Mitsubishi EVO VIII 260 User manual

33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 33-2
SERVICE SPECIFICATIONS. . . . . . . 33-3
SPECIAL TOOLS. . . . . . . . . . . . . . . . 33-3
ON-VEHICLE SERVICE. . . . . . . . . . . 33-4
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 33-4
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5
BALL JOINT DUST COVER CHECK . . . . . 33-5
STRUT ASSEMBLY. . . . . . . . . . . . . . 33-6
REMOVAL AND INSTALLATION . . . . . . . . 33-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 33-6
DISASSEMBLY AND ASSEMBLY . . . . . . . 33-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-9
LOWER ARM . . . . . . . . . . . . . . . . . . . 33-10
REMOVAL AND INSTALLATION . . . . . . . . 33-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-11
BALL JOINT DUST COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM PILLOW BALL BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
STABILIZER BAR* . . . . . . . . . . . . . . . 33-14
REMOVAL AND INSTALLATION . . . . . . . . 33-14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-16
CROSSMEMBER BAR . . . . . . . . . . . . 33-17
REMOVAL AND INSTALLATION . . . . . . . . 33-17
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
•Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
passenger (from rendering the SRS inoperative).
•Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
•MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance)
are indicated in the table of contents by an asterisk (*).

GENERAL DESCRIPTION
FRONT SUSPENSION
33-2
GENERAL DESCRIPTION
M1332000100311
A MacPherson strut independent suspension-type
suspension is used for the front suspension.
Aggressive use of special components that include
Mitsubishi Motor’s own inverted struts and forged
aluminium parts reduces weight to create a
suspension that gives superior performance made
with competition use in mind.
CONSTRUCTION DIAGRAM
SPECIFICATIONS
COIL SPRING
AC211383AC
Stabilizer bar
Lower arm assembly
(forged aluminum)
Front axle No.1
crossmember
Strut (inverted strut)
Strut insulator
Coil spring
Stabilizer link
(pillow ball bushing)
Front axle
crossmember bar
Lower arm bushing
(pillow ball bushing)
Item Specification
Wire diameter mm 14
Average diameter mm 155
Free length mm 286

SERVICE SPECIFICATIONS
FRONT SUSPENSION 33-3
SERVICE SPECIFICATIONS
M1332000300456
NOTE: *: Default factory setting
SPECIAL TOOLS
M1332000600350
Item Specification
Toe-in mm 0 ±2
Steering angle Inner wheel 31°45’ ±1°30’
Outer wheel (reference) 27°15’
Camber (selectable from 2 options) −1°00’ ±30’* or −2°00’±30’(Left/right
deviation within 30')
Caster 3°55' ±30' (Left/right deviation within 30')
Kingpin inclination 13°45' ±1°30'
Lower arm ball joint breakaway torque N⋅m0.5−3.4
Lower arm pillow ball bushing rotation starting torque N⋅m0.5−3.0
Stabilizer link ball joint turning torque N⋅m 1.7 −3.2
Tool Number Name Use
A: MB991237
B: MB991238
A: Spring compressor
body
B: Arm set
Coil spring compression
MB991680
A: MB991681
B: MB991682
Wrench set
A: Wrench
B: Socket
Strut assembly
disassembly and
reassembly
MB991006 Preload socket Lower arm ball joint
rotation starting torque
measurement
MB990326 Preload socket Lower arm ball bushing
rotation starting torque
measurement
MB990800 Ball joint dust cover
installer
Lower arm ball joint dust
cover press-in
MB991237
A
B
MB991680
A
B
MB991006
MB990326
MB990800

