oil MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

REAR AXLE -Drive Shaft27B-30
REMOVAL SERVICE POINTS
AA"REAR BRAKE CALIPER REMOVAL
Suspend the rear brake caliper from the body with wire, etc.
to prevent it from falling.
Caution
If the vehicle is equipped with 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.
And if there is brake fluid on the caliper, wipe out quickly.
AB"DRIVE SHAFT NUT REMOVAL
Caution
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
AC"REAR DRIVE SHAFT ASSEMBLY REMOVAL
1. Use the special tools to push out the drive shaft from
the hub.
2. Remove the drive shaft from the transmission by the
following procedure.
Insert a pry bar between the differential carrier and the
drive shaft, and then pry the drive shaft from the differential
carrier.
Caution
(1) Do not pull on the drive shaft; doing so will damage
the T.J.; be sure to use the pry bar.
(2) When pulling the drive shaft out from the
differential carrier, be careful that the spline part
of the drive shaft does not damage the oil seal.
(3) Do not apply the vehicle weight to the wheel
bearing while loosening the drive shaft nut.
Otherwise wheel bearing will be damaged. If,
however, the vehicle weight must be applied to
the bearing (because of moving the vehicle),
temporarily secure the wheel bearing by using
the special tool.
MB990767
MB990767
MB990242MB991354
MB990244
(3)
Differential carrier
T.J. assembly
Lever
MB991017 MB991000
(MB990998)

REAR AXLE -Drive Shaft27B-31
(4) To prevent entry of foreign matter into the
differential carrier, use the special tool as a cover.

INSTALLATION SERVICE POINTS
"AADRIVE SHAFT INSTALLATION
Caution
When installing the drive shaft to the differential carrier,
be careful that the spline part of the drive shaft does not
damage the oil seal.
"BADRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.
2. Tighten the drive shaft nut fully with special tools.
Caution
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing
before tightening drive shaft nut fully.
3. If the pin hole does not align with another, tighten the
drive shaft nut (less than 250 N
·m) and find the nearest
hole then bend the split pin to fit in.
MB991460
MB990767
225±25 N·m
Washer

REAR AXLE -Differential Carrier 27B-35
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation
DDifferential Gear Oil Draining (Refer to P.27B-17.)
DLower Arm Assembly Removal (Refer to GROUP
34.)
DRear Stabilizer Removal (Refer to GROUP 34.)
DDrive Shaft Removal (Refer to P. 27B-29.)Post-installation Operation
DDrive Shaft Installation (Refer to P. 27B-29.)
DRear Stabilizer Installation (Refer to GROUP 34.)
DLower Arm Assembly Installation (Refer to GROUP
34.)
DDifferential Gear Oil Filling (Refer to P.27B-17.)
12
765
4 8 910
32¶2Nm
2
3
3 3
3
76
9
120±10 N·m
88±10 N·m
69±9 N·m
88±10 N·m
88±10 N·m
88±10 N·m
120±10 N·m
120±10 N·m
120±10 N·m
69±9 N·m
88±10 N·m
Removal steps
AA"1. Propeller shaft connection (Refer to
GROUP 25.)
2. Toe control bar
3. Differential support member mount-
ing boots and nuts
AB""AA4. Rear crossmember and differential
carrier assembly5. Differential support member
6. Upper stopper
7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential carrier assembly

REAR AXLE -Differential Carrier 27B-38
DISASSEMBLY
19
2
6
8
20
22
26
5
113
4
9
12
15
16
1314
10
21
1
23
24
25
18
17
7
897
Disassembly steps
AA"DInspection before disassembly
1. Filler plug
2. Drain plug
3. Differential cover assembly
4. Vent plug
5. Bearing cap
AB"6. Differential case assembly
AB"7. Side bearing spacer
AB"8. Side bearing outer race
AC"9. Side bearing inner race
AD"10. Drive gear
11. Limited slip differential case assembly*
AE"12. Self-locking nut
13. Washer
AF"14. Drive pinion assemblyAF"15. Companion flange
16. Drive pinion front shim (For adjusting
preload of drive pinion)
17. Drive pinion spacer
AG"18. Drive pinion rear bearing inner race
19. Drive pinion rear shim (For adjusting
drive pinion height)
20. Drive pinion
AH"21. Oil seal
AH"22. Drive pinion front bearing inner race
AH"23. Drive pinion front bearing outer race
AI"24. Drive pinion rear bearing outer race
25. Oil seal
26. Differential carrier

REAR AXLE -Differential Carrier 27B-42
AF"DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
1. Make the mating marks to the drive pinion and companion
flange.
Caution
Do not make mating marks on the contact surfaces
of the companion flange and propeller shaft.
2. Use special tools to pull out the companion flange.
AG"DRIVE PINION REAR BEARING INNER RACE
REMOVAL
Use special tools to pull out the front bearing inner race.
AH"OIL SEAL/DRIVE PINION FRONT BEARING
INNER RACE/DRIVE PINION FRONT BEARING
OUTER RACE REMOVAL
Use special tool to remove drive pinion front bearing outer
race.
AI"DRIVE PINION REAR BEARING OUTER RACE
REMOVAL
Use special tool to remove the drive pinion rear bearing outer
race.
Companion
flange
MB990810
MB990339
MB990648
Drive pinion
front bearing
outer race
Oil seal
MB990939
Drive pinion
rear bearing
outer race
Drive pinion
front bearing
inner race
MB990939

