MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

REAR AXLE -Differential Carrier 27B-45
"BADRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
"CADRIVE PINION FRONT BEARING OUTER RACE
PRESS-FITTING
"DADRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool.
2. Install special tool and drive pinion front and rear bearing
inner races to the gear carrier in the sequence shown
in the illustration.
3. Tighten the nut of special tool a little at a time while
measuring the turning torque of the drive pinion. Then
confirm the turning torque (without the oil seal) is at the
standard value.
Standard value:
Bearing typeTurning torque
New0.88 - 1.17 N·m
Caution
Take care not to fit gear oil on the bearing.
NOTE
The special tool can not rotate, move several times in
moving area, after rotating the bearing, measure the
torque.
MB990938
MB990935
MB990938
MB990932
MB990836
(MB990835)
MB990836
MB990326 MB990685
MB990836

REAR AXLE -Differential Carrier 27B-46
4. Clean the side bearing hub.
5. Place special tool between the side bearing hub of the
gear carrier, and position the notch as shown in the
illustration. Then tighten side bearing mounting bolt.
6. Use a thickness gauge to measure the clearance (A)
between special tools.
7. Remove special tools (MB990835, MB990326).
8. Use a micrometer to measure the shown dimensions (B,
C) of special tools.
9. Install the bearing cap, and then use a cylinder gauge
to measure inside diameter (D) of the bearing cap.
10. Calculate thickness (F) of the required drive pinion rear
shim twice by the following formula. Select a shim which
most closely matches this thickness.
F = A + B + C - 1/2D - 86.00 mm
11. Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using special tool.
"EADRIVE PINION TURNING TORQUE ADJUSTMENT
/OIL SEAL INSTALLATION
1. Insert the drive pinion into the gear carrier, and then install
the following parts in sequence from the carrier rear side.
Drive pinion spacer, drive pinion front shim and drive
pinion front bearing inner race, companion flange.
NOTE
Do not install the oil seal.
2. Tighten the companion flange to the specified torque by
using special tool.
Thickness
gauge
MB990392
(MB990835)Notch
MB990836
(MB990835)A
BC
Cylinder
gauge
Drive pinion
rear shim
MB990728
MB990850
186±29 N·m

REAR AXLE -Differential Carrier 27B-47
3. Measure the drive pinion turning torque (without the oil
seal).
Standard value:
Bearing divisionTurning torque
New0.88 - 1.17 N·m
Caution
Take care not to fit gear oil on the bearing.
4. If the drive pinion turning torque is not within the standard
value, adjust the turning torque by replacing the drive
pinion front shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion front shims, if the number
of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following
two types.
Height of drive pinion spacer mmIdentification colour
57.72-
57.08Red
5. Remove the companion flange and drive pinion again.
Then insert the drive pinion front bearing inner race into
the gear carrier. Use special tool to press-fit the oil seal.
6. Install the drive pinion assembly and companion flange
with mating marks properly aligned. Tighten the
companion flange self-locking nut to the specified torque
using special tool.
MB990326
MB990685
Identification
colour
MB990727
MB990850
186±29 N·m

REAR AXLE -Differential Carrier 27B-48
7. Measure the drive pinion turning torque (with oil seal)
to verify that the drive pinion turning torque complies
with the standard value.
Standard value:
Bearing
divisionCompanion flange lubricationTurning torque
NewNone (With anti-rust agent)0.98 - 1.27 N·m
Gear oil applied0.49 - 0.58 N·m
8. If the turning torque is not within the standard value,
check the tightening torque of the companion flange
self-locking nut, and the installation of the oil seal.
"FADRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes
of the drive gear by turning the special tool (tap M8 x
1.0), and then clean the threaded holes by applying
compressed air.
3. Apply the specified adhesive to the threaded holes of
the drive gear.
Specified adhesive:
3M Stud Locking 4170 or equivalent
4. Install the drive gear onto the LSD case with the mating
marks properly aligned. Tighten the bolts to the specified
torque in a diagonal sequence.
Tightening torque: 84±4N
·m
"GASIDE BEARING INNER RACE INSTALLATION
Use special tool to press-fit the side bearing inner races into
the differential case.
MB990326
MB990685
MB990813
Contact plate
MB990728
Contact
plate

