3. Disconnectthe HeatedOxygen(HOPS)sensor and removethe front exhaustpipe. 4. Properlysupportthe engine. 5. Removeboth roll stoppermountingbolts and the four centermemberinstallationbolts. Removethe centermember. 6. Removethe centermember.

stallation purposes.

-

7. Removethe pinch bolt holdingthe lower steeringcolumnjoint to the rackand pinion input shaft. 8. Removethe cotterpins and disconnectthe tie rod endsfrom the steeringknuckle. 9. Disconnectthe powersteeringfluid pressure pipe and returnhosefrom the rackfittings. IO. Removethe rackand pinion steeringassembly and its rubbermountsfrom the right side of the vehicle.

11. Align the matchmarksof the inputshaftand install the rackto the vehicle. 12. Securethe rackusing the retainerclampsand bolts.Tightenthe bolts to 51 ft. Ibs. (70 Nm). 13. Tightenthe steeringcolumnpinch bolt to 13 ft. Ibs. (18 Nm). 14. UsingnewO-rings,connectthe powersteering fluid lines to the rackfittings. 15. Installthe centermember. 16. Installthe front exhaustpipe. 17. Connectthe H02Ssensor. 18. Connectthe tie rod endsto the steering knucklesand tightenthe castlenutsto 25 ft. Ibs.(34 Nm). Installnewcotterpins. 19. Installthe wheelsand connectthe negative batterycable. 20. Refill‘thereservoirand bleedthe system. 21. Havea front endalignmentperformed.

REMOVALANDINSTALLATION

2. Disconnectthe batterynegativecable. 3. Removethe pressureswitch connectorfrom the side of the pump. 4. If the alternatoris locatedunderthe oil pump, cover it with a shop towelto protectit from oil. 5. Disconnectthe pressureline. 6. Removethe steeringpumpdrive beltand the waterpumppulleydrive belt. 7. Removethe waterpumppulley. 8. Removethe boltsthat securethe oil pump, then removethe pumpfrom its bracket.

To install: 9. Installthe powersteeringpumpand tighten the mountingbolts to specifications. IO. Installthe waterpumppulleyandtightenthe mountingbolts 14 ft. Ibs. (19 Nm). 11. Installand adjustthe drive belts. 12. Replacethe O-ringsand connectthe pressure line. Connectthe pressureline so the notchin the fitting aligns and contactsthe pump’sguide bracket. Tightenthe nut that securesthe pressureline to 13 ft. Ibs. (18 Nm). 13. Connectthe returnline. 14. Attachthe pressureswitchconnector. 15. Refillthe reservoirand bleedthe system.

Mirage 1, Drainthe powersteeringsystemas follows: a. Disconnectthe return hoseat the reservoir and place into a suitablecontainer. b. Disablethe ignition system.While cranking the engine,turn the wheelsseveraltimes, until systemhas beendrained.

1990-93 Galant FRONT 1. Disconnectthe batterynegativecable. 2. Removethe pressureswitchconnectorfrom the side of the pump.

8-36 SUSPENSION ANDSTEERING 3. If the alternatoris locatedunderthe oil pump, cover it with a shoptowelto protectit from oil. 4. Disconnectthe returnfluid line. 5. Removethe reservoircapand allow the return line to drain the fluid from the reservoir.If the fluid is contaminated,disconnectthe ignition high tensioncableand crankthe engineseveraltimesto drain the fluid from the gearbox. 6. Disconnectthe pressureline. 7. Removethe pumpdrive belt. 8. Removethe pumpmountingbolts and removethe pumpfrom the engine.

4 SL Engine>

To install: <1.8L

9. Installthe pump,wrapthe belt aroundthe pulleyand looselytightenthe mountingbolts. 10. Replacethe O-ringsand connectthe pressure line. Connectthe pressureline so the notch in the fitting aligns and contactsthe pump’sguidebracket. 1I. Connectthe returnline. Attachthe pressure switchconnector. 12. Adjustthe belttensionand tightenthe adjusting bolts to 25-33 ft. Ibs. (35-45 Nm). 13. Refill the reservoirand bleedthe system.

