MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

MANUAL TRANSMISSION OVERHAUL – Specifications22B-3
SPECIFICATIONS
TRANSMISSION MODEL TABLE
<EVOLUTION-IV>
Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-1-X6AA29/364.529Not available
W5M51-1-X6A1A29/364.529Available
W5M51-1-X7AA30/364.529Not available
W5M51-1-X7A1A30/364.529Available
W5M51-1-Z6AB29/364.875Not available
W5M51-1-Z6A1B29/364.875Available
W5M51-1-Z7AB30/364.875Not available
W5M51-1-Z7A1B30/364.875Available
W5M51-1-X6A2B29/364.529Not available
W5M51-1-X6A3B29/364.529Available
W5M51-1-X7A2B30/364.529Not available
W5M51-1-X7A3B30/364.529Available
<EVOLUTION-V>
Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-2-X6AA29/364.529Not available
W5M51-2-X6A1A29/364.529Available
W5M51-2-Z6AB29/364.875Not available
W5M51-2-X6A2B29/364.529Not available
W5M51-2-Z6A1B29/364.875Available
W5M51-2-X6A3B29/364.529Available
<EVOLUTION-VI>
Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-2-X6A4A29/364.529Not available
W5M51-2-X6A6B29/364.529Not available
W5M51-2-Z6AB29/364.875Not available
W5M51-2-X6A8A29/364.529Available
W5M51-2-Z6A7B29/364.529Available
W5M51-2-X6A1B29/364.875Available

MANUAL TRANSMISSION OVERHAUL – Transmission22B-4
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
1 2 34 5
6
78
910
11
18 Nm
69 Nm69 Nm 18 Nm
69 Nm
3.9 Nm32 Nm32 Nm
3
Disassembly steps
1. Transfer
J2. O-ring
3. Roll stopper bracket
4. Insulator washer
(EVOLUTION-IV only)
5. Shift cable bracketI6. Select lever
H7. Speedometer gear
8. Back-up lamp switch
9. Gasket
10. Plug
11. Gasket
NOTE:
For each service point, refer to Basic Manual. (Pub. No. S9806CNCP9)

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)

MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear22B-6
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
5
4321
6
7
Disassembly steps
1. Snap ring
2. Cone spring
(except EVOLUTION-IV)
3. Thrust washer
4. Steel ball
(except EVOLUTION-IV)
5. Reverse idler gear
6. Needle roller bearing
7. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the shaft and gear are combined
and made to rotate, they rotate smoothly without looseness
and noise.
(2) Check to ensure that the cage is not deformed.

FRONT AXLE – General / Axle Hub and Knuckle <EVOLUTION-VI>26-1
GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE

The installation method of the ball joint between the knuckle and the lower arm has been changed,
and accordingly the removal and installation procedures of the axle hub and the knuckle have been
revised. <EVOLUTION-VI>
AXLE HUB AND KNUCKLE <EVOLUTION-VI>
REMOVAL AND INSTALLATION
Caution
(1) For vehicles with AYC, be careful when handling the pole piece at the tip of the speed sensor so as
not to damage it by striking against other parts.
(2) For vehicles with AYC, be careful not to damage the rotors installed to B.J. outer race during removal
and installation of the drive shaft.
Post-installation Operation

Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
1
23
4 5 6 7
8
12 1415
1388 Nm 108 – 127 Nm
90 – 110 Nm
15 – 33 Nm177 – 275 Nm 25 Nm
25 Nm
9 Nm
103 Nm
74 –87
Nm
11 910
1610
11
Ball joint kit
Removal steps
1. Front speed sensor<Vehicles with
AYC>
A2. Caliper assembly
3. Brake disc
4. Split pin
BA5. Drive shaft nut
6. Front hub assembly
7. Dust shield
8. Connection for lower arm ball joint
9. Connection bolt for lower arm joint10. Lower arm ball joint
11. Dust cover
12. Split pin
C13. Connection for tie rod end
D14. Front drive shaft
15. Front strut mounting bolt
16. Knuckle
NOTE
Follow the conventional procedures for removal
and installation service points.