ON-VEHICLE SERVICE
FRONT SUSPENSION
33-4
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1331000900541
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering
system, wheels, and tires should be serviced to
normal condition before measuring wheel alignment.
TOE-IN
Standard value: 0 ±2 mm
1. Adjust the toe-in by undoing the clip and jam nut,
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions).
NOTE: The toe will move out as the left
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
2. Install the clip and tighten the jam nut to the
specified torque.
Tightening torque: 52 ±2 N⋅m
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the
steering angle is at the standard value.
Standard value:
MB990651 Bar Lower arm pillow ball
bushing removal and
press-fitting
MB991816 Bushing remover &
installer base
MB991576 Base
MB991897 Ball joint remover Knuckle and tie rod end
ball joint disconnection
NOTE: Steering linkage
puller (MB990635 or
MB991113) is also
available to disconnect
knuckle and tie rod end
ball joint.
Tool Number Name Use
MB990883
MB991576
AC106827
AC006074 AB
Jam nut
Clip
Inner wheel 31°45’±1°30’
Outer wheel (for
reference)
27°15’

ON-VEHICLE SERVICE
FRONT SUSPENSION 33-5
CAMBER, CASTER AND KINGPIN
INCLINATION
Standard value:
NOTE: .
1. *1: difference between right and left wheels must
be less than 30’
2. *2: default factory setting
3. Caster and kingpin inclination are preset at the
factory and cannot be adjusted.
SELECTION THE CAMBER
Select the camber by the installation direction of the
arrow of the connecting bolt of the strut assembly
and the knuckle.
•-1°00’±30’: Install the bolt turning the arrow in
the direction of inside the vehicle.
•-2°00’±30’: Install the bolt turning the arrow in
the direction of outside the vehicle.
LOWER ARM BALL JOINT AXIAL PLAY
CHECK
M1332010900051
1. Raise the vehicle.
2. Remove the stabilizer bar from the lower arm
assembly.
3. Move the lower arm up and down with your hands
to check for excessive play in the axial direction of
the ball joint. If there is excessive play, replace the
lower arm assembly.
BALL JOINT DUST COVER CHECK
M1332008600398
1. Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.
2. If the dust cover is cracked or damaged, replace
the lower arm assembly.
NOTE: If the dust cover is cracked or damaged, it
is possible that there may also be damage to the
ball joint.
Item Specification
Camber (Selectable from
2 options) -1°00’*1, *2±30’* or
-2°00’±30’*1
Caster 3°55’±30’*1
Kingpin inclination 13°45’±1°30’
AC211728
<Camber: -1˚00´>
AB
<Camber: -2˚00´>

STRUT ASSEMBLY
FRONT SUSPENSION
33-6
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
M1332001100422
INSPECTION
M1332001200300
•Check for oil leaks from the strut assembly.
•Check the strut assembly for damage or
deformation.
Post-installation Operation
•Front Wheel Alignment Check and Adjustment (Refer to
P.33-4).
AC310743 AB
3
5
2
1
4
44 ± 5 N·m
167 ± 9 N·m
Removal steps
1. Front wheel speed sensor harness
bracket
2. Brake hose bracket
3. Knuckle connection
4. Strut mounting nut
5. Strut assembly

STRUT ASSEMBLY
FRONT SUSPENSION 33-7
DISASSEMBLY AND ASSEMBLY
M1332001300437
DISASSEMBLY SERVICE POINTS
<<A>> STRUT NUT REMOVAL
!
CAUTION
•Do not tighten the bolt of special tool spring
compressor body (MB991237) too tight.
Special tool spring compressor body
(MB991237) will be broken if the allowable
tightening torque of 74 N⋅m is exceed.
•Install special tool arm set (MB991238) evenly,
and so that the maximum length will be
attained within the installation range.
•Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237), otherwise the special tool will
break.
1. Use following special tools to compress the coil
spring.
•MB991237: Spring Compressor Body
•MB991238: Arm Set
AC310745
3
1
2
3
4
5
60 ± 10 N·m
6
7
8
9
AB
Disassembly steps
1. Strut cover
<<A>>>>A<<2. Strut nut
3. Strut insulator
4. Spring upper seat
5. Strut damper
6. Strut cover
7. Coil spring
8. Spring lower pad
<<B>>9. Front suspension strut
AC001085 AB
MB991238 MB991237