Engine>

REAR 1. Raisethe vehicleand supportsafely. 2. Drainthe differentialgearoil. 3. Matchmarkand removethe reardriveshaft. 4. Removethe rearhalfshafts. 5. Removethe centerexhaustpipe and muffler assembly,as required.

Removal 1. 2. 3. 4. 2

steps Drive belt Pressure switch Suction hose Pressure hose Elrg

7. 8. 9. 10. 11. 12.

connector

BoIt Bolt Oil Oil Oil Oil

pump pump pumo pump

brace bracket bracket

stay

93158gal

Explodedview of the power steering pump-Mirage

14-Z

Nm

35-45 25-33

Nm ft.lbs.

9

9-14

7-10

Nm klbs.


g-lb 7-10 6/

2

Explodedview of the front power steering pump-1990-93 Galant

without

Nm ft.lbs.
4WSP

with

4WS

SUSPENSION ANDSTEERING8-37 19-28 14-20 /

16. Lowerthe vehicle.With the vehicle level,fill the reardifferential. 17. Fill the powersteeringsystemand properly bleed.

Nm klbs. 12-18 Nm 9- 13 ft.lbs.

1994-00 Galant

2rd

2.4L ENGINE 1. Disconnectthe batterynegativecable. 2. Loosenand removethe powersteeringpump drive belt. 3. Removethe pressureswitchconnectorfrom the side of the pump.

,

*If the alternator is locatedunderthe oil pump,cover it with a shoptowel to protectit frqm oil. 4. Disconnectthe returnfluid line. Removethe reservoircapand allow the returnline to drain the fluid from the reservoir.If the fluid is contaminated, disconnectthe ignition high tensioncableand crank the engineseveraltimes to drain the fluid from the gearbox. 5. Disconnectthe pressureline. 6. Unboltand removethe pumpfrom the mountingbracket.

To install:

1. 2. 3. 4.

7. Installthe pump,wrapthe belt aroundthe pulleyand lightly tightenthe mountingbolts. 8. Replacethe O-ringsand connectthe pressure line. Connectthe pressureline so the notch in the fitting aligns and contactsthe pump’sguide bracket. Tightenthe fitting to 13 ft. Ibs.(18 Nm). 9. Connectthe returnline and securewith the clamp. IO. Attachthe pressureswitchconnector.

Feed tube O-ring Rear oil pump O-ring 93158ga:

Explodedview of the rear power steering pump-1990-93 Galant 6. Disconnectthe pressureand suction hoses from the fittings on the pump. 7. The largemountingbolts that hold the differential carriersupportplateto the underbodymayuse self-lockingnuts.Beforeremovingthem,supportthe rearaxleassemblyin the middlewith a transaxle jack. Removethe nuts,then removethe support plate(s)andthe squaredynamicdamperfrom the rear of the carrier. 8. Lowerthe differentialcarrierandremovefrom the vehicle. 9. Removethe pumpretainingbolt and remove the pumpfrom the reardifferentialassembly.

<2.4L

ENGINE> 12 N-m

12 N-m

<3.OL ENGINE>

To install: IO. Installthe pumpandtightenthe mounting bolt to 14-20 ft. Ibs. (19-28 Nm). 11. Raisethe reardifferentialcarrier into position and install supportmemberbolts. Replaceall selflocking nuts.Tightenall mountingnutsand bolts as follows: l Uppersupportplateto carrier bolts: 72-87 ft. Ibs. (100-120 Nm) l Supportmember/dynamicdamperto carrier bolts: 58-72 ft. Ibs. (80-100 Nm) l Differentialsupportmembermountingbolt nuts: 80-94 ft. Ibs. (110-130 Nm) 12. Connectthe pressureand suction linesto the pump. 13. Install newcirclips on both reardriveshafts I and install. 14. Installthe propellershaftand tightenthe mountinghardwareto 22-25 ft. Ibs. (30-35 Nm). 15. Installthe centerexhaustpipe and muffler.

32 ft-lb

1. 2. 3. ;

DRIVE BELT PRESSURE SWITCH SUCTION HOSE i’;;‘;;RE HOSE

CONNECTOR

7. BOLT 8. ~O~~~E;TEER’NG 9. OIL PUMP 10. OIL PUMP

PUMP

BRACKET

6. BOLT 93158gal

Explodedview of the power steering pump-1994-00 Galantwith 2.4L engine

1

- 8-38 SUSPENSION ANDSTEERING 11. Adjustthe powersteeringbelt for propertension and tightenthe adjustingbolts. 12. Reconnectthe negativebatterycable. 13. Refillthe reservoirand bleedthe system.

