torque MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

MANUAL TRANSMISSION OVERHAUL – Transmission22B-17
(3) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the transmission case at the positions
shown in the illustration.
(4) Install the bearing outer race.
(5) Install the transmission case and tighten the bolts to the
specified torque.
(6) Remove the transmission case. If the solder is not crushed,
repeat the steps (2) through (5) using the solder with
larger diameter.
(7) Measure the thickness of the crushed solder with a
micrometer and select spacers that will provide the
standard end play/preload value.
Standard value:
Input shaft end play 0 – 0.17 mm . . . . . . . . . .
Output shaft end play 0.13 – 0.18 mm . . . . . . . .
Center differential preload 0.05 – 0.11 mm . . . .
REASSEMBLY SERVICE POINTS

AINPUT SHAFT / OUTPUT SHAFT / CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and differential as a unit.

B5TH-REVERSE SPEED SHIFT FORK /
5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
RAIL INSTALLATION
(1) Install the 3rd-4th speed shift rails and fork, and
5th-reverse speed shift rail and fork.
Solders
Solders
Output shaft
Center
differentialInput
shaft
3rd-4th speed
shift fork
5th-reverse
speed shift fork5th-reverse
speed shift rail
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL – Center Differential22B-48
(5) Install the front output shaft to the side gear and fit the
snap ring.
(6) Attach the spacer on the other side gear, then install
the side gear in the center differential case.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).
(7) Install the center differential flange on the case while
aligning the mating marks, then secure it temporarily with
machine screw.
(8) Measure the backlash between the side gear and the
pinion.
Standard value: 0.025 – 0.150 mm
(9) If the measurement deviates from the standard value,
correct the backlash using a spacer of different thickness
and check it again.
NOTE
The backlash must be the same on both sides.

DCENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Apply sealant to the entire threaded portion of the bolt.
Specified sealant:
THREEBOND 1303 or LOKTITE 648
(2) Tighten the bolts to the specified torque in the illustrated
sequence.
1
8
7
6
5
4
3
2
10
9

FRONT AXLE – Service Specifications / Special Tools26-2
SERVICE SPECIFICATIONS
ItemsLimit
Hub axial play mm0.05
Hub rotation starting torque Nm {kgf
m}1.8 {1.8}
SPECIAL TOOLS
ToolNumberNameUse
MB990635 or
MB991113Steering linkage
pullerBall joint disconnection
MB990767End holderFixing of hub
MB991354Puller bodyRemoval of drive shaft
AB
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller bar
A: MB991017
B: MB990998
C: MB991000A, B: Front hub
remover &
installer
C: Spacer
Temporary fixing of unit bearing

Measurement of hub rotation starting
torque

Measurement of hub axial play
Use MB991000 (component of
MB990998) for the spacer.
MB990326Preload socketMeasurement of hub rotation starting torque

FRONT AXLE – Axle Hub and Knuckle26-5
INSPECTION
1. HUB ROTATION STARTING TORQUE CHECK
(1) Install the special tool to the front hub assembly and
tighten the nut to the specified torque.
(2) Use the special tool to measure the hub rotation starting
torque.
Limit: 1.8 Nm {18.0 kgf
cm}
(3) The hub rotation starting torque should be within the limit
value range, and there should be no engagement or
feeling of roughness.
2. HUB AXIAL PLAY CHECK
(1) Measure the hub play in the axial direction.
Limit: 0.05 mm
NOTE
Measure the hub play while clamping the hub in a vice
with wooden blocks against the bearing section.
(2) If the limit value of hub axial play cannot be obtained
with the nut tightened to the specified torque (177 to
275 Nm {18.0 to 28.0 kgf
m}), replace the front hub
assembly.MB991000
(MB990998)
MB990326
177 – 275 Nm
{18.0 – 28.0 kgf
m}
MB991017
MB991017
Wooden blocks
Wooden blocks

27-1
REAR AXLE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING <AYC> 5. . . . . . . . . . . . .
ON-VEHICLE SERVICE
<VEHICLES WITH AYC> 27. . . . . . . . . . . . . . .
1. Rear Axle Total Backlash Check 27. . . . . . .
2. Gear Oil Level Check 27. . . . . . . . . . . . . . . .
3. Gear Oil Change 28. . . . . . . . . . . . . . . . . . . . .
4. Fluid Level Check 29. . . . . . . . . . . . . . . . . . . .
5. Bleeding 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Differential Carrier Oil Seal
Replacement 30. . . . . . . . . . . . . . . . . . . . . . . . .
7. Speed Sensor Output Voltage
Measurement <Vehicles without ABS> 31.
8. Action When Battery Runs Out 32. . . . . . . .
REAR HUB ASSEMBLY 33. . . . . . . . . . . . . . . .
KNUCKLE 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT 36. . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CARRIER
<EVOLUTION-IV, EVOLUTION-V GSR> 39.
DIFFERENTIAL CARRIER
<EVOLUTION-V RS> 41. . . . . . . . . . . . . . . . . . .
TORQUE TRANSFER DIFFERENTIAL
<VEHICLES WITH AYC> 43. . . . . . . . . . . . . . .
LSD CASE ASSEMBLY
<VEHICLES WITHOUT AYC> 46. . . . . . . . . . .
HYDRAULIC UNIT
<VEHICLES WITH AYC> 50. . . . . . . . . . . . . . .
SENSOR RELAY
<VEHICLES WITH AYC> 52. . . . . . . . . . . . . . .
AYC-ECU 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE – Service Specifications / Lubricant / Sealant27-2
SERVICE SPECIFICATIONS
<Vehicles with AYC>
ItemsStandard valueLimit
Rear axle total backlash mm–5
Pressure generated by hydraulic unit MPa {kgf/cm2}0 – 1.6 {10.0 – 16.0}–
Wheel bearing axial play mm–0.05
Wheel bearing rotation starting torque Nm {kgf
cm}–1.0 {10.5} or less
<Vehicles without AYC>
ItemsStandard valueLimit
Right-to-left difference in combined thickness of friction plate and fric-
tion disc mm0 – 0.05–
Clearance between spring plate and differential case mm0.06 – 0.25–
LSD differential torque
Nm {kgf
m}
When new clutch plate is installed5 – 19 {0.5 – 1.9}–
Nm {kgf
m}
When existing clutch plate is installed2 – 19 {0.2 – 1.9}–
Distortion of friction plate and friction disc mm–0.08
Difference in thickness between friction plate, friction disc, and spring
plate mm–0.1
LUBRICANT
<Vehicles with AYC>
ItemsSpecified lubricantCapacity
Gear oilTorque
transfer
differential
DifferentialMITSUBISHI GENUINE DIA QUEEN SUPER
HYPOID GEAR OIL (GL-5)0.41 ± 0.02 dm3
{0.41 ± 0.02 }
differentialTorque transfer
mechanismMITSUBISHI GENUINE DIA QUEEN AYC FLUID0.700
0.05dm3
{0.700
0.05}
Hydraulic piping fluidMITSUBISHI GENUINE DIA QUEEN ATF-SPII1 dm3 {1 }
Torque transfer mechanism oil seal lipsVaselineAs required
SEALANT
<Vehicles with AYC>
ItemsSpecified sealant
Torque transfer differential vent plugSemi-drying sealant: THREEBOND 1281B (460 g)
Torque transfer mechanism cover