STRUT ASSEMBLY
FRONT SUSPENSION
33-8
!
WARNING
Do not use an impact wrench to remove the
strut nut.
•Vibration of the impact wrench will cause
special tools (MB991237 and MB991238)
to slip and cause personal injury.
•Vibration of the impact wrench will cause
the valve inside the strut to drop out.
2. Use following special tools to secure the strut, and
then remove the self-locking nut.
•MB991681: Wrench
•MB991682: Socket
<<B>> FRONT SUSPENSION STRUT
REMOVAL
!
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
The gas must be discharged from the front
suspension strut assembly before discarding it.
Place the strut horizontally with its piston rod
extended. Then drill a hole of approximately 3 mm in
diameter at the location shown in the illustration and
discharge the gas.
ASSEMBLY SERVICE POINTS
>>A<< STRUT NUT INSTALLATION
1. Ensure that the bearing is seated correctly.
2. Install following special tools to the strut assembly
same as its removal.
•MB991237: Spring Compressor Body
•MB991238: Arm Set
!
CAUTION
Do not use an impact wrench to tighten the bolt
of special tool spring compressor body
(MB991237), otherwise the special tool will break.
3. While the coil spring is being compressed by the
special tools, temporarily tighten the strut nut.
4. Align the hole in the strut spring lower seat with
the hole in the upper spring seat.
NOTE: Using a rod as shown facilitates the
alignment.
5. Correctly align both ends of the coil spring with
the grooves in the spring seat, and then loosen
the special tools.
AC006091 AB
MB991681
MB991682
AC001087
AC001085 AB
MB991238 MB991237
AC310747AB
Rod

STRUT ASSEMBLY
FRONT SUSPENSION 33-9
!
CAUTION
Do not use an impact wrench to tighten the strut
nut, otherwise the strut nut will be damaged.
Vibration of the impact wrench will cause the
valve inside the strut to dropout.
6. Using following special tools, tighten the strut nut
to 60 ±10 N⋅m.
•MB991681: Wrench
•MB991682: Socket
7. After tightening the strut nut, fill the multi purpose
grease to the bearing part of strut insulator.
INSPECTION
M1332001400229
•Check the strut bearing for wear or rust.
•Check the rubber parts for damage or
deterioration.
•Check the coil spring for deformation,
deterioration or damage.
•Check the front suspension strut for deformation.
AC211766AB
MB991681
MB991682
AC211769

LOWER ARM
FRONT SUSPENSION
33-10
LOWER ARM
REMOVAL AND INSTALLATION
M1332001600405
!
CAUTION
•During maintenance, take care not to contact the parts or tools to the caliper because the paint of
caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly.
•*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
Post-installation Operation
•Check the Dust Cover for Cracks or Damage by Pushing
it with Your Finger.
•Front Wheel Alignment Check and Adjustment (Refer to
P.33-4).
AC310744AB
5
3
186 ± 10 N·m*
108 ± 10 N·m
39 ± 5 N·m
2
5
4
1
39 ± 5 N·m
167 ± 9 N·m
3
Removal steps
1. Stabilizer link nut
2. Lower arm and knuckle connection
<<A>>3. Lower arm and crossmember
connection
4. Stabilizer bar bracket
5. Lower arm assembly
Removal steps (Continued)

