lock MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION -Sensor, Switch and Relay or vehicles with ACD and AYC>22A-56
SENSOR, SWITCH AND RELAY VEHICLES WITH ACD AND AYC>
REMOVAL AND INSTALLATION
Caution
Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP
52B Precautions in Servicing and Airbag Module Clock Spring.
1
3
2
4
5
Parking brake lever
Steering wheel sensor removal
steps
DSteering wheel and column cover
(Refer to GROUP 37A.)
1. Steering wheel sensor
G sensor removal steps
DFloor console (Refer to GROUP 52A.)
2. Longitudinal G sensor
3. Lateral G sensorElectric pump relay removal
4. Electric pump relay
ACD mode switch removal steps
DInstrument panel ornament (Refer to
GROUP 52A – Instrument Panel.)
5. ACD mode switch
NOTE
For details on the wheel speed sensor, refer to GROUP
35B.
REMOVAL SERVICE POINT
AA"STEERING WHEEL SENSOR REMOVAL
Remove the steering wheel sensor from the column switch.
Caution
Make sure no oil adheres to the steering wheel sensor
because a photocoupler is used.Steering wheel sensor

MANUAL TRANSMISSION OVERHAUL -Sealants22B-7
SEALANTS
TRANSMISSION
ItemsSpecified sealants
Clutch housing and transmission case contact surfaceMITSUBISHI genuine sealant Part
No MD997740orequivalent
Control housing and transmission case contact surface
No.MD997740or equivalent
Under cover and transmission case contact surface
Air breather3M SUPER WEATHERSTRIP No.8001 or
equivalent
Center differential drive gear bolt3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)
FIPG is used for several members of this transmission. With this gasket, caution is required to the application
amount, application procedure and state of the application surface so that the performance is sufficiently
attained.
If sufficient gasket is not applied, leaks could occur, and if too much is applied, the gasket could protrude
and plug or restrict the oil flow passage. Thus, to prevent leaks from the joined sections, it is absolutely
necessary to evenly apply the correct amount.
DISASSEMBLY
The parts assembled with FIPG can be easily disassembled without special means. However, in some
cases, the sealant on the contact surfaces must be broken by lightly tapping with a wood hammer or
similar tool.
Washing the gasket surface
Completely remove all matters adhered on the contact surfaces with a gasket scraper. Confirm that the
FIPG application surface is smooth. There must be no grease or foreign matter on the contact surfaces.
Always remove the old FIPG that has entered the mounting holes and screw holes.
APPLICATION PROCEDURES
Apply an even coat of FIPG within the predetermined radius (1.5±0.3 mm). Completely cover the areas
around the mounting holds. The FIPG can be wiped off if it has not hardened. Install at the set position
while the FIPG is still wet (within 10 minutes). When installing, make sure that the FIPG does not get
on areas other than the required areas. After installing, do not subject the application areas to oil or
water or start operation until the FIPG has sufficiently hardened (approx. one hour).
The FIPG application procedures differ according to the member, so follow the procedures given in this
manual and apply the FIPG.

MANUAL TRANSMISSION OVERHAUL -Tightening Torque22B-11
TIGHTENING TORQUE
TRANSMISSION
ItemsTightening torque N•m
Under cover mounting bolt6.9±1
Interlock plate bolt30±3
Clutch housing and transmission case tightening bolt44±5
Clutch release bearing retainer mounting bolt9.8±2
Control housing mounting bolt18±3
Shift cable bracket mounting bolt18±3
Speedometer gear mounting bolt3.9±1
Stopper bracket mounting bolt18±3
Select lever mounting bolt18±3
Select lever mounting nut11±1
Center differential drive gear mounting bolt132±5
Backup light switch32±2
Poppet spring32±2
Reverse idler gear shaft mounting bolt48±5
Roll stopper bracket mounting bolt69±9
TRANSFER
ItemsTightening torque N•m
Transfer cover mounting bolt23±3
Transmission and transfer tightening bolt69±9

MANUAL TRANSMISSION OVERHAUL -Transmission22B-16
18±3N•m
6.9±1N•m 48±5N•m 30±3N•m
44±5N•m
20
Apply gear oil on
all sliding sections
before installing.
2113
14
11
12
19
1716
18
15 25
23
22
2426
Disassembly steps
11. Interlock plate bolt
12. Gasket
"GA13. Control housing
14. Neutral return spring
"FA15. Under cover
16. Reverse idler shaft bolt
17. Gasket
18. Reverse idler gear"EA19. Transmission case
20. Outer race
21. Outer race
"DA22. Spacer
"DA23. Spacer
"DA24. Spacer
25. Oil guide
26. Oil guide