FRONT AXLE – Axle Hub and Knuckle <EVOLUTION-VI>26-2
INSPECTION
LOWER ARM BALL JOINT ROTATION STARTING
TORQUE CHECK
(1) After shaking the ball joint stud several times, install the
nut to the stud and use the special tool to measure the
rotation starting torque of the ball joint.
Standard value: 1.0 – 3.4 Nm
(2) When the measured value exceeds the standard value,
replace the ball joint assembly.
(3) When the measured value is lower than the standard
value, check that the ball joint turns smoothly without
excessive play. If so, it is possible to use that ball joint.
LOWER ARM BALL JOINT DUST COVER
REPLACEMENT
When the dust cover is damaged during service work or grease
leaks out from the dust cover, replace the dust cover in the
conventional procedure. After replacement, check the dust
cover for cracks or damage by pushing it with finger.
MB990326

27-1
REAR AXLE
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING <AYC> 4. . . . . . . . . . . . .
ON-VEHICLE SERVICE
<VEHICLES WITH AYC> 31. . . . . . . . . . . . . . .
Rear Axle Total Backlash Check 31. . . . . . . . . . .
Gear Oil Level Check 31. . . . . . . . . . . . . . . . . . . .
Gear Oil Change 32. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Check 33. . . . . . . . . . . . . . . . . . . . . . . . Bleeding 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AYC Operation Check 34. . . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Check 35. . . . . . . . . . . . . . . . .
Differential Carrier Oil Seal
Replacement 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Measurement <Vehicles without ABS> 37. . . . .
Action When Battery Runs Out 38. . . . . . . . . . . .
HYDRAULIC UNIT
<VEHICLES WITH AYC> 39. . . . . . . . . . . . . . .
SENSOR RELAY
<VEHICLES WITH AYC> 41. . . . . . . . . . . . . . .
AYC-ECU 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE – General / Service Specifications / Lubricant27-2
GENERAL
OUTLINE OF CHANGE

The descriptions of the service procedures for the AYC system including the troubleshooting using
an MUT-II tester has been incorporated.
SERVICE SPECIFICATIONS
<Vehicles with AYC>
ItemsStandard valueLimit
Rear axle total backlash mm–5
Pressure generated by hydraulic unit MPa0 – 1.6–
Wheel bearing axial play mm–0.05
Wheel bearing rotation starting torque Nm–1.0 or less
LUBRICANT
<Vehicles with AYC>
ItemsSpecified lubricantCapacity
Gear oilTorque
transfer
differential
DifferentialHypoid gear oil API classification GL-5 or higher
SAE viscosity No. 90, 80W0.41 ± 0.02

differentialTorque transfer
mechanismMITSUBISHI GENUINE DIA QUEEN AYC FLUID0.700
0.05

Hydraulic piping fluidDia Queen ATF SPII or equivalent1

Torque transfer mechanism oil seal lipsVaselineAs required

REAR AXLE – Special Tools27-3
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-II sub-
assemblyInspection of AYC
(diagnosis display by MUT-II)
MB991529Diagnosis code
check harnessInspection of AYC
(diagnosis display by AYC warning lamp)
MD998330
(MD998331)Oil pressure
gauge
(2,942 kPa)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)

REAR AXLE – Special Tools / Troubleshooting <AYC>27-4
MB990925
Brass bar
Bar (one-touch type)Toolbox
Installer adapter
Tool number (MB990925)O.D. mmTool number (MB990925)O.D. mm
AMB99092639.0AMB99093363.5
MB99092745.0MB99093467.5
MB99092849.5MB99093571.5
MB99092951.0MB99093675.5
MB99093054.0MB99093779.0
MB99093157.0BMB990938–
MB99093261.0CMB990939–
TROUBLESHOOTING <AYC>
BASIC TROUBLESHOOTING CONDITIONS
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.
NOTE
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.

The correct steering wheel has been properly installed in the neutral position of the steering column
shaft.

Tire and wheel sizes are correct with correct specifications. Inflation pressure, balance, and wear
conditions are okay.

Wheel alignment is correct.

The engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
DIAGNOSIS FUNCTION
READING THE DIAGNOSIS CODE
Read the diagnosis code using an MUT-II tester or the AYC warning lamp.
(Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.)
ERASING THE DIAGNOSIS CODE
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.