LOWER ARM
FRONT SUSPENSION 33-11
REMOVAL SERVICE POINT
<<A>> LOWER ARM AND
CROSSMEMBER DISCONNECTION
Lift the transmission with a transmission jack, and
then withdraw the front mounting bolt on the left
lower arm assembly.
INSPECTION
M1332001700338
LOWER ARM BALL JOINT BREAKAWAY
TORQUE CHECK
1. After shaking the ball joint stud several times, use
special tool preload socket (MB991006) to
measure the breakaway torque of the ball joint.
Standard value: 0.5 −3.4 N⋅m
2. When the measured value exceeds the standard
value, replace the lower arm assembly.
3. When the measured value is lower than the
standard value, check that the lower arm ball joint
turns smoothly without excessive play. If there is
no excessive play, the ball joint can be reused.
PILLOW BALL BUSHING ROTATION
STARTING TORQUE CHECK
1. Insert the bolt to the lower arm pillow ball bushing.
In the opposite direction, insert the washer then
install the nut. After rotating the inner sleeve
(contained washer) several times, measure the
rotation starting torque of the lower arm pillow ball
bushing using special tool preload socket
(MB990326).
Standard value: 0.5 −3.0 N⋅m
2. When the measured value exceeds the standard
value, replace the pillow ball bushing.
3. When the measured value is lower than the
standard value, check that the lower arm pillow
ball bushing turns smoothly without excessive
play. If there is no excessive play, the pillow ball
bushing can be reused.
AC006133AE
Mounting bolt
Piece of wood
Garage jack
AC211826AB
BALL JOINT
MB991006
BALL JOINT
AC211844AB
PILLOW BALL JOINT
PILLOW BALL
BUSHING
MB990326

LOWER ARM
FRONT SUSPENSION
33-12
LOWER ARM BALL JOINT DUST COVER
CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
2. If the dust cover is cracked or damaged, replace
the lower arm.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint. When it is
damaged during service work, replace the dust
cover.
BALL JOINT DUST COVER
REPLACEMENT
M1332008200312
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Remove the dust cover.
2. Apply multipurpose grease to the lip and inside of
the dust cover.
3. Using special tool ball joint remover and installer
(MB990800), press the dust cover until it contacts
the lower arm assembly.
4. Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.
LOWER ARM PILLOW BALL BUSHING
REPLACEMENT
M1332008100412
Replace the bushing as follows:
1. Use following special tools to drive out the
bushing.
•MB990651: Bar
•MB991576: Base
•MB991816: Bushing Remover & Installer base
2. Set the bushing to the lower arm assembly so that
the bushing marking and the opening are as
shown in the illustration.
AC006135 AB
MB990800
Dust cover
AC211847AB
PILLOW BALL
BUSHING
AC211849
MB990651
MB991576MB991576
LOWER ARM
ASSEMBLY
MB991816
AB
AC211851
MARKING
60˚
AB

LOWER ARM
FRONT SUSPENSION 33-13
3. Use special tools to press in the bushing until its
outer tube is flush with the lower arm assembly
surface.
AC211852
MB990651
MB991576
LOWER ARM
ASSEMBLY
MB991816
AB
OUTER TUBE

STABILIZER BAR
FRONT SUSPENSION
33-14
STABILIZER BAR
REMOVAL AND INSTALLATION
M1332004000383
!
CAUTION
•Before removing the steering wheel and air bag module assembly, refer to GROUP 52B −Service
Precautions (P.52B-4) and Driver’s, Front Passenger’s Air Bag Module(s) and Clock Spring
(P.52B-113). Also, put the front wheels in straight-ahead position. Failure to do so may damage the
SRS clock spring and render the SRS air bag inoperative, which results serious driver injury.
•During maintenance, take care not to contact the parts or tools to the caliper because the paint of
caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly.
•*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
Stabilizer Bar Pre-removal Operation
•Steering Wheel - Driver’s Air Bag Module Assembly
Removal (Refer to GROUP 37, Steering Wheel P.37-15).
•Clock Spring Removal (Refer to GROUP 52B, Driver’s,
Front Air Bag Module(s) and Clock Spring P.52B-113).
•Front Axle Crossmember Bar Removal (Refer to
P.33-17).
•Front Axle No.1 Crossmember Assembly Removal (Refer
to GROUP 32, Crossmember P.32-11).
•Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-19).
Stabilizer Bar Post-installation Operation
•Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-19).
•Front Axle No.1 Crossmember Assembly Installation
(Refer to GROUP 32, Crossmember P.32-11).
•Front Axle Crossmember Bar Installation (Refer to
P.33-17).
•Clock Spring Installation (Refer to GROUP 52B, Driver’s,
Front Air Bag Module(s) and Clock Spring P.52B-113).
•Steering Wheel - Driver’s Air Bag Module Assembly
Installation (Refer to GROUP 37, Steering Wheel
P.37-15).
•Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
•Checking Steering Wheel Position with Wheels Straight
Ahead
•Front Wheel Alignment Check and Adjustment (Refer to
P.33-4).

