oil MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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

REAR AXLE -Lubricants/Sealants/Special tools27B-4
ItemQuantity Specified lubricants
Vehicles with
ACDand
Hydraulic piping fluidATF-SP™1L
ACDand
AY CTorque transfer mechanism oil
seal lipsVaselineAs required
B.J. jointRepair kit grease85±10 g
T.J. jointRepair kit grease105±10 g
SEALANTS
ItemsSpecified sealantsRemarks
Vehicles with me-
chanicalLSD
Vent plug3M ATD Part No. 8661, 8663 or
equivalent
Semi-drying sealant
chanicalLSD
Differential cover assembly
equivalent
Vehicles with ACD
andAYC
Vent plug
andAYC
Differential carrier cover
mounting part
Vehicles with me-
chanical LSDDrive gear and differential
case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IIsub as-
semblyInspection of AYC (diagnosis display by
MUT-II)
MB991529Diagnosis code
check harnessInspection of AYC
(diagnosis display by ACD mode indicator
lamp)
MD998330
(MD998331)Oil pressure gaugeHydraulic pressure measurement with AYC>
MB991705Hose adapter
MB990925Bearing and oil
seal installer setRemoval of wheel bearing

REAR AXLE -Special Tools27B-5
Tool UseName Number
MB991115Oil seal installerPress-fitting of oil seal
(AYC differential: used in combination with
MB990938)
MD998812Installer capPress-fitting of oil seal
(torque transfer mechanism of vehicles with
AYC)
MD998813Installer100
MD998829Installer adapter
(60)
MB990767Front hub and
flange yoke holderRemoval, installation of the drive shaft nut
A
B
MB990241
A: MB990242
B: MB990244Rear axle shaft
puller
A:Puller shaft
B:Puller barDRemoval of drive shaft
DRemoval of rear hub assembly
MB991354Puller body
A
CB
00005697
A: MB991017
B: MB990998
C: MB991000A,B: Front hub re-
mover and in-
staller
C: SpacerDTemporary fixing of wheel bearing
DMeasurement of wheel bearing rotation
starting torque
DMeasurement of wheel bearing axial play
Use MB991000 (component of MB990998)
for the spacer.

REAR AXLE -Special Tools27B-6
ToolNumberNameUse
MB990685Torque wrenchMeasurement of the starting torque of wheel
bearing
MB990326Preload socket
MB991113 or
MB990635Steering linkage
pullerDisconnection of ball joint
MB990641Lower arm bush
(A) remover & in-
stallerRemoval and press-fitting of differential
support member bush
MB991439Bush remover &
installerRemoval and press-fitting of differential
support arm bush
MB991460PlugPrevention of differential oil from being
discharged and entry of foreign matter differential>
MB990909Working baseSupporting of the differential carrier
MB991116AdapterSupport of differential carrier assembly
MB990810Side bearing pullerDRemoval of the side bearing inner race
DRemoval of the companion flange

REAR AXLE -Special Tools27B-7
Tool UseName Number
MB990850End yoke holderDRemoval of the self-locking nut
DAdjustment of the drive pinion turning
torque
MB990339Bearing pullerDrive pinion rear bearing inner race removal
MB990648Bearing remover
B A
MB990835
A: MB990836
B: MB990392Drive pinion setting
gauge set
A: Drive pinion
gauge assem-
bly
B: Cylinder
gaugeAdjustment of drive pinion height
MB990988Side gear holding
tool setMeasurement of clutch plate preload (vehicles
with mechanical LSD)
MB990728Side & rear bearing
inner race installerPress-fitting of drive pinion rear bearing inner
race
MB990727Oil seal installerPress-fitting of drive pinion oil seal
MB990813Ta pRemoval of adhesive