REAR AXLE -Differential Carrier 27B-49
"HABEARING CAP INSTALLATION/FINAL DRIVE
GEAR BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Assemble the differential case with the side bearing outer
race to the gear carrier.
2. Press the differential case to one side to measure the
clearance of the side bearing outer race and the gear
carrier.
3. Select two pairs of the side bearing spacer with the thickness
derived from the sum of the clearance and a half of pre-load,
0.05 mm.
4. Remove the side bearing with special tools.
NOTE
Hook the claws of the special tool with the side bearing
inner race by using the notches (two areas) of the LSD
case side.
5. Assemble the selected side bearing spacers to each side.
6. Use special tools to press-fit the side bearing inner case
into the LSD case. After installing the outer race, assemble
the LSD case to the gear carrier.
7. Align the mating marks of differential carrier and the bearing
cap with each other to tighten to the specified torque.
Tightening torque: 37±2N
·m
8. Measure the drive gear backlash.
NOTE
Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11 - 0.16 mm
9. If the backlash is not within the standard value, move the
side bearing spacer as shown in the illustration to adjust
the backlash.
NOTE
The increment of side bearing spacer must be coincided
with the decreased amount.
10. Inspect the tooth condition at the final drive gear and make
an adjustment if required. (Refer to P.27B-39.)
MB990810
Socket
wrench
Contact plate
MB990728
Contact
plate
De-
creasedIn-
creased
De-
creased In-
creased
When the backlash is large
When the backlash is small

REAR AXLE -Differential Carrier 27B-50
11. Measure the drive gear runout.
Limit: 0.05 mm
12. When drive gear runout exceeds the limit, remove the
differential case and then the drive gears, moving them
to different positions and reinstall them.
13. If adjustment is not possible, replace the differential case
or drive gear and drive pinion as a set.
LSD CASE ASSEMBLY
DISASSEMBLY AND REASSEMBLY
19
2
6
20
5
11
3
4
12
15
16
13
14
10
1
1817
8
9
7
10
11
11
Differential gear set
1011
11
Disassembly steps
"CADLSD differential torque check
AA""BA1. 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 ring10. Side gear
11. Pinion gear
12. Pinion shaft
13. Pressure ring
14. Friction plate
15. Friction disc
16. Friction plate
17. Friction disc
18. Friction plate
19. Friction plate
"AA20. Differential case B

REAR AXLE -Differential Carrier 27B-51
REMOVAL SERVICE POINT
AA"SCREWS 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.
INSTALLATION SERVICE POINTS
"AADIFFERENTIAL CASE B INSTALLATION
Before starting the assembly procedure, perform the following
steps to adjust dimensional differences (clutch plate friction
force) in the axial direction of the components inside the
differential case and axial clearance of the differential side
gear.
1. Place friction discs (two each) and friction plates (three
each) one on top of another as illustrated and, using
a micrometer, measure the thickness of each of the right
and left assemblies. Select different discs and plates so
that the difference between the right and left assemblies
falls within the specified range.
Standard value: 0 – 0.05 mm
NOTE
If a new part is used, note that the friction disc comes
in two thicknesses: 1.6 mm and 1.7 mm.
2. Measure the thickness of each of the right and left spring
plates.
3. Assemble the pressure ring internal parts (pinion shaft
and pressure ring), friction plates, and friction discs and,
using a micrometer, measure the overall width.
NOTE
When taking measurements, press the assembly from
both sides so that the pinion shaft makes a positive contact
with the groove in the pressure ring.
4. Find value (A) which is the thickness measured in step
(3) added to the thickness of two spring plates.
A
Groove