2. Disconnectthe returnfluid line. Removethe reservoircapand allow the returnline to drain the fluid from the reservoir.If the fluid is contaminated, disconnectthe ignition high tensioncableand crank the engineseveraltimes to drain the fluid from the gearbox. 3. Removethe powersteeringpumpdrive belt. 4. Removethe pressureswitchconnectorfrom the side of the pump. 5. If the alternatoris locatedunderthe oil pump, cover it with a shop towelto protectit from oil. 6. Disconnectthe high pressurehoseandthe returnhosefrom the pump. 7. Removethe pumpdrive belt and unboltthe pumpfrom its bracketand removethe pump.

3.Of EIJGINE 1. Disconnectthe batterynegativecable. 2. Disconnectthe returnfluid line. Removethe reservoircapand allow the returnline to drain the fluid from the reservoir.If the fluid is contaminated, disconnectthe ignition high tensioncableand crank the engineseveraltimes to drain the fluid from the gearbox. 3. Removethe powersteeringpumpdrive belt. 4. Removethe pressureswitchconnectorfrom the side of the pump. 5. If the alternatoris locatedunderthe oil pump, cover it with a shop towelto protectit from oil. 6. Disconnectthe high pressurehoseand the returnhosefrom the pump. 7. Removethe pumpdrive belt and unboltthe pumpfrom its bracketand removethe pump.

To install:

To install: 8. Installthe pump,*rap the belt aroundthe pulleyand tightenthe bolts that securethe pumpto 17 ft. Ibs.(24 Nm). 9. Replacethe O-ringsand connectthe high pressurehose.Connectthe pressureline so the notch in the fitting alignsand contactsthe pump’s guide bracket.Tightenthe mountingnut with lockwasherto 17 ft. Ibs. (24 Nm). IO. Usinga newhoseclamp,connectthe return line. 11. Attachthe pressureswitchconnector. 12. Adjustthe belttensionand tightenthe adjusting bolts. 13. Refillthe reservoirand bleedthe system.

Diamante

*

FRONT

.

8. Installthe pump,wrapthe belt aroundthe pulleyand tightenthe boltsthat securethe pumpto 17ft. Ibs. (24 Nm). 9. Replacethe O-ringsand connectthe high pressurehose.Connectthe pressureline so the notch in the fitting aligns and contactsthe pump’s guidebracket.Tightenthe mountingnut with lockwasherto 17 ft. Ibs. (24 Nm). 10. Using a newhoseclamp,connectthe return line. Il. Attachthe pressureswitchconnector. 12. Adjustthe belttensionand tightenthe adjusting bolts. 13. Refillthe reservoirandbleedthe system.

REAR 1. Disconnectthe negativebatterycable. 2. Drainthe powersteeringfluid. 3. Removethe rearpowersteeringpumpheat protector,locatedon the engineside of the differential on the transaxle. 4. Disconnectthe pressureline from the pump. 5. Disconnectthe suction hosefrom the pump. 6. Removethe mountingbolts and removethe pumpfrom the transaxle.

1. Disconnectthe batterynegativecable.

’

I

5. POWER STEERING BRACKET STAY 6. OIL PUMP

PUMP

93158ga5

Explodedview of the power steering pump-Diamante

.

Extremecautionshouldbe takenwhen testing the rear steeringpump.Ensurethat the vehicle is supportedsafely and that all componentsare torquedto specificationprior be testing.

. SYSTEMBLEEDING ,Front 1. Raisethe vehicleand supportsafely. 2. Manuallyturn the pumppulleya few times. 3. Turn the steeringwheelall the wayto the left andto the right 5 or 6 times. 4. Disconnectthe ignition high tensioncable and,while operatingthe startermotor intermittently, turn the steeringwheelall the way to the letI and right 5-6 times for 15-20 seconds.Duringbleeding, makesurethe fluid in the reservoirneverfalls below the lowerposition of the filter. If bleedingis attemptedwith the enginerunning,the air will beabsorbedin the fluid. Bleedonly while cranking. 5. Connectignition high tensioncable,startengine and allow to idle. 6. Turn the steeringwheelleft and right until thereare no air bubblesin the reservoir.Confirmthat the fluid is not milky andthe level is up to the specified position on the gauge.Confirmthat thereis very little changein the fluid levelwhenthe steeringwheel is turned.If the fluid levelchangesmorethan0.2 in. (5mm),the air hasnot beencompletelybled.Repeat the process.

