Recall - Lower Ball Joint/Control Arm Inspection
No.: SR-04-001DATE: January, 2004
MODEL: See below
SUBJECT:
LOWER BALL JOINT
- SAFETY RECALL CAMPAIGN
This bulletin supercedes SR-01-007, issued March, 2001, for revised ball joint inspection procedures.
PURPOSE
Owners of vehicles involved in the recall announced in SR-01-007 who have not yet had their vehicle inspected are being renotified. Mitsubishi Motors North America, Inc. (MMNA) is voluntarily recalling affected vehicles for possible premature wear to the lower lateral arm ball joint assembly as a result of moisture intrusion. The lower lateral arm ball joint may have other areas of leakage beyond a cut or torn boot. Such moisture intrusion could result in excessive ball joint clearances that could eventually result in ball joint separation.
This bulletin contains revised inspection procedures that must be performed in order to determine whether the lower lateral arm assembly requires replacement.
Replace the lower lateral arm assembly if:
- the boot is damaged
- evidence of grease leakage is found, or
- the ball joint free play is excessive, as determined by the revised inspection method
If inspection does not reveal any boot damage, grease leakage, or excessive ball joint free play, sealant must be applied to the ball joint bottom surface on both sides of the vehicle. This bulletin also contains sealant application instructions.
AFFECTED VEHICLES
1994-1998 Galant, 1995-1999 Eclipse, and 1996-1999 Eclipse Spyder models
IMPORTANT
Affected new or used inventory vehicles must be inspected/repaired before the vehicle is sold. Dealers must check their inventory vehicles' VINs on the Warranty Super Screen to verity whether the vehicle is an affected VIN for this recall campaign.
CUSTOMER NOTIFICATION
A renotification letter will be sent to owners of affected vehicles who have not yet had their vehicle inspected, telling them to bring their vehicle to their Mitsubishi Motors dealer to have the lower ball joint inspected. A copy of the customer renotification letter appears later in this bulletin. Due to the large number of vehicles involved in this renotification, the customer renotification letters will be mailed monthly over a five-month period, from February to June 2004. If a customer brings in their vehicle for this inspection before they receive the renotification letter, inspect the vehicle as soon as possible. Do not wait for their renotification letter.
REQUIRED OPERATIONS
CHECK ON THE WARRANTY SUPERSCREEN to verity that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.
1. Raise the vehicle.
2. Inspect the lateral lower arm ball joint rubber boot on both sides for cracks and damage. Gently push the boot in with your fingers. Do not remove any parts for the inspection. Damage to the boot is evident if any cuts or tearing are observed if grease comes out when it is pushed in, or if there are any other signs of leakage.
a. If the rubber boot is not damaged on either side of the vehicle, go to Step 4 or ball joint free play inspection.
b. If the rubber boot is damaged, replace the lateral lower arm assembly, using the parts listed in the PARTS INFORMATION section of this bulletin. Go to Step 5 for lateral lower arm replacement instructions.
3. Measure the lower ball joint end cap diameter as shown. Note this measurement. (The free play specification is different for end caps 28 - 30 mm diameter, than for end caps 32 - 35 mm diameter.)
a. Lower the vehicle.
4. Check the ball joint tree play as follows:
a. Adjust the steering wheel so the wheels are in the straight ahead position.
b. Remove the ignition key.
c. Raise the vehicle.
d. Remove both front tires. Then install two wheel nuts on each hub to secure the brake discs.
e. Set up a dial indicator in one of the following ways:
f. Adjust the dial indicator plunger to approximately the center of its travel.
g. Adjust the vehicle height so that the wheel hub center is even with your shoulder.
h. Use a rope to suspend one of the vehicle's tires from the rotor as shown. The weight of the tire will bottom out the ball joint.
i. Place the tip of an approximately 10' long (270 mm) pry bar to the flat side of the knuckle between the lateral lower arm and the compression lower arm.
Using the shock absorber fixing bolt as a pivot, apply 44 lbs. (20 kg) of force downward on the pry bar. Note any dial indicator movement. Then release the force on the pry bar and note any dial indicator movement. Record the dial indicator reading for the warranty claim.
WARNING
Use care to prevent personal injury.
Do not damage the boot with the pry bar.
^ For 28 - 30 mm diameter end cap ball joints, replace the lower lateral arm assembly if the ball joint free play is greater than 0.5 mm (0.0197 in.). Go to Step 5.
^ For 32 - 35 mm diameter end cap ball joints, replace the lower lateral arm assembly if the ball joint free play is greater than 0.1 mm (0.0039 in.). Go to Step 5.
^ If the ball joint free play is within specification (0.5 mm or less for 28 - 30 mm end cap diameter; 0.1 mm or less for 32 - 35 mm end cap diameter), go to Step 6 for sealant application instructions.
j. Repeat Steps e. through i. on the other side of the vehicle.
Then remove the dial indicator.
5. If the ball joint free play exceeds the specifications in Step 4.j., replace the lower lateral arm assembly. Refer to the appropriate service manual for replacement instructions.
* NOTE: On 1994 Galant only, when replacing a lower lateral arm assembly, determine the appropriate replacement part number by determining the size of the nut which fits on the ball joint thread on the original part.
- If the nut size is 19 mm, use replacement part number MR972469 (LH) or MR972470 (RH).
- If the nut size is 22 mm, use replacement part number MR972465 (LH) or MR972466 (RH).
IMPORTANT:
Be sure that the replacement part has sealant on the bottom cap of the ball joint. If it does not have sealant, follow the sealant application instructions in Step 6.
Before installation, apply molybdenum chassis grease to the lip area of the ball joint rubber boot.
Do not apply grease to the ball stud. Place a 17 mm deep socket wrench on the stud to prevent grease application to the stud. Use care to prevent removing the sealant from the bottom of the ball joint.
After installation, confirm the toe-in specification is correct. The specification is 0 +/- 3 mm (0 +/- 0.12 in.). Perform toe-in adjustment as required.
6. If the ball joint free play is within specification, apply sealant to the entire bottom end cap of the ball joint as follows:
a. Use a dry cloth to remove dirt, oil and moisture from the bottom of the ball joint. Do not use any detergent or solvent. Dry thoroughly with a clean, dry rag.
If the bottom of the ball joint is heavily coated with contaminates, carefully use a wire brush to clean it. Use care to prevent damaging the original coating of sealant.
b. Use a small natural-hair paintbrush to apply ThreeBond 6151 sealant to the entire bottom area Of the ball joint end cap. Be sure that the sealant covers the area between the bottom cap and the case.
WARNING
ThreeBond 6151 sealant is a flammable material. Refer to the Material Safety Data Sheet on the MMSA Diamond Dealer Link. (Select "Parts" then "Hazardous Materials", then "Request MSDS.") Observe the sealant manufacturer's safety precautions. Wear protective gloves while applying sealant. When disposing of the brush, observe local, state, and Federal regulations.
WARNING
Use care to prevent removing the sealant after application.
PARTS INFORMATION
WARRANTY INFORMATION
Claims for this campaign must be entered as Recall type "C" claims. Check the repair process(es) performed. You may only claim the repairs actually made associated with the specific vehicle condition found. Sample claim screens are shown.
Replaced Parts Retention Time - For this recall, replaced lower control arms may be scrapped two days after the recall claim is paid unless a related parts return request is received.
When damage to the boot is observed, or grease comes out when the boot is pushed in, or there are other signs of leakage: