rear MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-13
Tool UseName Number
MD998364Camshaft oil seal
installerInstallation of each gear, bearing and sleeve
MD998800Oil seal installerInstallation of differential oil seal and transfer
cover oil seal
MD998801Bearing removerInstallation and removal of each gear, bearing
and sleeve
MD998812Installer capUse for installer and installer adaptor
MD998813Installer 100Use for installer cap and installer adaptor
MD998814Installer 200Use for installer cap and installer adaptor
MD998818Installer adapter
(38)Installation of input shaft front bearing
MD998819Installer adapter
(40)Installation of input shaft rear bearing and
output shaft taper roller bearing
MD998820Installer adapter
(42)Installation of reverse gear bearing sleeve

MANUAL TRANSMISSION OVERHAUL -Transmission22B-18
DISASSEMBLY SERVICE POINTS
AA"SPRING PIN REMOVAL
Shift the 5th-reverse speed shift fork in the direction shown
in the illustration, and remove the spring pin.
AB"3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/5TH-REVERSE SPEED SHIFT
RAIL/5TH-REVERSE SPEED SHIFT FORK
REMOVAL
(1) Move each shift rail in the direction shown in the illustration,
and remove from the shift rail hole on the clutch housing.
(2) Remove each shift rail and shift fork as a set.
AC"CENTER DIFFERENTIAL/OUTPUT SHAFT/INPUT
SHAFT REMOVAL
Remove the input shaft, output shaft and center differential
from the clutch housing at the same time.
ADJUSTMENT BEFORE REASSEMBLY
SELECTION OF INPUT SHAFT END PLAY/OUTPUT
SHAFT END PLAY/OUTPUT SHAFT PRELOAD AND
CENTER DIFFERENTIAL PRELOAD ADJUSTMENT
SPACER
(1) Install the input shaft, output shaft and center differential
onto the clutch housing at the same time.
(2) Set solder (approx. 10 mm long, 1.6 mm diameter) on
the input shaft rear bearing at the position shown in the
illustration.
5th-reverse
speed shift
fork
3rd-4th speed
shift rail
5th-reverse
speed shift rail
Output shaft
Center differentialInput
shaft
Output shaft
Center differentialInput
shaft
Solder

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-26
"IA5TH SPEED GEAR INSTALLATION
Using the special tool, install the 5th speed gear onto the
input shaft.
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 4th speed gear
rotates smoothly.
"JATHRUST PLATE INSTALLATION
Select and install the thrust plate onto the input shaft so
that the input shaft 5th speed gear clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
Caution
Assemble the side with the identification stamp facing the
thrust plate stopper side.
"KATHRUST PLATE STOPPER INSTALLATION
Press the special tool by hand, and accurately fit the thrust
plate stopper onto the input shaft so that it is not inclined.
"LABALL BEARING INSTALLATION
Using the special tool, install the ball bearing onto the input
shaft.
"MASNAP RING INSTALLATION
Select and install the snap ring onto the input shaft so that
the input shaft rear bearing clearance is at the standard value.
Standard value: 0.01 mm tight to 0.12 mm looseMD998812
MD998813
MD998825 MD998801
Thrust
plateStamped
surface
MD998812
MD998813
MD998825
MD998801MD998812
MD998819
Snap
ring

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-35
"PASNAP RING INSTALLATION
Select and install the snap ring onto the output shaft so that
the output shaft rear bearing clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
INSPECTION
OUTPUT SHAFT
Check the spline for damage and wear.
NEEDLE BEARING
(1) When the needle bearing is assembled with the bearing
sleeve and gear and rotated, the needle bearing must
rotate smoothly without play or abnormal noise.
(2) The holder must not be deformed.
SYNCHRONIZER RING
(1) The clutch gear teeth must not be damaged or broken.
(2) The inner diameter of the cone must not be damaged
or worn, and the screw threads must not be crushed.
(3) Press the synchronizer ring against the gears, and check
the clearance “A”. Replace if “A” is less than the limit
value.
Limit value: 0.5 mm
Snap ring
Gear“A”
Synchronizer
ring

PROPELLER SHAFT - Propeller Shaft25-5
DISASSEMBLY AND REASSEMBLY
LJ kit LJ boot kit11 9
876 5
4
3
1
2
1716
15 14
1312
16
15
141312
111415
1412
11
187±29 N·m
34±5 N·m187±29 N·m
34±5 N·m
10
Disassembly steps
1. Bolt
2. Front propeller shaft assembly
"DA3. Self locking nut
AA""DA4. Companion flange
AB""DA5. Center bearing assembly
AC"6. Bolt
"DA7. Self locking nut
"DA8. Companion flange
"DA9. Center bearing assembly10. Center propeller shaft
11. Snap ring
"CA12. Boot band
AD""BA13. LJ assembly
14. Rubber packing
AE""AA15. LJ boot
16. Washer
17. Rear propeller shaft

