lock MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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-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-57
BUSHING REPLACEMENT
1. Remove and press fit the bush with special tool.
2. Press fit th bush so that the hollow of the bush is on
the position shown as the illustration.
3. Press fill the bush until the surface of the outer sleeve
of the bush,differential support member or differential
support arm contact.

Removal
Press-fitting Bush
Hollow Differential
support
member

Bush
Differential
support arm
HollowMB990641
MB991439 Steel block
Steel blockSteel block

REAR AXLE -Differential Carrier 27B-58
TORQUE TRANSFER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
Caution
1. The differential carrier assembly is non-maintainable.
2. No foreign matter should be allowed inside and at the joints of the differential carrier assembly.
14
2
6
4
35
7
1
9
10
8
3
4
11
13
12
186¶29 Nm
32¶2Nm 49¶10 Nm
5¶1Nm
9¶1Nm 49¶10 Nm
Disassembly steps
1. Drain plug
2. Packing
3. Filler plug
4. Gasket
5. Vent plug
6. Bleeder screw
7. CoverAA"8. Self-locking nut
9. Washer
10. Companion flange
11. Oil seal
"BA12. Oil seal
"AA13. Oil seal
14. Differential carrier assembly

REAR AXLE -Differential Carrier 27B-59
Lubrication and Adhesive Points
Grease: VaselineSealant: 3M ATD Part
No.8661, 8663 or equivalent
Sealant: 3M ATD Part
No.8661, 8663 or equivalent
DISASSEMBLY SERVICE POINT
AA"SELF-LOCKING NUT REMOVAL
MB990850

32-1
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATION 2..................
SPECIAL TOOL 3............................
ENGINE MOUNTING 4........................TRANSMISSION MOUNTING 5................
ENGINE ROLL STOPPER, CENTERMEMBER
6 ............................................
CROSSMEMBER* 8..........................
WARNING 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 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 (*).

POWER PLANT MOUNT - Crossmember32-8
CROSSMEMBER
REMOVAL AND INSTALLATION
Caution
1. Before removing the steering wheel and air bag module assembly, always refer to GROUP
52B - Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so
that they are facing straight forward, and remove the ignition key. If you fail to do this, the
SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
2. *
1: 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.
3. *
2: Indicates parts which should be temporarily tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
Caution
If the vehicle is equipped the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operations
DUnder Cover Removal
(Refer to GROUP 51 - Front Bumper.)
DCentermember, Crossmember Bar Removal
(Refer to P.32-6.)
DFront Exhaust Pipe Removal
(Refer to GROUP 15.)
DSteering Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37A.)
DPower Steering Fluid Draining
(Refer to GROUP 37A - On-vehicle Service.)Post-installation Operations
DCentermember, Crossmember Bar Installation
(Refer to P.32-6.)
DFront Exhaust Pipe Installation
(Refer to GROUP 15.)
DSteering Wheel Air Bag Module Assembly
Installation (Refer to GROUP 37A.)
DPower Steering Fluid Supplying
(Refer to GROUP 37A - On-vehicle Service.)
DPower Steering Fluid Line Bleeding
(Refer to GROUP 37A - On-vehicle Service.)
DPress the dust cover with a finger to check whether
the dust cover is cracked or damaged.
DChecking Steering Wheel Position with Wheels
Straight Ahead
DFront Wheel Alignment Check and Adjustment
(Refer to GROUP 37A - On-vehicle Service.)
DUnder Cover Installation
(Refer to GROUP 51 - Front Bumper.)

POWER PLANT MOUNT - Crossmember32-11
REMOVAL SERVICE POINTS
AA"LOWER ARM ASSEMBLY REMOVAL
Lift the transmission with a transmission jack, and then
withdraw the front mounting bolt on the left lower arm
assembly.
AB"TIE ROD END AND KNUCKLE DISCONNECTION
Caution
1. The thread on the ball joint may be damaged. Do
not remove the tie rod end mounting nut from the
ball joint.Just loosen the nut. For this operation, use
the special tool.
2. Suspend the special tool with a cord to prevent it
from dropping.
AC"CROSSMEMBER ASSEMBLY REMOVAL
Retain the crossmember with a transmission jack, and then
remove the crossmember mounting bolt.
INSTALLATION SERVICE POINT
"AASTABILIZER BAR INSTALLATION
Align the identification colour on the left side of the stabilizer
bar with the right end of the bushing.
INSPECTION
DCheck the crossmember for cracks and damage.
Wooden block
Transmission jack
Mounting bolt
Cord
Ball joint
MB990635
MB991113 or
MB991406
Nut
Wooden
block
Transmission
jack
Identification
colourOutside of
vehicle
BushingFixture

FRONT SUSPENSION -Special Tools/On-vehicle Service33A-4
Tools UseName Number
MB990800Ball joint remover &
installerLower arm ball joint dust cover press-in
MB990651BarLower arm pillow ball bushing removal and
press-fitting
MB990816Bushing remover &
installer base
MB991576Base
MB990635,
MB991113 or
MB991406Steering linkage
pullerTie rod end and knuckle disconnection
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
Measure the wheel alignment with the vehicle parked on a
level surface.
The front suspension, steering system, and wheels should be
serviced to normal condition prior to measurement of wheel
alignment.
TOE-IN
Standard value:
At the centre of tyre tread 0±2mm
Toe angle (per wheel) 0_00’±05’
1. Adjust the toe-in by undoing the clip and lock nut, and
turning the left and right tie rod turnbuckles by the same
amount (in opposite directions).
NOTE
The toe will move out as the left turnbuckle is turned
toward the front of the vehicle and the right turnbuckle
is turned toward the rear of the vehicle.
2. Install the clip and tighten the lock nut to the specified torque.
Clip
Lock nut

FRONT SUSPENSION -Strut Assembly33A-7
DISASSEMBLY AND REASSEMBLY
60±10 N·m
3
2
1
5
6
7
8
9
4
3
Disassembly steps
1. Dust cover
AA""AA2. Self-locking nut
3. Strut insulator assembly
4. Upper spring seat assembly
5. Bump rubber6. Dust cover
7. Coil spring
8. Lower spring pad
AB"9. Strut assembly
DISASSEMBLY SERVICE POINTS
AA"SELF-LOCKING NUT REMOVAL
1. Use the special tools to compress the coil spring.
Caution
(1) Do not tighten the special tool bolt too tight. The
special tool will be broken if the allowable
tightening torque of 74 N·m is exceed.
(2) Install the special tools evenly, and so that the
maximum length will be attained within the
installation range.
(3) Do not use an impact wrench as it will cause the
bolt of the special tool to be seized.
2. Using the special tools, loosen the self-locking nut.
Caution
To prevent the piston rod lock nut inside the strut
from loosening, do not use an impact wrench when
the self-locking nut is loosened.
MB991237
MB991238
MB991681
MB991682