rear MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION - Troubleshooting 22A-14

OK OK NG
OK NG
OK OK
OK
NG
Measure at 4WD-ECU connector C-44.
DDisconnect the connector and measure at the harness
side.
(1) Resistance between terminals 9 and 22 (vehicle speed
sensor )
(2) Resistance between terminals 6 and 19 (vehicle speed
sensor )
(3) Resistance between terminals 7 and 20 (vehicle speed
sensor )
(4) Resistance between terminals 8 and 21 (vehicle speed
sensor )
OK:1.2 - 1.6 kΩCheck the wheel speed sensor. (Refer to GROUP 35B -
Wheel Speed Sensor.)
NG→Replace
Check the installation of the wheel speed sensor.
NG→Repair
Check the wheel speed sensor and rotor.
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→Repair
Check the wheel bearing (Refer to GROUP 26 - On-vehicle
Service, and GROUP 27B - Rear Hub Assembly.)
NG→RepairOK
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Check the following connectors:
C-44, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, A-43
C-44, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-136, C-147
NG→Repair
Check the harness between the 4WD-ECU and wheel speed
sensor.
DCheck for open circuit, grounding, and short-circuit of the
output line.
DCheck for open circuit and damage of the earth line
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions) OK
Check the following connector:C-44
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Check the wheel speed sensor output voltage. (Refer to
P.22A-44.)

MANUAL TRANSMISSION - Troubleshooting 22A-31
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure No.Reference
page
No communication possible between MUT-IIand all systems.122A-31
No communication possible between MUT-IIand 4WD-ECU.222A-32
ACD mode indicator lamp does not light up when the ignition switch is set to ”ON“
(engine is stopped).322A-33
More than two ACD mode indicator lamps remain lit even after the engine is started422A-34
The ACD does not operate (no diagnostic code).522A-34
The AYC does not operate (no diagnostic code).6Refer to
GROUPThe rear tire sounds when turning at low speed corners (vehicle slows down)7GROUP
27B.
Noise is produced from the torque transfer differential during turning.8
27B.
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS
Inspection procedure 1
No communication possible between MUT-IIand all
systems.
Probable cause
The diagnosis connector power supply circuit, earth circuit, or MUT-IImay be
faulty.DDiagnostic connector fault
DHarness or connector fault
DMUT-IIfault
OK
NG
NG
Check the harness between the fusible link No.1 and
diagnosis connector.
DCheck for open circuit or damage of the power line.
NG→Repair
OK
Check the trouble symptoms.
Measure at diagnosis connector C-22.
DVoltage between terminal 16 and body earth
OK:System voltageNGCheck the following connectors:
C-22, C-213, C-211, C-132
C-22, C-213, C-211, C-35, C-132
NG→Repair
Check the harness between the body earth and diagnosis
connector.
DCheck for open circuit and damage of the earth line.
NG→Repair
OK
Replace the MUT-II.
Measure at diagnosis connector C-22.
DResistance between terminals 4 and 5 and body earth.
OK:2Ωor less

MANUAL TRANSMISSION - Troubleshooting 22A-37
ACTUATOR TEST JUDGEMENT VALUE
Item
no.Check itemTest descriptionNormal state
01Bleeding Input current to the Proportional valve
according to the steering angle, and operate
the Proportional valve for five minutes.Make sure no air leaks from the bleeder
screw on the transfer.
02Bleeding Input current to the Proportional valve
according to the steering angle, and operate
the directional valve for five minutes.Make sure no air leaks from the bleeder
screw on the torque transfer differential.
03Check the oil vol-
umeOperate the directional valve to the left and
right for 20 seconds.Check that the oil volume of the reservoir
tank is appropriate.
04Electric pump
driveOperate the electric pump for 5 seconds.Operation sounds of the electric pump
can be heard.
05Check the opera-
tions of the ACDOperate the Proportional valve and
supply the maximum oil pressure to the multi
plate clutch.9Generate the tight corner braking
phenomenon.
06Check clutch op-
erations Operate the direction valve and supply the
maximum oil pressure to the left clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
07Check clutch op-
erations Operate the direction valve and supply the
maximum oil pressure to the right clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
08Control OFFTurn OFF the electric pump relay, and turn
OFF the control of the ACD and AYC.In actual driving, there is difference
between control ON and OFF.
(1) The actuator test can be executed only when all the following conditions are satisfied.
DAll wheel speed sensor inputs below 20 km/h
DNo system malfunction detected
DSteering angle is within±30 degrees from the neutral position
(2) When the actuator test corresponds to one of the following conditions, forced driving will be cleared.
DWhen any one of the wheel speed sensor input is detected to be above 20 km/h (excluding
Item No.08 “Control OFF”.)
DWhen system malfunction is detected (excluding diagnostic code No.82, 84, and 85)
DWhen the forced drive time is exceeded
DWhen the MUT-IIis removed
DWhen the Clear key of the MUT-IIis operated