PROPELLER SHAFT - Propeller Shaft25-7
DISASSEMBLY SERVICE POINTS
AA"COMPANION FLANGE REMOVAL
Make mating marks on the companion flange and center
propeller shaft. Then, remove the companion flange.
AB"CENTER BEARING ASSEMBLY REMOVAL
AC"BOLT REMOVAL
Make mating marks on the rear propeller shaft, LJ assembly
and companion flange. Then, remove the bolt.
AD"LJ ASSEMBLY REMOVAL
1. Remove the LJ boot from the LJ assembly.
2. Mark the mating marks in outer race, cage and inner
race, then remove the circlip, outer race and ball.
NOTE
Ensure the installation position of ball and keep the ball
in order to refer in installation.Mating marks
MD998801
Center
bearing
assembly
LJ assembly
LJ boot
Circlip Outer race
Inner race
Cage
Ball

PROPELLER SHAFT - Propeller Shaft25-10
"DACENTER BEARING ASSEMBLY/COMPANION
FLANGE/SELF LOCKING NUT INSTALLATION
1. Install the center bearing assembly to the rear propeller
shaft in the direction shown as the illustration.
2. After alining the mating marks of the companion flange
and rear propeller shaft, install them.
3. Tightening the self locking nut, press fit the center bearing
assembly using companion flange.Center propeller shaft rear side
Companion
flange
Self
locking
nut
Center bearing
assembly
Dust sealRubber
mount
Center propeller shaft front side
Companion
flange
Self
locking
nut

27B-1
REAR AXLE
CONTENTS
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
SEALANTS 4................................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING (AYC) 8.................
ON-VEHICLE SERVICE 16....................
Rear Axle Total Backlash Check 16...............
Gear Oil Level Check 16........................
Gear Oil Change 17............................
Fluid Level Check 19............................
Bleeding 19....................................
AYC Operation Check 20........................
Oil Pressure Check 21..........................Wheel Bearing Axial Play Check 22...............
Wheel Bearing Rotary-sliding Resistance Check 22.
Hub Bolt Replacement 23.......................
Differential Carrier Oil Seal Replacement 23........
Action When Battery Runs Out 24................
REAR HUB ASSEMBLY 25....................
KNUCKLE 28................................
DRIVE SHAFT 29.............................
DIFFERENTIAL CARRIER
35......
DIFFERENTIAL CARRIER
55...................
HYDRAULIC UNIT
61..............

REAR AXLE -General Information27B-2
GENERAL INFORMATION
The rear axle consists of rear hubs, wheel bearings,
drive shafts, and rear differential and, it has the
following features.
DThe wheel bearing is a unit bearing (double-row
angular contact ball bearing).
DThe drive shaft incorporates B.J.-T.J. type
constant velocity joints with high transmission
efficiency and low vibration and noise.DABS rotors for detecting the wheel speeds are
press-fitted to the B.J. outer wheels in vehicles
with ABS or ACD.
NOTE
1. B.J.: Birfield Joint
2. T.J.: Tripod Joint
SPECIFICATIONS
ItemVehicles without AYCVehicles with AYC
Wheel
bearingsWheel bearing typeUnit bearing (Double-row angular contact ball
bearing)
g
Bearing (outside diameter×inside diameter) mm78×40
Drive
shaft
Joint typeOutsideB.J.
shaftInsideT.J.
Shaft length*1×Shaft diameter
mm
Left483×25426×25
mmRight573×25446×25
NOTE
*1: The shaft length indicates the length between the center points of each joint.
STRUCTURAL DIAGRAM
Oil sealRear hub Differential carrier
B.J.
Drive shaftT. J .

REAR AXLE -Service Specifications/Lubricants27B-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Rear axle total backlash mm-6
Wheel bearing rotation starting torque N·m-1.0
Wheel bearing axial play mm-0.05 or less
Wheel bearing rotary-sliding resistance N-22 or less
TJ boot assembly dimension mm90±3-
Drive gear backlash mm0.11 – 0.16-
Drive gear runout mm-0.05
Drive pinion turning
torqueN·m
Without oil seal0.88 – 1.17-
torqueN·m
With oil sealCompanion flange (oil seal contact-
ing area) with anti-rust agent0.98 – 1.27-
Companion flange (oil seal contact-
ing area) with gear oil applied0.49 – 0.58-
Vehicles with mechani-
cal LSDRight-to-left difference in combined thickness of friction
plate and friction disc
mm
0 – 0.05-
Clearance between spring plate and differential case
mm
0.06 – 0.25-
LSDdifferential
torqueN·m
When new clutch plate is installed5–19-
torqueN·m
When existing clutch plate is
installed2–19-
Distortion of friction plate and friction discmm-0.08
Difference in thickness between friction plate, friction
disc, and spring plate
mm
-0.1
Vehicles with ACD and
AY CPressure generated by hydraulic unit (pressure sensor
value
)MPa
0.9 – 1.1-
LUBRICANTS
ItemSpecified lubricantsQuantity
Vehicles with
mechanical
S
Gear oilHypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 81496300.55L
LSDMITSUBISHIGenuineGearOilPartNo.8149630
EX, CASTROL HYPOY LS (GL-5, SAE 90),
SHELL-LSD (GL-5, SAE 80W - 90) or equivalent
Vehicles with
ACD and
AY CGear oilDifferentialHypoid gear oil
API classification GL-5 or higher SAE viscosity
No.90, 80W0.55±0.02L
Torque transfer
mechanismATF-SP™0.65 - 0.7L