STABILIZER BAR
FRONT SUSPENSION 33-15
AC310741AB
7
N
25 ± 5 N·m
39 ± 5 N·m
1
108 ± 10 N·m
49 ± 10 N·m
167 ± 9 N·m
52 ± 7 N·m*
9
8
21 ± 4 N·m
5
18 ± 2 N·m
6
10
4
3
39 ± 5 N·m
Removal steps
1. Stabilizer link
2. Stabilizer bar bracket
3. Lower arm and knuckle
connection
<<A>> 4. Tie rod end knuckle
connection
5. Steering shaft cover
6. Steering gear and joint
connection bolt
7. Rear roll stopper connection
bolt
<<B>> >>A<< 8. Stabilizer bracket
<<B>> >>A<< 9. Stabilizer bushing
<<B>> >>A<< 10. Stabilizer bar
Removal steps (Continued)

STABILIZER BAR
FRONT SUSPENSION
33-16
REMOVAL SERVICE POINTS
<<A>> TIE ROD END AND KNUCKLE
DISCONNECTION
!
CAUTION
•Do not remove the nut from ball joint. Loosen
it and use special tool ball joint remover
(MB991897) to avoid possible damage to ball
joint threads.
•Hang special tool ball joint remover
(MB991897) with a cord to prevent it from
falling.
1. Install special tool ball joint remover (MB991897)
as shown in the figure.
2. Turn the bolt and knob as necessary to make the
jaws of special tool ball joint remover (MB991897)
parallel, tighten the bolt by hand and confirm that
the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the
figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
<<B>> STABILIZER
BRACKET/STABILIZER
BUSHING/STABILIZER BAR REMOVAL
Carry out the following operations to ensure working
space in order to remove the fixture, the bushing and
the stabilizer bar.
1. Use a transmission jack to hold the crossmember,
remove the crossmember mounting nuts and
bolts.
!
CAUTION
Be careful not to lower the crossmember
excessively. The power steering return hose
bracket may deform if the crossmember is
lowered too much.
2. Lower the crossmember until the fixture, the
bushing and the stabilizer bar can be removed.
INSTALLATION SERVICE POINTS
>>A<< STABILIZER BAR/STABILIZER
BUSHING/FIXTURE/INSTALLATION
Align the stabilizer bar identification mark with the
right end of the bushing (LH).
INSPECTION
M1332002000321
•Check the stabilizer bushings for wear and
deterioration.
•Check the stabilizer bar for deterioration or
damage.
•Check all bolts for condition and straightness.
AC208247AE
Cord
Bolt
MB991897
Nut
Ball joint
AC106821
Knob
Parallel
Bolt
Good
Bad
AB
AC102600 AD
Piece of wood
Transmission
jack
AC006141AJ
Outside of vehicle
Stabilizer bushing (LH)
Identification mark
Stabilizer bracket (LH)

CROSSMEMBER BAR
FRONT SUSPENSION 33-17
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK
1. After shaking the ball joint stud several times,
install the nut to the stud and use special tool
preload socket (MB990326) to measure the
turning torque of the ball joint.
Standard value: 1.7 −3.2 N⋅m
2. When the measured value exceeds the standard
value, replace the stabilizer link.
3. When the measured value is lower than the
standard value, check that the ball joint turns
smoothly without excessive play. If so, it is
possible to re-use that ball joint.
STABILIZER LINK BALL JOINT DUST
COVER CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
2. If the dust cover is cracked or damaged, replace
the stabilizer link.
NOTE: Cracks or damage of the dust cover may
cause damage to the ball joint.
CROSSMEMBER BAR
REMOVAL AND INSTALLATION
M1332016100086
AC001129
MB990326
AB
AC310742
Front axle crossmember bar
AB
49 ± 10 N·m

127(6