differential MITSUBISHI LANCER EVOLUTION 2007 Service User Guide

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-41
4. Fill with specified oil till the level comes to the lower portion
of oil filler plug hole.
Specified transfer 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
Quantity:
0.55 L ACD and AYC>
0.6 L and AYC>
5. Tighten the oil filler plug to the specified torque.
Tightening torque: 32±2 N·m
FLUID CHECK VEHICLES WITH ACD AND AYC>
1. Remove the maintenance lid located in the luggage
compartment.
2.
If the vehicle has been run, leave it for 90 min. or more
in an ordinary temperature (10_C–30_C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is 10_C or less, allow more
time to leave the vehicle to stand idle.

Set the MUT-IIto the 16-pin diagnosis connector. Turn ON
the ignition switch, perform MUT-IIactuator test (Item
No.03), forcibly drive the hydraulic unit and remove the
pressure in the accumulator.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
NOTE
(1) In the actuator test (Item No. 03: Oil Level Check
Mode), the directional valve of the hydraulic unit is
moved to the left and right for 20 times, and then
the differential is cleared automatically. Drive can also
be cleared forcibly using the Clear key of the MUT-II.
(2) If the function has been stopped by fail-safe, the
hydraulic unit cannot be cleared forcibly.
3. Check that the fluid level in the oil reservoir is in the
range between MAX and MIN.
4. If the fluid level is lower than MIN, add the specified
fluid.
Specified fluid: Dia Queen ATF SP III
5. Reinstall the maintenance lid.

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 6..........................
SERVICE SPECIFICATIONS 6.................
SEALANTS 7................................
LUBRICANTS 8..............................
SNAP RINGS, SPACERS AND THRUST
PLATES FOR ADJUSTMENT 9................
TIGHTENING TORQUE 11....................
SPECIAL TOOLS 12..........................
TRANSMISSION 15...........................
INPUT SHAFT 22............................OUTPUT SHAFT 29..........................
REVERSE IDLER GEAR 37...................
SPEEDOMETER GEAR 38....................
SELECT LEVER 39...........................
CONTROL HOUSING 40......................
CLUTCH HOUSING 43........................
TRANSMISSION CASE 46....................
CENTER DIFFERENTIAL 48..................
TRANSFER 51...............................

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 -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 -Lubricants22B-8
LUBRICANTS
TRANSMISSION
ItemsSpecified lubricants
Drive shaft oil seal lip sectionMITSUBISHI genuine “DIA-QUEEN” multi
gearoil<75W/85W>orequivalent
Input shaft oil seal lip section
gear oil<75W/85W> or equivalent
Control shaft oil seal lip section
Select lever shoeMITSUBISHI genuine grease Part
No.0101011 or equivalent
TRANSFER
ItemsSpecified lubricants
Drive shaft oil seal lip sectionMITSUBISHI genuine “DIA-QUEEN
SUPER”hypoidgearoil(GL 5)or
Front differential oil seal lip section
SUPER”hypoidgear oil(GL-5)or
equivalent
Each O-ring

MANUAL TRANSMISSION OVERHAUL -Snap Rings, Spacers and Thrust
Plates for Adjustment22B-10
SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT BEARING CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.36
1.40
1.44
1.48
1.51Yellow
Green
None
Black
BlueMD748449
MD748450
MD746602
MD748451
MD7466031.55
1.58
1.63
1.68White
Brown
Orange
BlueMD748452
MD746604
MD748453
MD748454
SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
2.81
2.85
2.89
2.93None
Blue
Brown
YellowMD746594
MD746595
MD746596
MD7465972.97
3.01
3.05
3.09Green
Black
White
OrangeMD746598
MD746599
MD746600
MD746601
SPACERS (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.74
0.77
0.80
0.83
0.86
0.89
0.92
0.95
0.98
1.0174
77
80
83
86
89
92
95
98
01MD727660
MD754476
MD727661
MD720937
MD720938
MD720939
MD720940
MD720941
MD720942
MD7209431.04
1.07
1.10
1.13
1.16
1.19
1.22
1.25
1.28
1.3104
07
J
D
K
L
G
M
N
EMD720944
MD750945
MD710454
MD700270
MD710455
MD710456
MD700271
MD710457
MD710458
MD706547
SPACERS (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PINION
BACKLASH)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.6
0.7
0.8-
-
-MD748362
MD748363
MD7483640.9
1.0
1.1-
-
-MD748365
MD748366
MD748367

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 -Special Tools22B-12
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bush remover
and installer ringInstallation of transfer oil seal
MB990891Bush remover and
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller
bearing
MB990936Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing
MB990937Installer adapterInstallation of differential case taper roller
bearing and transfer extention housing oil
seal
MB990938HandleUse for installer adaptor
MB991445Bush remover and
installer baseInstallation of differential case taper roller
bearing outer race

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