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-40
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
16107
11
8
9
6
5
3 41
2
17 1213
15 14
18
18±3N•m
Disassembly steps
AA""FA1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate
"EA7. Spring pin
"DA8. Spring pin
9. Stopper body10. Neutral return spring
11. Control shaft
"CA12. Air breather
13. Control shaft boot
"BA14. Oil seal
"AA15. Needle bearing
16. Spring washer
17. Stopper bracket
18. Control housing

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-41
DISASSEMBLY SERVICE POINT
AA"LOCK PIN REMOVAL
Tap out the lock pin from the direction shown in the illustration.
REASSEMBLY SERVICE POINTS
"AANEEDLE BEARING INSTALLATION
Press the needle bearing into the dimensions shown in the
illustration so that the type stamp side faces the indicated
direction.
"BAOIL SEAL INSTALLATION
Apply transmission oil on the oil seal lip section.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"CAAIR BREATHER INSTALLATION
(1) Apply sealant on the periphery of the insertion section.
Sealant
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or
equivalent
(2) Install so that the protrusion faces the direction shown
in the illustration.
Lock pin
Control
finger
Control
housing
Needle
bearing
2mm Type
stamp
side

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-42
"DASPRING PIN INSTALLATION
Install the spring pin onto the stopper body from the direction
shown in the illustration.
"EASPRING PIN INSTALLATION
Install the spring pin onto the stopper body.
"FALOCK PIN INSTALLATION
Tap the lock pin into the control finger from the direction
shown in the illustration.Control shaftStopper body
Installation
direction
Slit
Spring
pin
Spring pin
45_
Lock pin
Control finger

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-48
CENTER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
Apply gear oil on
all sliding sections
before installing.
161310 7
11
8 9653
41
2
17
12
1514
912 121112
132±5N•m
Disassembly steps
"DA1. Center differential drive gear
"CA2. Center differential flange
AA""BA3. Taper roller bearing
"CA4. Snap ring
"CA5. Front output shaft
"CA6. Spacer
"CA7. Side gear
"CA8. Lock pin
"CA9. Pinion shaft"CA10. Pinion shaft holder
"CA11. Pinion
"CA12. Washer
"CA13. Side gear
"CA14. Spacer
AB""AA15. Taper roller bearing
16. Speedometer drive gear
17. Differential case
DISASSEMBLY SERVICE POINTS
AA"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the center differential flange.MD998917

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-49
AB"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the center differential case.
REASSEMBLY SERVICE POINTS
"AATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing onto
the center differential case.
"BATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing onto
the center differential flange.
"CASPACER/SIDE GEAR/WASHER/PINION/PINION
SHAFT HOLDER/PINION SHAFT/LOCK
PIN/FRONT OUTPUT SHAFT/SNAP RING/CENTER
DIFFERENTIAL FLANGE INSTALLATION
(1) After assembling the spacer onto the side gear, install
the side gear into the center differential case.
NOTE
When installing a new side gear, assemble a medium
thickness (0.8 or 0.9 mm) spacer.
(2) Align the washer on the back of the pinion. Engage the
four pieces onto the side gear simultaneously, and rotate
to install at the specified position. Then, install the pinion
shaft holder.
(3) Insert the pinion shaft into the differential case.
(4) Install the lock pin in the direction shown in the illustration.
MD998917 MB990932
MB990937
MD998823MD998812
Differential case
Lock pin
Pinion shaft

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-50
(5) Install the front output shaft onto the side gear, and install
the snap ring.
(6) After assembling the side gear into the center differential
case, install the spacer onto the side gear.
(7) Match the alignment marks, install the center differential
flange, and temporarily fix the machine screw.
(8) Measure the backlash between the side gear and pinion.
Standard value: 0.025 - 0.150 mm
(9) If the backlash is not within the standard value, select
a spacer, and measure the backlash again.
NOTE
Adjust so that the backlash on both sides is even.
"DACENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Confirm that rust-proofing oil is applied, and then apply
sealant on all of the bolt threads.
Sealant
Specified sealant:
3M STUD Locking No.4170 or equivalent
(2) Tighten with the specified torque following the order shown
in the illustration.