Rear

.

1. Bleedthe front steeringsystem. 2. Startthe engineand let it idle. 3. Loosenthe bleederscrewon the left side of the control valve and installspecialtool MB991230to the bleeder. 4. Turn the steeringwheelall the way to the left, then immediatelyturn it halfwayback.Confirmthat air hasdischargedwith the fluid. 5. RepeatStep4 two or threetimes as required, to removeall air from the rearsystem.Stopthe engine. 6. Loosenthe powercylinder(rearsteeringgear) bleederscrewaboutI/* turn and installthe same specialtool with the rotationpreventionmetalfixtures to preventthe bleederfrom openingmore. 7. Startthe engineand run to 50 mph to circulate the fluid. 8. Maintaina speedof 20 mph andturn the steering wheelbackand forth. Air should be discharged , throughthe tubeof the specialtool and into the oil reservoir. 9. Repeatuntil all air is removedfrom the power cylinder.

44 33

REMOVAL STEPS 1. DRIVE-BELT 2. SUCTION HOSE 3. PRESSURE HOSE 4. PRESSURE SWITCH CONNECTOR

7. The installationis the reverseof the removal procedure.Tightenthe mountingbolts to 17 ft. Ibs. (24Nm). 8. Refill the reservoirand bleedthe system.

SUSPENSION ANDSTEERliG 8-39 TORQUE SPECIFICATIONS Components Air bag retaining screws Front Suspension Damper fork-to-lateral arm (1994-98 Galant) Hub and bearing assembly-to-steering knuckle bolts Lower ball joint-to-steering knuckle I All Lower control arm Diamante, 1990-93 Galant, and 1999-00 Galant Rear mount clamp retaining bolts Rear mount clamp retaining nuts Frame mount through bolt 1994-98 Galant Lateral arm rear bolt Compression arm retaining bolt Mirage Front mount Rear mount Shock absorber and coil spring-to-body nuts 1994-98 Galant Shock absorber and coil spring-to-damper fork through bolt 1994-98 Galant Shock absorber and coil spring-to-damper fork pinch bolt Mirage Strut-to-body mounting bolts/nuts Diamante, 1990-93 Galant, and 1999-00 Galant Mirage Strut-to-steering knuckle mounting bolts Diamante, 1990-93 Galant, and 1999-00 Galant Mirage Sway bar mount retaining bolts 1994-00 Galant Diamante Mirage Sway bar links-to-damper fork (1994-98 Galant) Tie-rod end-to-steering knuckle nuts Mirage Galant and Diamante Tie rod end jam nut Mirage . Galant and Diamante Upper ball joint-to-steering knuckle nut (1994-98 galant) Upper control arm-to-shaft through bolts (1994-98 Galant) Upper control arm-to-body nuts (1994-98 Galant) Wheel hub retaining nut Manual rack and pinion Steering shaft upper pinch bolt Rack retainer bolts Power rack and pinion Front Inner tie rod-to-rack and pinion Steering shaft upper pinch bolt I Diamante Except Diamante Rack retainer bolts Diamante 1990-93 Galant 1994-00 Galant Mirage

.

English 48 inch Ibs.

Metric 5Nm

64 ft. Ibs. 65 ft. Ibs.

88 Nm 88 Nm

43-52 ft. Ibs.

60-72 Nm

72-87 ft. Ibs. 29 ft. Ibs. 75-90 ft. Ibs.

100-120 Nm 40 Nm 102-l 22 Nm

71-85 ft Ibs. 60 ft. Ibs.

98-l 18 Nm 83 Nm

65 ft. tbs. 78 ft. Ibs.

90Nm 108 Nm

32 ft. Ibs.

44 Nm

65 ft. Ibs.

