steering MITSUBISHI LANCER EVOLUTION VI 1999 Owner's Manual

REAR AXLE – On-vehicle Service <Vehicles with AYC>REAR AXLE – On-vehicle Service <Vehicles with AYC>27-34
BLEEDING
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. Operate the MUT-II (Item No.10) to activate the hydraulic
unit forcibly.
NOTE
(1) The forced activation (air bleeding mode) will be
automatically canceled after 5 minutes 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 hydraulic unit
can not be executed.
5. Remove the cap of the left bleeder screw on the torque
transfer differential and connect a vinyl hose.
6. 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.
7. 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.
8. Repeat steps (6) and (7) 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
9. Perform steps (5) through (8) for the right bleeder screw.
Note, however, that the steering wheel should be turned
counterclockwise.
10. After the system has been completely bled of air, check
for the fluid level. (Refer to P.27-33.)
Caution
If the system is not completely bled of air, the hydraulic
unit could generate noise, degrading pump durability.
AYC OPERATION 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. Start the engine.
4. Operate the MUT-II with the transmission in 2nd or a
higher gear and check to ensure that the vehicle speed
is higher than 10 km/h using the Data List (Item 10).
Bleeder
screws Vinyl hose

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 – Sensor Relay <Vehicles with AYC>27-41
SENSOR RELAY <VEHICLES WITH AYC>
REMOVAL AND INSTALLATION
Caution: SRS
For vehicles with SRS, before removal of air bag module and clock spring, refer to GROUP 52B
– Service Precautions and Air Bag Module and Clock Spring.
12
3
4
Steer sensor removal steps

Steering wheel and column cover
A1. Steer sensorAcceleration sensor and AYC relay
removal
2. Longitudinal acceleration sensor
3. Lateral acceleration sensor
4. AYC relay
NOTE
For the wheel speed sensor, refer to GROUP 35B.
REMOVAL SERVICE POINT
ASTEER SENSOR REMOVAL
Remove the steer sensor from the column switch.
Caution
(1) A photocoupler is used as the steer sensor. Use care
not to allow dust or grease to be on the sensor.
(2) Do not bend or dirty with grease the slit plate on
the column switch side.Slit plate
Steer sensor

BASIC BRAKE SYSTEM – Brake Pedal35A-4
BRAKE PEDAL <L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
Pre-removal Operation

Instrument Under Cover Removal

Steering Column Assembly Removal
(Refer to GROUP 37A – Steering Wheel and Shaft.)

Accelerator Pedal RemovalPost-installation Operation

Accelerator Pedal Installation

Steering Column Assembly Installation
(Refer to GROUP 37A – Steering Wheel and Shaft.)

Instrument Under Cover Installation

Brake Pedal Adjustment (Refer to P.35A-2.)
29 Nm
12 Nm
14 Nm
1 2
3
4 5
67 813 Nm
11
910
8 9
Removal steps
1. Stop lamp switch connector
2. Stop lamp switch
3. Snap pin
4. Clevis pin
5. Brake pedal shaft bolt
6. Brake pedal7. Brake pedal pad
8. Brake pedal return spring
9. Bushing
10. Pipe
11. Pedal support member

37A-1
STEERING
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL AND SHAFT* 2. . . . . . . .
POWER STEERING GEAR BOX* 5. . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B – Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are
indicated in the table of contents by an asterisk (*).

STEERING – General / Steering Wheel and Shaft37A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below. The
service procedures for components not mentioned below are the same as for the preceding models.
STEERING WHEEL AND SHAFT <L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
CAUTION: SRS
For vehicles with SRS, before removal of air bag module, refer to GROUP 52B – Service Precautions and
Air Bag Module and Clock Spring.
Pre-removal Operation
Instrument Under Cover RemovalPost-installation Operation