REAR AXLE -Differential Carrier 27B-52
5. Find dimension (B) between the spring plate faying
surfaces when differential case A and B are assembled
together.
B=C+D - E
6. If the clearance between the spring plate and differential
case (B - A) is outside the specified range, change the
friction discs and make adjustments.
Standard value: 0.06 – 0.25 mm
7. Coat each part with the specified gear oil and mount
it in the specified direction and order into differential case
B.
Specified gear oil:
Hypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 8149630
EX, CASTROL HYPOY LS (GL-5, SAE 90),
SHELL-LSD (GL-5, SAE 80W - 90) or equivalent
NOTE
Apply a careful coat of gear oil to the contacting and
sliding surfaces.
"BASCREW TIGHTENING
1. Align the alignment mark on differential case A with that
on differential case B.
2. Tighten the screws connecting differential case A and
B a uniform amount little by little in the diagonal order.
NOTE
If tightening the screws does not bring the two cases
properly together, spring plates are not probably
assembled properly. Reassemble from the start.
"CALSD DIFFERENTIAL TORQUE CHECK
1. Using the special tool, check for differential torque.
Standard value:
ItemLSD differential
torque N·m
Whennewclutchplateisinstalled5–19When new clutchplateisinstalled5–19
Whenexistingclutchplateisinstalled2–19When existing clutchplateisinstalled2–19
NOTE
Before measuring the differential torque, first turn the
gears so they snug each other, then take measurements
during rotation.
2. If the measurement falls outside the specified range,
disassemble the differential case assembly and repair
or replace defective parts.
D
Differential
case A
E C
Differential
case B
Spring plateFriction plate Friction disc
MB990990
MB990989

REAR AXLE -Differential Carrier 27B-53
INSPECTION
DIFFERENTIAL CASE INTERNAL PARTS CONTACT/
SLIDING SURFACE CHECK
1. Clean the disassembled parts with cleaning oil and dry
them with compressed air.
2. Check each plate, disc, and pressure ring for the following:
A. Friction and sliding surfaces of friction discs, friction
plates, and spring plates.
Replace a defective part with heat discoloration and
excessive wear with a new one, as it degrades locking
performance.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
B. Inner periphery and outer periphery protrusions of
friction discs, friction plates, and spring plates.
Replace a cracked or damaged part with a new one.
C. Friction and sliding surfaces between pressure rings
and friction discs.
Grind a dented or scratched part with oil stone and
then lap and correct with a compound on a surface
plate.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
3. Check the following parts for contact and siding surfaces
(D to M) and correct burrs and dents with oil stone.
D: Sliding surfaces of side gear and case
E: Contacting surfaces of differential case and spring
plate
F: Contacting surfaces of pressure ring and differential
case inner face
G: Sliding surfaces of pressure ring hole and side gear
H: Protrusions on outer periphery of pressure ring
I: Pressure ring inner surface and differential pinion
gear spherical surface
J: Pressure ring V-groove and pinion shaft V
K: Sliding surfaces of pinion shaft and differential pinion
gear hole
L: Side gear grooves on outer periphery
M: Slits in inner periphery of differential
Friction disc
A
AB
C B Friction plateFriction plate
Pressure ring
E
D M
F
J
I
H D
G
F
D
K
K
I GLJ E

REAR AXLE -Differential Carrier 27B-54
FRICTION PLATE AND FRICTION DISC DISTORTION
CHECK
Apply a dial indicator to the friction plate or disc on a surface
plate and, turning the friction plate or disc, measure the
distortion (flatness).
Limit: 0.08 mm (total runout)
FRICTION PLATE, FRICTION DISC, AND SPRING
PLATE WEAR CHECK
1. For the purpose of determining wear, measure thickness
(A, B) of the friction surface and protrusion at several
places and find the difference between the two.
Limit: 0.1 mm
2. If the wear exceeds the limit, replace the part with a
new one.
A
B
A B