REAR AXLE -Differential Carrier 27B-43
REASSEMBLY
11
14
26
25
1310
6
124
7
24
21
18
17
15
2019
9
3
8
5
2
1
22
23
16
191820
5
17
15
84±4 N·m
186±29 N·m64±4 N·m
49±9 N·m
37±2 N·m
36±5 N·m
Final drive gear set
Reassembly steps
1. Differential carrier
"AA2. Oil seal
"BA3. Drive pinion rear bearing outer race
"CA4. Drive pinion front bearing outer race
"DADDrive pinion height adjustment
5. Drive pinion
6. Drive pinion rear shim (For adjusting
drive pinion height)
7. Drive pinion rear bearing inner race
8. Drive pinion spacer
"EADDrive pinion turning torque adjustment
9. Drive pinion front shim (For adjusting
drive pinion preload)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
"EA12. Oil seal13. Companion flange
14. Washer
15. Self-locking nut
16. Limited slip differential case assembly
"FA17. Drive gear
"GA18. Side bearing inner race
19. Side bearing outer race
20. Side bearing spacer
21. Differential case assembly
"HA22. Bearing cap
23. Vent plug
24. Differential cover assembly
25. Drain plug
26. Filler plug
"HADFinal drive gear backlash adjustment

REAR AXLE -Differential Carrier 27B-44
Lubrication and Adhesive Points
Vent plug
2 - 3mm
(bead diameter)
Adhesive: 3M Stud Locking
4170 or equivalentSealant: 3M ATD Part No.8661, 8663
or equivalent
REASSEMBLY SERVICE POINTS
"AAOIL SEAL PRESS-FITTING
MB990938
MB991115

REAR AXLE -Differential Carrier 27B-45
"BADRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
"CADRIVE PINION FRONT BEARING OUTER RACE
PRESS-FITTING
"DADRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool.
2. Install special tool and drive pinion front and rear bearing
inner races to the gear carrier in the sequence shown
in the illustration.
3. Tighten the nut of special tool a little at a time while
measuring the turning torque of the drive pinion. Then
confirm the turning torque (without the oil seal) is at the
standard value.
Standard value:
Bearing typeTurning torque
New0.88 - 1.17 N·m
Caution
Take care not to fit gear oil on the bearing.
NOTE
The special tool can not rotate, move several times in
moving area, after rotating the bearing, measure the
torque.
MB990938
MB990935
MB990938
MB990932
MB990836
(MB990835)
MB990836
MB990326 MB990685
MB990836

REAR AXLE -Differential Carrier 27B-46
4. Clean the side bearing hub.
5. Place special tool between the side bearing hub of the
gear carrier, and position the notch as shown in the
illustration. Then tighten side bearing mounting bolt.
6. Use a thickness gauge to measure the clearance (A)
between special tools.
7. Remove special tools (MB990835, MB990326).
8. Use a micrometer to measure the shown dimensions (B,
C) of special tools.
9. Install the bearing cap, and then use a cylinder gauge
to measure inside diameter (D) of the bearing cap.
10. Calculate thickness (F) of the required drive pinion rear
shim twice by the following formula. Select a shim which
most closely matches this thickness.
F = A + B + C - 1/2D - 86.00 mm
11. Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using special tool.
"EADRIVE PINION TURNING TORQUE ADJUSTMENT
/OIL SEAL INSTALLATION
1. Insert the drive pinion into the gear carrier, and then install
the following parts in sequence from the carrier rear side.
Drive pinion spacer, drive pinion front shim and drive
pinion front bearing inner race, companion flange.
NOTE
Do not install the oil seal.
2. Tighten the companion flange to the specified torque by
using special tool.
Thickness
gauge
MB990392
(MB990835)Notch
MB990836
(MB990835)A
BC
Cylinder
gauge
Drive pinion
rear shim
MB990728
MB990850
186±29 N·m

REAR AXLE -Differential Carrier 27B-47
3. Measure the drive pinion turning torque (without the oil
seal).
Standard value:
Bearing divisionTurning torque
New0.88 - 1.17 N·m
Caution
Take care not to fit gear oil on the bearing.
4. If the drive pinion turning torque is not within the standard
value, adjust the turning torque by replacing the drive
pinion front shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion front shims, if the number
of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following
two types.
Height of drive pinion spacer mmIdentification colour
57.72-
57.08Red
5. Remove the companion flange and drive pinion again.
Then insert the drive pinion front bearing inner race into
the gear carrier. Use special tool to press-fit the oil seal.
6. Install the drive pinion assembly and companion flange
with mating marks properly aligned. Tighten the
companion flange self-locking nut to the specified torque
using special tool.
MB990326
MB990685
Identification
colour
MB990727
MB990850
186±29 N·m