Instrument Under Cover Installation

Checking Steering Wheel Position with Wheels
Straight Ahead
<Vehicles without SRS>
5 Nm
17 Nm11 Nm
<Vehicles with SRS>
10
98 431
532
41 Nm
25 Nm
6
25 Nm41 Nm
7
9 Nm
Section A – A Section B – B
Claw
: Claw position
AB 4
5
AB
11 Nm 21 Nm Standard bolt Earth bolt
NOTE
4
5
Claw
Removal steps
1. Horn pad <Vehicles without SRS>
2. Air bag module
(Refer to GROUP 52B – Air Bag
Module and Clock Spring.)
A3. Steering wheel
4. Upper column cover
5. Lower column coverA6. Column switch
<Vehicles without SRS>
A7. Clock spring and column switch
(Refer to GROUP 52B – Air Bag
Module and Clock Spring.)
8. Steering shaft assembly
9. Band
10. Steering cover assembly

STEERING – Steering Wheel and Shaft37A-3
REMOVAL SERVICE POINT
ASTEERING WHEEL REMOVAL
INSTALLATION SERVICE POINT
ACLOCK SPRING AND COLUMN SWITCH / COLUMN
SWITCH INSTALLATION
Tighten the screws in an alphabetical order.
DISASSEMBLY AND REASSEMBLY
1
2
3 4
Disassembly steps
AA1. Special bolt
A2. Steering lock bracket
A3. Steering lock cylinder
4. Steering shaft
MB990803
A
BC

STEERING – Steering Wheel and Shaft37A-4
DISASSEMBLY SERVICE POINT
ASTEERING LOCK BRACKET / STEERING LOCK
CYLINDER REMOVAL
If it is necessary to remove the steering lock cylinder, use
a hacksaw to cut the special bolts at the steering lock bracket
side.
REASSEMBLY SERVICE POINT
ASTEERING LOCK CYLINDER/STEERING LOCK
BRACKET / SPECIAL BOLT INSTALLATION
1. When installing the steering lock cylinder and steering
lock bracket to the column tube, temporarily install the
steering lock in alignment with the column boss.
2. After checking that the lock works properly, tighten the
special bolts until the head twists off.
Caution
The steering lock bracket and bolts must be replaced
with new ones when the steering lock is installed.
Steering lock bracket
Steering lock cylinder

STEERING – Power Steering Gear Box37A-5
POWER STEERING GEAR BOX <L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
CAUTION: SRS
For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and
remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative,
risking serious driver injury.
Pre-removal Operation

Power Steering Fluid Draining

Center Member Removal

Front Exhaust Pipe RemovalPost-installation Operation

Front Exhaust Pipe Installation

Center Member Installation

Power Steering Fluid Supplying

Power Steering Fluid Line Bleeding

Steering Wheel Position Check with Wheels Straight
Ahead

Front Wheel Alignment Adjustment

Dust Cover Check for Cracks or Damage by
Pushing it with Finger.
15 Nm 15–33 Nm
69 Nm17 Nm
5 Nm
15–33 Nm
789
3
45 1 2
611 Nm
Removal steps
1. Steering shaft assembly and gear
box connecting bolt
2. Band
3. Split pin
A4. Tie-rod end and knuckle connection5. Return tube connection
6. Pressure tube connection
7. Cylinder clamp
B8. Gear box assembly
9. Steering cover assembly

STEERING – Power Steering Gear Box37A-6
REMOVAL SERVICE POINTS
ATIE-ROD END AND KNUCKLE DISCONNECTION
Caution
1. In order not to damage the ball joint thread, the tie
rod end mounting nut must be only loosened but not
removed from the ball joint. Be sure to use the special
tool.
2. Tie the special tool with a cord so as not to fall off.
BGEAR BOX ASSEMBLY REMOVAL
Caution
Do not damage the bellows and the tie-rod end dust cover
when removing the gear box assembly.
INSPECTION

Check the rubber parts for cracks and breakage.
GEAR BOX TOTAL PINION TORQUE
Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.9 – 1.7 Nm
[Change in torque: 0.4 Nm]
Caution
When holding the steering gear box assembly in a vice,
secure its mounting positions. If it is secured in any other
places, the gear housing may become deformed or
damaged.
NOTE
When measuring, remove the bellows from the rack housing.
Measure the pinion torque through the whole stroke of the
rack.
If the measured value is not within the standard range, first
adjust the rack support cover, and then check the total pinion
starting torque again.
Cord
Ball joint
NutMB990635 or
MB991113
MB991006