REAR AXLE – Special Tools27-3
SPECIAL TOOLS
ToolNumberNameUse
MB991529Diagnosis code
check harnessInspection of AYC (diagnosis display by AYC
warning lamp)
MD998330
(MD998331)Oil pressure
gauge
(2,942 kPa
{30 kgf/cm
2})
Hydraulic pressure measurement <vehicles
with AYC>
MB991705Hose adapter
MB990925Bearing & oil seal
installer setPressfitting of oil seal <differential>
MB991115Oil seal installerPressfitting of oil seal <differential> (used in
combination with MB990938)
MD998812Installer capPressfitting of oil seal <torque transfer mecha-
nism of vehicles with AYC>
MD998813Installer 100
MD998829Installer adapter
(60)
MB990767End yoke holderFixing of hub

REAR AXLE – Special Tools27-4
Tool UseName Number
AB
MB990241
A: MB990242
B: MB990244Rear axle shaft
puller
A: Puller shaft
B: Puller bar
Removal of drive shaft

Removal of rear hub assembly
MB991354Puller body
A: MB991017
B: MB990998
C: MB991000A, B: Front hub
remover &
installer
C: Spacer
Temporary fixing of unit bearing

Measurement of wheel bearing rotation
starting torque

Measurement of wheel bearing axial play
Use MB991000 (component
of MB990998) for the spacer.
MB990326Preload socket
Measurement of wheel bearing rotation
starting torque

Measurement of drive pinion preload
MB991406,
MB990635, or
MB991113Steering linkage
puller
Disconnection of ball joint

Removal of hub bolt
MB991460PlugPrevention of differential oil from being dis-
charged and entry of foreign matter <differen-
tial>
MB990988Side gear holding
tool setMeasurement of clutch plate preload <vehicles
without AYC>
MB990850End yoke holderRemoval and installation of companion flange

REAR AXLE – Troubleshooting <AYC>27-22
INSPECTION PROCEDURE 2
AYC warning lamp remains lit up after the engine has
started.
Probable cause
The AYC warning lamp ON circuit is probably short-circuited.
Defective combination meter

Defective harness (short-circuit)

Defective AYC-ECU
NOTE
This symptom is limited only when AYC-ECU power supply is in normal condition and the diagnosis
code is correct.
OK
Replace combination meter.
NO
Check the harness between AYC
warning lamp and AYC-ECU.NG
Repair
Does the AYC warning lamp goes out
when the B-96 AYC-ECU connector
is disconnected?YESReplace AYC-ECU.
INSPECTION PROCEDURE 3
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.
Probable cause
The hydraulic oil level is probably low, there is an oil leak, the hydraulic unit is defective,
or the torque transfer differential is defective.
Low hydraulic oil level

Oil leak

Defective hydraulic unit

Defective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the hydraulic unit.
NG
Replace the torque transfer differential.
Check the trouble symptom.
NG
Replace AYC fluid.
OK
Correct
Check the trouble symptom.NO
Replace the torque transfer differential.
OK
Is foreign matter trapped in the hydrau-
lic line?YES
Repair
OK
Check the AYC for operation.OKCheck the AYC fluid.
NG
Add hydraulic oil.
NG
Check hydraulic pressure.NGBleed the system of air.
Check the hydraulic oil level.NGCheck for oil leak.OK
Repair

REAR AXLE – Troubleshooting <AYC>27-23
INSPECTION PROCEDURE 4
Rear tires are noisy during low-speed cornering.
Probable cause
The hydraulic unit or torque transfer differential is probably defective.
Defective hydraulic unit

Defective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the hydraulic unit.
NG
Replace the torque transfer differential.
Check the trouble symptom.
NG
Replace AYC fluid.
OK
Correct
Check the trouble symptom.NO
Replace the torque transfer differential.
OK
Is foreign matter trapped in the hydrau-
lic line?YES
Repair
Check the AYC for operation.OKCheck the AYC fluid.
NG
Check hydraulic pressure.NGBleed the system of air.