torque MITSUBISHI LANCER EVOLUTION IV 1998 Owner's Manual

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-27
ON-VEHICLE SERVICE
<VEHICLES WITH AYC>
1. REAR AXLE TOTAL BACKLASH CHECK
If the drive system roars or the vehicle vibrates, use the
following procedure to measure total backlash in the rear
axle. Based on the measurement taken, determine whether
the differential carrier assembly needs to be removed or not.
(1) Place the shift lever in the neutral position and operate
the parking brake.
(2) Turn the propeller shaft fully clockwise and make an
alignment mark on the companion flange dust cover and
gear carrier.
(3) Turn the propeller shaft fully counterclockwise and
measure the deviation between the alignment marks.
Limit: 5 mm
(4) If the backlash exceeds the limit, replace the differential
carrier assembly.
2. GEAR OIL LEVEL CHECK
2-1 DIFFERENTIAL
(1) Remove the filler plug.
(2) Check that the gear oil level is within the specified range
from the bottom end of the filler plug hole.
Standard value (A): 6 mm
(3) If the gear oil level exceeds the standard value, add the
specified gear oil up to the bottom end of the filler plug
hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER
HYPOID GEAR OIL (GL-5)
NOTE
10
C or more: #90, less than 10
C: #80
(4) Fit the filler plug and tighten it to the specified torque.
Alignment marks
Filler plug
49 Nm
{5.0 kgf
m}
Gear oil
Upper
limit
Lower
limit

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-28
2-2 TORQUE TRANSFER MECHANISM
(1) Remove the filler plug.
(2) Check that the gear oil level is up to the bottom end
of the filler plug hole.
(3) If the gear oil level is lower than the bottom end of the
filler plug hole, add the specified gear oil up to the bottom
end of the filler plug hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
(4) Fit the filler plug and tighten it to the specified torque.
3. GEAR OIL CHANGE
3-1 DIFFERENTIAL
(1) Remove the drain plug to discharge the gear oil.
(2) Fit the drain plug and tighten it to the specified torque.
Tightening torque: 49 Nm {5.0 kgf
m}
(3) Remove the filler plug and add the specified gear oil
up to the bottom end of the filler plug hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER
HYPOID GEAR OIL (GL-5)
Quantity used: 0.41 ± 0.02 dm
3 {0.41 ± 0.02 }
NOTE
10
C or more: #90, less than 10
C: #80
(4) Fit the filler plug and tighten it to the specified torque.
Filler plug
49 Nm {5.0 kgf
m}
Gear oil
Filler plug
49 Nm
{5.0 kgf
m}
Gear oil
Drain plug

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-29
3-2 TORQUE TRANSFER MECHANISM
(1) Remove the drain plug to discharge the gear oil.
(2) Fit the drain plug and tighten it to the specified torque.
(3) Remove the filler plug and add the specified gear oil
up to the bottom end of the filler plug hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
Quantity used: 0.70
0
0.05dm3{0.700
0.05}
(4) Fit the filler plug and tighten it to the specified torque.
4. FLUID LEVEL CHECK
(1) Remove the maintenance lid located in the luggage
compartment.
(2) If the vehicle has been run, leave it for 5 min. or more
in an ordinary temperature (10
C to 30
C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is less than 10
C or less,
allow more time to leave the vehicle to stand idle.
(3) Check that the fluid level in the oil reservoir is in the
range between MAX and MIN.
(4) If the fluid level is lower than MIN, add the specified
fluid.
Specified fluid: MITSUBISHI DIA QUEEN ATF-SPII
(5) Reinstall the maintenance lid.
5. BLEEDING
(1) Lift up the vehicle.
(2) Remove the cap of the left bleeder screw on the torque
transfer differential and connect a vinyl hose.
(3) Gradually turn the steering wheel clockwise from the
straight-ahead position. At this time, loosen the left bleeder
screw and check that fluid is discharged with air.
(4) After air has been completely discharged, tighten the
bleeder screw.
Caution
While the system is being bled of air, add fluid as
necessary to ensure that it is left in the oil reservoir
during the entire procedure.
(5) Repeat steps (3) and (4) two to three times until no air
bubbles are recognized in the fluid that comes out. Then,
tighten the bleeder screw to the specified torque.
Tightening torque: 9 Nm {0.9 kgf
m}
(6) Perform steps (2) through (5) for the right bleeder screw.
Note, however, that the steering wheel should be turned
counterclockwise.
Filler plug
49 Nm {5.0 kgf
m}
Gear oil
Drain plug
49 Nm
{5.0 kgf
m}
Bleeder
screws Vinyl hose

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-30
(7) After the system has been completely bled of air, check
for the fluid level.
Caution
If the system is not completely bled of air, the hydraulic
unit could generate noise, degrading pump durability.
6. DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
6-1 DIFFERENTIAL
(1) Remove the drive shaft. (Refer to p. 27-36.)
(2) Remove the oil seal from the differential carrier.
(3) Using the special tool, drive a new oil seal all the way
into position.
(4) Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with multi-purpose grease.
(5) Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier. (Refer to P.27-36.)
(6) Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)
6-2 TORQUE TRANSFER MECHANISM
(1) Remove the drive shaft. (Refer to p. 27-36.)
(2) Remove the oil seal from the differential carrier.
(3) Using the special tool, drive a new oil seal all the way
into position.
(4) Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with the specified grease.
Specified grease: Vaseline
(5) Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier. (Refer to P.27-36.)
(6) Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)MB990938
MB991115
MD998829
MD998812
MD998813