REAR AXLE -Troubleshooting REAR AXLE -Troubleshooting 27B-14
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure No.Reference
page
Communication between MUT-IIand the whole system is not possible.1Refer to
GROUP22
Communication between MUT-IIand 4WD-ECU is not possible.2
GROUP22.
3 ACD mode indicator lamps do not light up when the ignition key is turned to “ON”
(engine stationary).3
3 ACD mode indicator lamps remain lit up after the engine has started.4
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.527B-14
Rear tires are noisy during low-speed cornering.
Vehicle skews.627B-15
Noise is produced from the torque transfer differential during turning.727B-15
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 5
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.
Probable cause
The hydraulic oil level is probably low, there is an oil leak, the hydraulic unit is defective,
or the torque transfer differential is defective.DLow hydraulic oil level
DOil leak
DDefective hydraulic unit
DDefective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the hydraulic unit. (Refer to
P.27B-61.)
NG
Add fluid. (Refer to P.27B-19.)
OKRepair
Check the trouble symptom.NO
Replace the torque transfer differential.
OK
Is foreign matter trapped in the hydrau-
lic line?YES
Repair
OK
Check the fluid level.
(Refer to P.27B-19.)Check the hydraulic pressure line for
leak.
OK
Add gear oil. (Refer to P.27B-16.)
OK
Check hydraulic pressure.
(Refer to P.27-21.)NGBleed the system of air.
(Refer to P.27-19.)
Check the gear oil level. (Refer to
P.27B-16.)NGCheck for oil leak.NG
Repair
Check the AYC for operation.
(Refer to P.27B-20.)Check the trouble symptom. OKOK
NGNormal
NGNG

REAR AXLE -Troubleshooting 27B-15
INSPECTION PROCEDURE 6
Rear tires are noisy during low-speed cornering.
Vehicle skews.
Probable cause
The hydraulic unit or torque transfer differential is probably defective.DDefective hydraulic unit
DDefective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the hydraulic unit. (Refer to
P.27B-61.)
NG
Add fluid. (Refer to P.27B-19.)
OKRepair
Check the trouble symptom.NO
Replace the torque transfer differential.
OK
Is foreign matter trapped in the hydrau-
lic line?YES
Repair
Check the fluid level.
(Refer to P.27B-19.)Check the hydraulic pressure line for
leak.
OK
Check hydraulic pressure.
(Refer to P.27-21.)NGBleed the system of air.
(Refer to P.27-19.)
Check the AYC for operation.
(Refer to P.27B-20.)Check the trouble symptom. OK
NG
NGNG
INSPECTION PROCEDURE 7
Noise is produced from the torque transfer differential
during turning
Probable cause
The torque transfer differential is probably defective.DDefective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the gear oil of the torque transfer differential. (Refer to
P.27B-17.)
Replace the gear oil of the torque transfer differential. (Refer to
P.27B-17.)Normal
Replace the gear oil of the torque transfer differential. (Refer to
P.27B-17.)
Replace the torque transfer differential.
Check the trouble symptom.
OKNG
NG
MUT-IIActuator test
DNo. 06 Clutch operation check (left side) 5 times
DNo. 07 Clutch operation check (right side) 5 times
DSteering wheel on neutral position
DDrive straight in 20 km/h or less
MUT-IIActuator test
DNo. 06 Clutch operation check (left side) 5 times
DNo. 07 Clutch operation check (right side) 5 times
DSteering wheel on neutral position
DDrive straight in 20 km/h or less
Check the trouble symptom.
Normal

REAR AXLE -On-vehicle Service27B-16
DATA LIST REFERENCE TABLE
For check, refer to GROUP 22.
ACTUATOR TEST REFERENCE TABLE
For check, refer to GROUP 22.
CHECK AT 4WD-ECU TERMINALS
For check, refer to GROUP 22.
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position.
Apply the parking brake. Raise the vehicle on a jack.
3. Turn the companion flange clockwise as far as it will go.
Make the mating mark on the dust cover of the companion
flange and on the differential carrier.
4. Turn the companion flange anti-clockwise as far as it
will go, and measure the amount of distance the mating
marks moved.
Limit: 6 mm
5. If the backlash exceeds the limit value, replace the
differential carrier assembly.
GEAR OIL LEVEL CHECK

1. Remove the filler plug.
2. Check that the gear oil level is within the specified range
from the bottom end of the filler plug hole.
3. If the gear oil level exceeds the standard value, add the
specified gear oil up to the bottom end of the filler plug
hole.
Specified gear oil:
Hypoid gear 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
4. Fit the filler plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m
Mating marks
Upper
limit
Lower
limit
Gear oil
8mm