MANUAL TRANSMISSION - On-vehicle Service22A-43
4. Set the gear to the 2nd gear or above, operate the MUT-II,
and check from the service data (Item No.09) that the
wheel speed is within 10 km/h to 20 km/h.
NOTE
(1) Set the steering wheel to the neutral position
(2) The ACD may continue operating (operation sounds
can be heard) when the steering wheel is steered,
this is not a system fault. In this case, set the steering
wheel to the neutral position, and perform the following
operations to stop the ACD.
DRelease the clutch.
DSet the gear to “N”.
DStop the engine
5. Perform the MUT-IIactuator test (Item No.05), and forcibly
drive the transfer.
NOTE
(1) The actuator test (Item No. 05: ACD Operation Check
Mode) is performed for 1 minute, after which it will
be cleared automatically. Drive can also be cleared
during forced driving using the clear key of the MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the transfer cannot be forcibly driven.
6. Check that the front and rear wheel speeds satisfy the
following in the MUT-IIactuator test (Item No.05).

The front wheel will be faster than the back wheels by
more than 2 km/h.
NOTE
If the above are not satisfied, check the oil pressure as
the system may be faulty.
HYDRAULIC PRESSURE CHECK WITH ACD OR VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2. Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Disconnect the hydraulic unit and transfer connector
assembly, and connect the special tool to the hydraulic
unit.
4. Turn the ignition switch to “ON”.
5. Perform the MUT-IIactuator test (Item No.05), and forcibly
drive the hydraulic unit.
NOTE
(1) The actuator test (Item No. 05 ACD Operation Check
Mode) is performed for 1 minute, after which it will
be cleared automatically. Drive can also be cleared
during forced driving using the clear key of the MUT-II.
MD998330
MB991705

MANUAL TRANSMISSION - On-vehicle Service22A-44
(2) If the hydraulic unit function has been stopped by
fail-safe, the hydraulic unit cannot be forcibly driven.
6. Check that the generated oil pressure of the hydraulic
unit satisfies the standard value.
Standard value: 1.0 – 1.6 MPa
Caution
While the oil pressure is checked, add fluid as
necessary to ensure that it is left in the oil reservoir
during the entire procedure.
7. If the measured value exceeds the standard value, replace
the hydraulic unit.
8. Connect the hydraulic unit and transfer connector
assembly, and tighten the flare nut at the specified torque.
Tightening torque: 34±5 N·m (when screw is dry)
26±4 N·m (when screw is applied with oil)
9. Supply the specified fluid up to the MAX level of the
oil reservoir, and bleed the oil pressure pipes.
Specified fluid: DIA QUEEN ATF SP III
Quantity:
0.9 dm
3
1.0 dm3
WHEEL SPEED SENSOR OUTPUT VOLTAGE
MEASUREMENT (VEHICLES WITHOUT AYC)>
1. Lift the vehicle, and release the parking brake.
2. Disconnect the 4WD-ECU connector, and measure at
the connector of the harness.
Caution
Insert the probe from the harness of the connector.
Inserting in the terminal side may cause contact fault.
3. Rotate the measured wheel by about 1/2 to 1
rotations/second, and check the output voltage between
the following terminals using a circuit tester (AC mV range)
or oscilloscope.
Terminal No.
Front leftFront rightRear leftRear right
6987
19222120

MANUAL TRANSMISSION - On-vehicle Service22A-45
Output voltage:
Above 70 mV when measured with the circuit
tester
Above 200 mVP-P when measured with the
oscilloscope
4. If the output voltage is lower than the above values, the
following reasons may be suspected. Check or replace
the wheel speed sensor.
DExcessive clearance between the ball piece of the
wheel speed sensor and ABS rotor
DWheel speed sensor faul
INSPECTION PROCEDURE USING OSCILLOSCOPE
After checking the connected state of the harness of the
wheel speed sensor and connector, and measure the output
voltage waveform of each wheel speed sensor on the
oscilloscope as follows.
Start the engine, shift the transmission to the 1st gear to
rotate the driving wheel, and rotate the non-driving wheel
at constant velocity with the hand.
NOTE
1. It is also possible to actually drive the vehicle and observe
the waveform.
2. The output voltage is low if the wheel speed is low and
gradually increases as the speed increases.

PhenomenonProbable causeSolution
Waveform amplitude is too small or
not output at allWheel seed sensor faultReplace the sensor
Excessive waveform amplitude
(However allowed if above the
iilit df100V)
Excessive vibration or concentricity of
the axle hubReplace the hub
(
minimum amplitude of 100 mV)4WD-ECU earth faultCorrect
Noise in the waveform or waveform
ibl
Open circuit of the sensorReplace the sensor
is abnormalOpen circuit of the harnessReplace the harness
Wheel speed sensor installation faultCorrect the installation of the sensor
Chipping or flattening of the ABS rotorReplace the ABS rotor
Caution
As the wheel speed sensor cable follows the movement of the front or rear suspension, it will
change considerably on poor condition roads. Therefore, also observe the output voltage waveform
of the wheel speed sensor with the sensor harness vibrated to simulate special conditions such
as driving in poor road conditions.
When rotated with the hand
When idling (5 – 6 km/h)
1st gear
10.0 ms/DIV
IV/DIV

