clutch MITSUBISHI LANCER EVOLUTION VI 1999 User Guide

CLUTCH – Clutch Pedal21A-4
CLUTCH PEDAL <L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P. 21A-2.)
13 Nm
1
14 13
12 2
818
911
3
10
13 Nm
29 Nm
19
64
7
12 Nm
5
517
15 16 12
Removal steps
1. Clutch master cylinder installation
nut
2. Master cylinder member bracket
installation bolt
3. Clevis pin
4. Pedal support member and clutch
pedal assembly
5. Split pin
6. Clevis pin
7. Bushing
8. Rod A9. Rod B
10. Turn over spring
11. Bolt
12. Bushing
13. Pipe
14. Clutch pedal
15. Pedal pad
16. Stopper
17. Adjusting bolt
18. Locking nut
19. Pedal support member

CLUTCH – Clutch Control21A-5
CLUTCH CONTROL <L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
Pre-removal Operation

Clutch Fluid Draining

Air Cleaner RemovalPost-installation Operation

Air Cleaner Installation

Clutch Fluid Supplying

Clutch Line Bleeding (Refer to P.21A-3.)

Clutch Pedal Adjustment (Refer to P. 21A-2.)
15 Nm
Specified grease:
MITSUBISHI genuine grease
Part No. 0101011
56 8
7
6
1
4
13 Nm
15 Nm
15 Nm
19 Nm
5
15 Nm
3
2
7
Release
fork
Clutch master cylinder removal
steps
1. Clevis pin
2. Clutch pipe connection
3. Clutch master cylinder
Clutch release cylinder removal
steps
4. Clutch pipe connection
5. Clutch release cylinderClutch line removal steps
6. Clutch pipe
7. Hose clip
8. Clutch hose

CLUTCH – Clutch Control21A-6
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
13 Nm
6 7
3
1
2
Piston repair kitClutch fluid:
Brake fluid DOT3 or DOT4
Grease: Rubber grease
2 5
4
413
44 8
Disassembly steps
1. Piston stopper ring
A2. Push rod assembly
3. Boot
4. Piston assembly
5. Reservoir cap
6. Spring pin
7. Reservoir tank
8. Clutch master cylinder bodyCaution
Do not disassemble piston assembly.
INSTALLATION SERVICE POINT
APUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of the clutch pedal easier.
122.5 mm

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 4. . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH HOUSING 5. . . . . . . . . . . . . . . . . . . . . .
REVERSE IDLER GEAR 6. . . . . . . . . . . . . . . . .

MANUAL TRANSMISSION OVERHAUL – General22B-2
GENERAL
OUTLINE OF CHANGE
Of the newly introduced transmission model, the service procedures for the following unit sections are
described.

Transmission

Clutch housing

Reverse idler gear

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-5
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
4
2
1
3
8 6 7
5*
9.8 Nm
Disassembly steps
1. Clutch release bearing retainer
E2. Oil seal
AD3. Outer race
BC4. Outer raceB5. Bushing*
A6. Cover-A
A7. Cover-B
8. Clutch housing
NOTE:
(1)*: Never remove the bushings from the clutch housing.
Only the case when installing new bushings into a new clutch housing, refer to B.
(2) For each service point, refer to Basic Manual. (Pub. No. S9806CNCP9)

REAR AXLE – Troubleshooting <AYC>27-27
ACTUATOR TEST REFERENCE TABLE
The following items can be tested by driving the corresponding actuator forcibly using the MUT-II.
Item No.Check itemChecking requirementsNormal value
10Air bleedingSupply current to proportioning
valve in accordance with steering
angle to operate directional valve.No air is to be bled from the
bleeder plug on the torque transfer
differential.
11Oil level checkLet the directional valve operate to
left and right 20 times.To be checked by oil level in
reservoir tank.
12Electric pump operationLet the electric pump operate for 5
seconds.Operation sounds of the electric
pump are to be heard.
13Clutch operation (left)Let the directional valve operate to
supply the maximum pressure to the
left clutch.The operation conditions are to be
checked by the speed difference
between left and right rear wheels
with the wheels raised. For details,
refer to AYC Operation Check on
P.27-34.
14Clutch operation (right)Let the directional valve operate to
supply the maximum pressure to the
right clutch.The operation conditions are to be
checked by the speed difference
between left and right rear wheels
with the wheels raised. For details,
refer to AYC Operation Check on
P.27-34.
15Control OFFTurn off the electric pump relay to
deactivate AYC control.During the test run, some
differences are to be recognized in
running behaviors between when
the system is ON and when it is
OFF.
NOTE
(1) The actuator test is feasible only when the following requirements are all satisfied.

All of inputs from four wheel speed sensors show 20 km/h or lower.

No system failure is registered.

The steering angle is within ±30 deg. from the neutral position.
(2) The actuator test comes to an end when either of the following conditions is met since the forced
actuation is canceled.

Either of inputs from four wheel sensors shows higher than 20 km/h (with exception of Item
No.15 “Control OFF”).

Some trouble with the system is registered.

Forced activation time expires.

MUT-II is removed.

The clear key of MUT-II is operated.