88 Nm

76 ft. Ibs.

103 Nm

33 ft. tbs. 29 ft. Ibs.

45 Nm 40 Nm

70-76 ft. Ibs. 80-94 ft. Ibs.

90-105 Nm 110-130 Nm

28 ft. Ibs. 32 ft. Ibs. 16 ft. Ibs. 29 ft. Ibs

39 Nm 44 Nm 22 Nm 40 Nm

25 ft. Ibs. 21 ft. Ibs.

34 Nm 29 Nm

30 ft. tbs. 36-39 ft. Ibs. 20 ft. Ibs. 41 ft. Ibs. 62 ft. Ibs. 145-188 ft. Ibs.

42 Nm 49-53 Nm 28 Nm 57 Nm 86 Nm 200-260 Nm

13 ft. Ibs. 51 ft. lbs.

18Nm 70 Nm

65 ft. Ibs.

88 Nm

21 fta Ibs. 13 ft. Ibs.

29 Nm l8Nm

51 ft. Ibs. 43-58 ft. Ibs 51 ft. Ibs. 51 ft. Ibs.

70Nm 60-80 Nm 70 Nm 70 Nm

-

93158cOl

8-40 SUSPENSION ANDSTEERING TORQUE SPECIFICATIONS Components Rear Rack retainer bolts Diamante Power steering pump Hose fittings Front pump retaining bolts Mirage 1990-93 Galant 1994-00 Galant Diamante Rear pump retaining bolts 1990-93 Galant Diamante Rear suspension Axle retaining nut 1990-92 Mirage 1993-00 Mirage 1990-93 Galant w/drum brakes 1990-93 Disc brakes Lower control arm Diamante Control arm-to-trailing arm nut Control arm-to-crossmember Galant Rear mount Ball joint-to-knuckle Strut Upper mounting nuts Diamante 1990-93 Galant 1994-00 Galant Mirage Lower strut mounting bolt All models Sway bar mount retaining bolts Diamante and 1994-00 Galant 1990-93 Galant Trailing arm-to-body through bolt 1990-93 Galant 1993-00 Mirage 1994-00 Galant and 1997-00 Diamante 1992-96 Diamante Upper ball joint retaining nut 1990-93 Galant 1994-98 Galant Upper control arm retaining bolts 1990-93 Galant 1994-98 Galant Diamante Wheel hub mounting bolts Steering wheel retaining nut 1990-93 Galant 1994-00 Diamante All other models Wheel lug nuts

English

Metric

51 ft. Ibs

70 Nm

13 ft. Ibs,

18 Nm

14 ft. Ibs. 25-33 ft. tbs. 17 ft. tbs. 17 ft. Ibs.

19 Nm 35-45 Nm 24 Nm 24 Nm

25-33 ft. Ibs. 17 ft. Ibs.

35-45 Nm 24 Nm

108-145 ft. Ibs. 130 ft. Ibs. 20 ft. Ibs. 145-188 ft. Ibs.

150-200 Nm 180 Nm 27 Nm 200-260 Nm

54-61 ft. Ibs. 54-61 ft. Ibs.

75-89 Nm 75-89 Nm

72 ft. Ibs. 43-52 ft. Ibs.

100 Nm 60-72 Nm

33 ft. Ibs. 29 ft. Ibs. 32 ft. Ibs. 20 ft. Ibs.

45 Nm 40 Nm 44 Nm 28 Nm

71 ft. Ibs.

98 Nm

28 ft. Ibs. 33 ft. tbs.

39 Nm 45 Nm

72-87 ft. Ibs. 72-87 ft. Ibs. 99414 ft. Ibs. 101-116 ft. Ibs.

100-120 Nm 100-120 Nm 137-157 Nm 140-160 Nm

52 ft. Ibs. 71 ft. Ibs.

72Nm 98 Nm

116 ft. Ibs. 28 ft. Ibs. 54-61 ft. Ibs. 54-65 ft. Ibs.

160 Nm 39 Nm 75-89 Nm 74-88 Nm

25-33 ft. Ibs. 33 ft. Ibs. 29 ft Ibs. 65-80 ft. Ibs.

35-45 Nm 45 Nm 40 Nm 90-l IO Nm

*

93158co2