REAR AXLE – Rear Hub Assembly27-34
INSTALLATION SERVICE POINT
ADRIVE SHAFT NUT INSTALLATION
(1) Install the washer on the drive shaft in the direction shown
on the left.
(2) Using the special tool, tighten the drive shaft nut to the
specified torque.
Caution
Before torquing the drive shaft nut to specification,
do not apply vehicle weight to the wheel bearing.
(3) If, at this time, the split pin holes are not aligned, tighten
the nut further (within 255 Nm {26.0 kgf
m}), insert the
split pin in the first matching holes, and bend it securely.
INSPECTION
1. REAR WHEEL BEARING ROTATION STARTING
TORQUE
(1) Install the special tool to the rear hub assembly and tighten
it to the specified torque.
(2) Using the special tool, measure the wheel bearing rotation
starting torque.
Limit: 1.0 Nm {10.5 kgf
cm}
(3) The wheel bearing starting torque should be within the
limit and the hub should be free of binding or rough motion
when turned.
2. WHEEL BEARING AXIAL PLAY CHECK
(1) Check the wheel bearing for axial play.
Limit: 0.05 mm
(2) If the specified torquing range (196 to 255 Nm {20.0
to 26.0 kgf
m}) does not bring the wheel bearing axial
play into the limit, replace the rear hub assembly.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}
MB990326 MB991000
(MB990998)
Wood block 196 – 255 Nm
{20.0 – 26.0 kfg
m} MB991017
Wood block
Wood block
MB991017

REAR AXLE – Drive Shaft27-38
INSTALLATION SERVICE POINTS
ADRIVE SHAFT INSTALLATION
Caution
Use care not to allow the drive shaft splines to damage
the oil seal of the differential carrier.
BDRIVE SHAFT NUT INSTALLATION
(1) Install the washer on the drive shaft in the direction shown
on the left.
(2) Using the special tool, tighten the drive shaft nut to the
specified torque.
Caution
Before torquing the drive shaft nut to specification,
do not apply vehicle weight to the wheel bearing.
(3) If, at this time, the split pin holes are not aligned, tighten
the nut further (within 255 Nm {26.0 kgf
m}), insert the
split pin in the first matching holes, and bend it securely.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}

REAR AXLE – Torque Transfer Differential <Vehicles with AYC>27-43
TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC>
DISASSEMBLY AND REASSEMBLY
1 23
4 5
6
7 891011
12 1314
Unit: Nm {kgf
m}
186 {19.0}4
49 {5.0}
49 {5.0}9 {0.9}9 {0.9} 49 {5.0}
3
Disassembly steps
1. Drain plug
2. Packing
3. Filler plug
4. Gasket
5. Vent plug
6. Bleeder screw
7. Cover
A8. Self-locking nut
9. Washer
10. Companion flange11. Oil seal
B12. Oil seal
A13. Oil seal
14. Differential carrier assembly
Caution
(1) The differential carrier assembly is non-main-
tainable.
(2) No foreign matter should be allowed inside and
at the joints of the differential carrier assembly.

REAR AXLE – Torque Transfer Differential <Vehicles with AYC>27-44
GREASE AND SEALANT APPLICATION POINTS
Grease: VaselineSemi-drying sealant:
THREEBOND 1281B
Semi-drying sealant:
THREEBOND 1281B
φ3.0 mm

REAR AXLE – Torque Transfer Differential <Vehicles with AYC>27-45
DISASSEMBLY SERVICE POINT
ASELF-LOCKING NUT REMOVAL
ASSEMBLY SERVICE POINTS
AOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the specified grease to the oil seal lip.
Specified grease: Vaseline
BOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the multi-purpose grease to the oil seal lip.
MB990850
MD998812MD998829
MD998813
MB990938
MB991115

REAR AXLE – LSD Case Assembly <Vehicles without AYC>27-46
LSD CASE ASSEMBLY <VEHICLES WITHOUT AYC>
DISASSEMBLY AND REASSEMBLY
1
2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20
Differential gear set
1011
1110
Disassembly steps
CLSD differential torque check
AB1. Screw
2. Differential case A
3. Spring plate
4. Friction plate
5. Friction disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Pressure ring
10. Side gear11. Pinion gear
12. Pinion shaft
13. Pressure ring
14. Friction plate
15. Friction disc
16. Friction plate
17. Friction disc
18. Friction plate
19. Spring plate
A20. Differential case B
DISASSEMBLY SERVICE POINT
ASCREW REMOVAL
(1) Check out the alignment marks.
(2) Loosen a uniform amount little by little the screws securing
differential case A to B.
(3) Separate differential case B from differential case A and
remove their components.
Keep the removed spring plates, friction plates, and friction
discs organized in the order of removal and for right and
left use.