MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

21B-1
CLUTCH
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 2..........................
SERVICE SPECIFICATIONS 2.................
TIGHTENING TORQUE 2.....................LUBRICANTS 2..............................
CLUTCH 3...................................
CLUTCH RELEASE CYLINDER 6.............

CLUTCH OVERHAUL -General Description/Specifications/Service Specifications/
Tightening Torque/Lubricants21B-2
GENERAL DESCRIPTION
The pull-type clutch has been adopted to improve the cut-off at high rotations and reduce the clutch
pedal pressing force.
SPECIFICATIONS
Clutch discTypeDry single-disc type
Facing dimension mm240×160
Clutch coverTypeDiaphragm spring, pull-type
Set load N9,320
Clutch control methodHydraulic method
SERVICE SPECIFICATIONS
ItemsLimit value mm
Clutch disc facing rivet sink0.3
Clearance between release cylinder inner diameter and
piston outer diameter0.15
TIGHTENING TORQUE
ItemsTorque N•m
Clutch tube flare nut15±2
Clutch fluid line bracket mounting bolt18±3
Clutch release cylinder air breather11±1
Clutch release cylinder mounting bolt18±3
Clutch release fork shaft mounting bolt9.8±2
Clutch release cylinder union bolt22±2
LUBRICANTS
ItemsSpecified lubricants
Release fork and release cylinder push rod contact sectionMITSUBISHI genuine grease Part No.0101011
orequivalent
Release fork and release fork shaft sliding section
or equivalent
Release fork and release bearing contact section
Piston and piston cup circumferenceMITSUBISHI genuine brake fluid
“
DIA QUEENBRAKEFLUIDSUPER4”
Release cylinder inner circumference
“DIA-QUEENBRAKEFLUIDSUPER4”
or equivalent

CLUTCH OVERHAUL -Clutch21B-3
CLUTCH
REMOVAL AND INSTALLATION
18±3N•m
111
12
9
10
17
1519
18
16
18±3N•m9.8±2N•m
18±3N•m
15±2N•m
22±2N•m
16
14
1320 2
8
7
6
3 45
Removal steps
1. Clutch fluid line bracket
2. Clutch tube
3. Union bolt
4. Union
5. Gasket
"EA6. Valve plate
"EA7. Valve plate spring
"DA8. Clutch release cylinder
9. Clutch cover
10. Clutch disc"CA11. Sealing cap
12. Release fork shaft
13. Support spring (L)
14. Packing
"BA15. Release fork
"AA16. Bush
17. Clutch release bearing
18. Packing
19. Support spring (R)
20. Release fork boot

CLUTCH OVERHAUL -Clutch21B-4
REASSEMBLY SERVICE POINTS
"AABUSH INSTALLATION
Press the bush into the position of the release valve shown
in the illustration.
"BARELEASE FORK INSTALLATION
Apply grease on the release fork at the position shown in
the illustration.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011
or equivalent
"CASEALING CAP INSTALLATION
Press the sealing cap into the position shown in the illustration
while taking care so that it is not tilted.
"DACLUTCH RELEASE CYLINDER INSTALLATION
Fill grease in the release fork to the position shown in the
illustration.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011
or equivalent
"EAVALVE PLATE SPRING/VALVE PLATE
INSTALLATION
Set the spring’s large diameter side to the valve plate side,
and install the valve plate spring and valve plate.
Bush
2mm
Release fork
Valve plate spring
Release cylinder
Valve plate