MANUAL TRANSMISSION - Transfer Assembly22A-50
11 12
9
1013
14
15 16
13
59±9 N·m
59±9 N·m
44±5 N·m
69±10 N·m
52±7 N·m*
52±7 N·m*
69±10 N·m
9. Rear roll stopper connection bolt
10. Centermember assembly
11. Front propeller shaft
(Refer to GROUP 25.)
12. Transfer oil pressure hose assem-
bly
13. Gasket
14. Dust seal guard
AD"15. Transfer assembly
16. O-ring
Caution
*: Indicates parts which should be initially tightened,
and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine
on the vehicle body.
REMOVAL SERVICE POINTS
AA"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.MB991113 or
MB990635
Cord Ball joint
Nut

MANUAL TRANSMISSION - Transmission Assembly22A-52
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DTransfer Assembly Removal and Installation (Refer to P.22A-49.)
DStarter Motor Removal and Installation (Refer to GROUP 16.)
DAir Cleaner Bracket Removal and Installation (Refer to GROUP 15 - Air Cleaner.)
DRear Roll Rod Assembly and Rear Roll Rod Bracket , Rear Roll Mount
Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper.)
1
2
3 45
5 6
7
18±3 N·m18±3 N·m
18±3 N·m
70±10 N·m
Removal steps
1. Transmission harness clamp
2. Back-up lamp switch connector
connection
3. Vehicle speed sensor connector
connection
4. Clutch release cylinder and clutch
oil pipe5. Snap pin
6. Shift cable and select cable as-
sembly connection
7. Rear roll mount bracket
AA"DEngine and transmission
assembly supporting

MANUAL TRANSMISSION OVERHAUL -Specifications/Service Specifications22B-6
SPECIFICATIONS
TRANSMISSION MODEL TABLE
Transmission
modelGear ratioSpeedometer
gear ratioFinal
reduction
ratioFront LSDVehicle modelEngine model
W5M51 - 2 - X5BA28/364.529CT9A4G63 - I/C•T/C
W5M51 - 2 - X5B1B28/364.529Not providedCT9A4G63 - I/C •T/C
W5M51 - 2 - X5B2C28/364.529ProvidedCT9A4G63 - I/C •T/C
W5M51 - 2 - X5B3B28/364.529Not providedCT9A4G63 - I/C •T/C
W5M51 - 2 - X5B4C28/364.529ProvidedCT9A4G63 - I/C •T/C
GEAR RATIO TABLE
ABC
1st2.9282.785←
2nd1.950←←
3rd1.407←1.444
4th1.031←1.096
5th0.720←0.825
Reverse3.416←←
Transfer gear ratio0.3018←←
SERVICE SPECIFICATIONS
ItemsStandard value mmLimit value mm
Input shaft end play0.05 loose to 0.17 loose-
Input shaft front bearing end play0.01 tight to 0.12 loose-
Input shaft rear bearing end play0.01 tight to 0.12 loose-
Input shaft 5th speed gear end play0.01 tight to 0.09 loose-
Output shaft preload0.13 tight to 0.18 tight-
Output shaft bearing end play0.01 tight to 0.09 loose-
Output shaft 3rd speed gear end play0.01 tight to 0.09 loose-
Center differential case preload0.05 tight to 0.11 tight-
Center differential case pinion backlash0.025 - 0.150-
Clearance between synchronizer ring rear surface and gears-0.5
Provided

MANUAL TRANSMISSION OVERHAUL -Snap Rings, Spacers and Thrust
Plates for Adjustment22B-9
SNAP RINGS, SPACERS AND THRUST PLATES FOR ADJUSTMENT
SPACERS (FOR ADJUSTMENT OF INPUT SHAFT END PLAY)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.34
1.43
1.5234
43
52MD723600
MD723603
MD7236061.61
1.70
1.7961
70
79MD723609
MD756760
MD756763
SNAP RINGS (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.43
1.51Green, two pieces
White, two piecesMD746708
MD7467091.59Yellow, two piecesMD746710
SNAP RINGS (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.44
1.51None
BlueMD746602
MD7466031.58BrownMD746604
THRUST PLATES (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
3.82
3.86
3.90
3.940
2
3
5MD748465
MD748466
MD748467
MD7484683.98
4.02
4.06
4.106
7
8
9MD748469
MD748470
MD748471
MD748472
SPACERS (FOR ADJUSTMENT OF OUTPUT SHAFT PRELOAD)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.86
0.89
0.92
0.95
0.98
1.01
1.04
1.07
1.10
1.13
1.1686
89
92
95
98
01
04
07
J
D
KMD720938
MD720939
MD720940
MD720941
MD720942
MD720943
MD720944
MD720945
MD710454
MD700270
MD7104551.19
1.22
1.25
1.28
1.31
1.34
1.37
1.40
1.43
1.46L
G
M
N
E
O
P
None
Q
RMD710456
MD700271
MD710457
MD710458
MD706574
MD710459
MD710460
MD706573
MD710461
MD710462