oil MITSUBISHI LANCER EVOLUTION IV 1998 Manual Online

MANUAL TRANSMISSION OVERHAUL – Transfer22B-49
TRANSFER
DISASSEMBLY AND REASSEMBLY
10 2
114
8
7
9
5
3
1
6
Apply gear oil to all
moving parts before
installation.
23 {2.4}
Unit: Nm {kgf
m}
Disassembly steps

F1. Air breather
2. Dust seal guard

E3. Oil seal

D4. Oil seal

A5. O-ring

A6. O-ring

C7. Oil seal

B8. Oil seal

A9. O-ring
10. Transfer cover
11. Transfer

MANUAL TRANSMISSION OVERHAUL – Transfer22B-50
REASSEMBLY SERVICE POINTS

AO-RING INSTALLATION
Apply transmission oil to the O-ring.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

BOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

COIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

DOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

EOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.
MD998800
MB990938
MB990933
MB990891
MB990887
MD998304

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>27-18
Code No. 81: AYC relay systemProbable cause
This code is output when the coil circuit of the AYC relay is open- or short-circuited.
Defective AYC relay

Defective harness or connector

Defective AYC-ECU
NG
Check and repair the harness between
AYC relay and body ground.
OK
Check the trouble symptom.
OK
Replace AYC-ECU.
NG
Check the harness between AYC relay
and AYC-ECU.NG
Repair
NG
Check the trouble symptom.
OK
Check the following connectors:
B-96, B-126NG
Repair
OK
Measure at A-126 AYC relay connec-
tor.

Disconnect the connector and
measure at the harness side.

Continuity across 1 and body
ground
OK:ConductingNGCheck the following connector:
A-126NG
Repair
Check the AYC relay.
(Refer to P.27-52.)NGReplace the AYC relay.

REAR AXLE – Troubleshooting <AYC>27-19
Code No. 82: Electric pump systemProbable cause
This code is output if the pressure switch is not set to high-pressure position despite
the AYC-ECU’s command to drive the AYC relay for a given period of time.
Low hydraulic oil level

Oil leak

Defective fusible link

Defective AYC relay

Defective harness or connector

Defective AYC motor

Defective accumulator pressure switch

Defective AYC-ECU
OK
Replace AYC-ECU.
Check the harness
between AYC relay and
AYC motor, and between
AYC motor and body
ground.NG
Replace
NG
OK
Check the trouble symptom.
OK
Check the following
connectors:
A-126, B-94, B-27, F-32NG
Repair
OK
Replace AYC-ECU.
NG
Check the harness
between AYC-ECU and
accumulator pressure
switch.NG
Repair
NG
Check and repair the har-
ness between fusible link
no. 10 and AYC relay.
OK
Check the trouble symp-
tom.
OK
Replace the hydraulic unit
for a defective accumula-
tor pressure switch.
NO
Repair the leak.
OK
Check the trouble symptom.
NG
Check the following
connector: A-126NG
Repair
YES
Add hydraulic oil.
Is the hydraulic oil level correct in the reservoir tank?
(Refer to P.27-29.)NOIs there a hydraulic oil leak?
Measure at A-126 AYC relay connector.

Disconnect the connector and measure at the harness side.

Voltage across 5 and body ground
OK: Battery voltage
NG
NO
Can pump be operated?YESMeasure at F-31 accumulator pressure switch connector.

Disconnect the connector and measure at the harness side.

Ignition switch: ON

Voltage across 2 and body ground
OK:Battery voltage
YES
Is diagnosis code no. 81 output?YESCheck the AYC relay system. (Refer to P.27-18.)
NG
Check the following
connectors: B-95, B-94,
D-06, F-30, F-31NG
Repair
OK

Check AYC relay for
continuity.
(Refer to P.27-52.)

Check AYC motor for
operation.NG
Repair

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 – 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