CLUTCH OVERHAUL -Clutch21B-5
INSPECTION
CLUTCH COVER
(1) Check the pressure plate surface for wear, cracks or
discoloration.
(2) Check the strap plate rivet for looseness. If loose, replace
the clutch cover.
CLUTCH DISC
Caution
Do not wash the clutch disc with cleaning oil.
(1) Check the facing for decomposition caused by rivet
looseness, single-side contact or seizure, and check for
the presence of grease. If any fault is found, replace
the clutch disc.
(2) Measure the rivet sinking level, and replace the clutch
disc if the limit is exceeded.
Limit value: 0.3 mm
(3) Check the torsion spring for play and breakage. If faulty,
replace the clutch disc.
(4) Set the clutch disc onto the input shaft, and check the
sliding state and for play in the rotation direction. If the
sliding state is poor, wash the disc, reassemble and then
check the state again. If there is extreme play, replace
the clutch disc or input shaft or both parts.
CLUTCH RELEASE BEARING
Caution
Grease is filled in the release bearing, so do not wash with
washing oil.
(1) Check the bearing for seizure, damage, abnormal noise
or improper rotation.
(2) Check that the pull ring of the release bearing is not
worn.
(3) If the surface where the bearing contacts the release
fork is abnormally worn, replace the bearing.
RELEASE FORK AND RELEASE FORK SHAFT
(1) If the surface where the release fork contacts the bearing
is abnormally worn, replace the release fork.
(2) Check the release fork shaft for bending and wear. If
any abnormality is found, replace the release fork shaft.

CLUTCH OVERHAUL -Clutch Release Cylinder21B-6
CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
5 341
2
678
11±1N•m
Disassembly step
1. Cap
2. Air breather
3. Push rod
4. Boot"AA5. Piston cup
"AA6. Piston
7. Conical spring
8. Release cylinder

CLUTCH OVERHAUL -Clutch Release Cylinder21B-7
REASSEMBLY SERVICE POINT
"AAPISTON/PISTON CUP INSTALLATION
After applying brake fluid on the inner surface of the release
cylinder and circumference of the piston and piston cup, insert
the piston and piston cup into the release cylinder.
Brake fluid
Specified fluid:
MITSUBISHI genuine brake fluid “DIA-QUEEN
BRAKE FLUID SUPER 4” or equivalent
INSEPCTION
RELEASE CYLINDER
(1) Check the inner surface of the release cylinder for rust
and damage.
(2) Using a cylinder gauge, measure the inner diameter of
the release cylinder at approx. three positions (deepest
section, middle, opening). If the clearance with the outer
diameter of the piston exceeds the limit value, replace
the release cylinder assembly.
Limit value: 0.15 mm
Piston cup Piston

NOTES

MANUAL TRANSMISSION 22A........................................
MANUAL TRANSMISSION OVERHAUL 22B............................
22A-1
MANUAL
TRANSMISSION
CONTENTS

22A-2
MANUAL
TRANSMISSION
CONTENTS
GENERAL 3.................................
Outline of Changes 3...........................
GENERAL INFORMATION 3..................
SERVICE SPECIFICATION 3..................
LUBRICANTS 3..............................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING <ACD> 5...............
ON-VEHICLE SERVICE 40....................
Transmission Oil Check 40......................
Transmission Oil Replacement 40................
Transfer Oil Check 40..........................
Transfer Oil Replacement 40....................
Fluid Check <Vehicles with ACD or vehicles with
ACD and AYC> 41.............................
Bleeding <Vehicles with ACD or vehicles with
ACD and AYC> 42.............................ACD Operation Check <Vehicles with ACD or
vehicles with ACD and AYC> 42................
Hydraulic Pressure Check <Vehicles with ACD or
vehicles with ACD and AYC> 43................
Wheel Speed Sensor Output Voltage
Measurement <Vehicles with ACD or vehicles with
ACD and AYC> 44.............................
TRANSMISSION CONTROL* 46...............
TRANSFER ASSEMBLY 49...................
TRANSMISSION ASSEMBLY 52...............
4WD-ECU <VEHICLES WITH ACD OR
VEHICLES WITH ACD AND AYC> 55.........
SENSOR, SWITCH AND RELAY <VEHICLES
WITH ACD OR VEHICLES WITH ACD AND
AYC> 56.....................................
HYDRAULIC UNIT Refer to GROUP27B.......
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) 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 driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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 (*).