REAR AXLE – Troubleshooting <AYC>27-29
Terminal
No.Normally Check requirement Check item
17Steer sensor (ST-N)Engine:
Idle speed
Steering wheel: Neutral position0.5 V or less
Idle speed
Steering wheel: Turned 90 from
neutral position2.5 – 3.5 V
18TPSIgnition switch:
ON
Accelerator pedal: Fully closed0.3 – 1.0 V
ON
Accelerator pedal: Fully open4.5 – 5.0 V
23Diagnosis data input/outputWhen MUT-II is connectedSerial communica-
tion with MUT-II
When MUT-II is disconnected1 V or less
24Idle position switchIgnition switch:
ON
Accelerator pedal: Fully closed2 V or less
ON
Accelerator pedal: Fully open4.5 – 5.0 V
25Accumulator pressure
switchIgnition switch:
ONAccumulator internal pressure:
Low2 V or less
Accumulator internal pressure:
HighSystem voltage
26ECU groundAt all times0 V
31AYC-ECU power supplyIgnition switch: ONSystem voltage
Ignition switch: OFF0 V
35AYC motor relayIgnition switch:
ON
When motor is energizedSystem voltage
ON
When motor is deenergized2 V or less
36AYC warning lampIgnition switch:
ON
When lamp is OFFSystem voltage
ON
When lamp is ON2 V or less
37Directional control valve
(right)
Ignition switch:
ON
Right clutch: ONSystem voltage
(right)ON
Right clutch: OFF0 V
38Proportioning valveIgnition switch:
ONAYC-ON0 V to system volt-
age
AYC-OFF0 V
39ECU backup power supplyAt all timesSystem voltage
45Directional control valve
(left)
Ignition switch:
ON
Left clutch: ONSystem voltage
(left)ON
Left clutch: OFF0 V
46ECU groundAt all times0 V
NOTE
*1: Indicates the vehicles with ABS.

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-35
NOTE
(1) Hold the steering wheel in the neutral position.
(2) If the steering wheel is turned, it may happen that
the AYC system continues to operate (operation
sounds are heard from the torque transfer differential).
However, it does not mean a system failure. If such
a case is encountered, perform the following
operations with the steering wheel in the neutral
position to cancel the AYC function.

Disengage the clutch.

Set the transmission to neutral.

Stop the engine.
5. Operate the MUT-II (Item Nos.13 and 14) to activate
the torque transfer differential.
NOTE
(1) The forced activation (clutch operation mode) will be
automatically canceled after 1 minute operation.
It can also be canceled forcibly by operating the clear
key on the MUT-II.
(2) While this function is being disabled by the fail-safe
function, the forced activation of the torque transfer
differential can not be executed.
6. Operate the MUT-II to confirm that the several speeds
of the wheels are as shown below, using the Data List
(Item Nos.07 and 08).
<Forced activation Item No.13 is being executed>
The speed of left rear wheel is more than 2 km/h
higher than that of right rear wheel.
<Forced activation Item No.14 is being executed>
The speed of right rear wheel is more than 2 km/h
higher than that of left rear wheel.
NOTE
If the above requirements are not satisfied, the system
is probably failed. Check the hydraulic pressure.
HYDRAULIC PRESSURE CHECK
1. Lift up the vehicle.
2. Connect the MUT-II to the 16-pin diagnosis connector.
Caution
Before connecting or disconnecting the MUT-II,
always turn off the ignition switch.
3. Turn on the ignition switch.
4. Disconnect the joint between the hydraulic unit and the
hydraulic unit hose assembly. Connect the special tool
to the L port. To the R port, attach a blind plug or connect
the L port of the removed hydraulic unit hose assembly.
5. Operate the MUT-II (Item No.13) to activate the hydraulic
unit.
NOTE
(1) The forced activation (clutch left side operation check
mode) will be automatically canceled after 1 minute
operation.
It can also be canceled forcibly by operating the clear
key on the MUT-II.
MB991705
MD998330

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-36
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
6. Check to ensure that the hydraulic pressure generated
by the hydraulic unit conforms to the standard value.
Standard value: 1.0 – 1.6 MPa
NOTE
During checking the hydraulic pressure, occasionally
replenish the oil reservoir with fluid so that it does not
become empty.
7. Check the hydraulic pressure of the clutch right side by
repeating the steps (4) through (6). At this time, however,
the special tool must be connected to the R port and
the blind plug or the R port of the removed hydraulic
unit hose assembly must be attached to the L port. Further,
the MUT-II must be operated in the forced activation mode
Item No. 14 (clutch right side operation check mode).
8. If the measured value exceeds the standard value, replace
the hydraulic unit.
9. Connect the hydraulic unit hose assembly to the hydraulic
unit and to the torque transfer differential and tighten
the flare nuts to the specified torque.
Specified torque: 34 Nm
10. Pour the specified fluid in the oil reservoir up to the MAX
mark. Then, bleed the system.
Specified fluid: Dia Queen ATF SP II or equivalent
Fluid amount used: Approx. 1

DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
DIFFERENTIAL
1. Remove the drive shaft.
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.
6. Check for correct wheel alignment.
TORQUE TRANSFER MECHANISM
1. Remove the drive shaft.
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.
6. Check for correct wheel alignment.
MB990938
MB991115
MD998829
MD998812
MD998813