oil 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-52
5. Find dimension (B) between the spring plate faying
surfaces when differential case A and B are assembled
together.
B=C+D - E
6. If the clearance between the spring plate and differential
case (B - A) is outside the specified range, change the
friction discs and make adjustments.
Standard value: 0.06 – 0.25 mm
7. Coat each part with the specified gear oil and mount
it in the specified direction and order into differential case
B.
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
NOTE
Apply a careful coat of gear oil to the contacting and
sliding surfaces.
"BASCREW TIGHTENING
1. Align the alignment mark on differential case A with that
on differential case B.
2. Tighten the screws connecting differential case A and
B a uniform amount little by little in the diagonal order.
NOTE
If tightening the screws does not bring the two cases
properly together, spring plates are not probably
assembled properly. Reassemble from the start.
"CALSD DIFFERENTIAL TORQUE CHECK
1. Using the special tool, check for differential torque.
Standard value:
ItemLSD differential
torque N·m
Whennewclutchplateisinstalled5–19When new clutchplateisinstalled5–19
Whenexistingclutchplateisinstalled2–19When existing clutchplateisinstalled2–19
NOTE
Before measuring the differential torque, first turn the
gears so they snug each other, then take measurements
during rotation.
2. If the measurement falls outside the specified range,
disassemble the differential case assembly and repair
or replace defective parts.
D
Differential
case A
E C
Differential
case B
Spring plateFriction plate Friction disc
MB990990
MB990989

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-55
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation
DHydraulic Piping Fluid Draining
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.)
DHydraulic Piping Fluid Filling and Bleeding (Refer
to P.27B-17 and P.27B-19.)
1
2
88¶10 Nm
7 6
5
48
9
10 3
11
44¶10 Nm
120¶10 Nm34¶5Nm*
1
32¶2Nm
12¶2Nm 26¶4Nm*
2
88¶10 Nm
88¶10 Nm 88¶10 Nm 88¶10 NmNOTE:
*1:Thread is not lubricated
*2:Thread is lubricated
Removal steps
1. Hydraulic unit hose assembly con-
nection
AA"2. Propeller shaft connection (Refer to
GROUP 25.)
3. Differential support member mount-
ing nuts
4. Rear crossmember and differential
carrier assembly
(Refer to P. 27B-35.)5. Differential support member
"AA6. Upper stopper
"AA7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential mount bracket
11. Differential carrier assembly

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-60
ASSEMBLY SERVICE POINTS
"AAOIL SEAL PRESS-FITTING
1. Using the special tool, pressfit the oil seal as far as it
will go.
2. Apply the specified grease to the oil seal lip.
Specified grease: Vaseline
"BADRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
1. Using the special tool, pressfit the oil seal as far as the
oil seal will go.
2. Apply the multipurpose grease to the oil seal lip.
MD998829
MD998812
MD998813
MB990938
MB991115

REAR AXLE- Hydraulic Unit 27B-61
HYDRAULIC UNIT
REMOVAL AND INSTALLATION
Caution
(1) When connecting the return hose and suction hose, do not apply lubricant.
(2) No foreign matter should be allowed in the hydraulic piping and joints.
Pre-removal Operation
DTrunk Side Trim Removal (Refer to GROUP 52A.)
DHydraulic Piping Fluid DrainingPost-installation Operation
DHydraulic Piping Fluid Filling and Bleeding
(Refer to P.27B-17 and P.27B-19.)
DTrunk Side Trim Installation (Refer to GROUP 52A.)
12
7 6 4
8 9
10
311
34¶5Nm*1
24¶4Nm
12¶2Nm
26¶4Nm*
2
5
12¶2Nm
12¶2Nm
18¶2Nm 34¶5Nm*1
26¶4Nm*2
18¶2Nm12¶2Nm 34¶5Nm*
1
26¶4Nm*2
12¶2Nm
NOTE:
*1:Thread is not lubricated
*2:Thread is lubricated
Removal steps
1. Dust guard
2. Reservoir hose assembly and hy-
draulic unit connection
3. Hydraulic unit hose assembly and
hydraulic unit connection
4. Transfer connector assembly and
hydraulic unit connection
5. Hydraulic unit bracket assembly
mounting bolt
"BA6. Hydraulic unit assembly7. Hydraulic unit bracket
DStabilizer bar to differential support
arm connection (Refer to GROUP 34.)
DDifferential support arm (Refer to P.
27B-55.)
AA"8. Hydraulic unit hose assembly hicles with ACD+AYC>
9. Transfer connector assembly
"AA10. Reservoir hose assembly
11. Oil reserve

FRONT SUSPENSION -General Information33A-2
GENERAL INFORMATION
The front suspension is a McPherson strut with
coil spring. The shock absorber is gas-filled
hydraulic double-acting type.
COIL SPRING
ItemRS ,
RS-IIRS
Wire diameter·average
diameter·free length mm14·155·28114·155·275
CONSTRUCTION DIAGRAM
Stabilizer barCoil spring
Strut assembly
(shock absorber) Crossmember
Lower armStrut insulator
Stabilizer link
Crossmember bar
Lower arm bushing
(pillow ball bushing with rubber)

FRONT SUSPENSION -Service Specifications/Special Tools33A-3
SERVICE SPECIFICATIONS
ItemsStandard value
Toe-inAt the centre of tyre tread mm0±2
Toe-angle (per wheel)0_00’±05’
Toe-out angle on turns (inner wheel when outer wheel at 20_)22_00’±1_30’
Steering angleInner wheel31_45’±1_30’
Outer wheel (for reference)27_15’
Camber (Selectable from 2 options)-1_00’±30’* or - 2_00’±30’*
Caster3_55’±30’*
Kingpin inclination13_45’±1_30’
Lower arm ball joint rotation starting torque N·m0.5 - 3.4
Lower arm pillow ball bushing rotation starting torque N·m0.5 - 3.0
NOTE
*: difference between right and left wheels: less than 30’
SPECIAL TOOLS
ToolsNumberNameUse
B
A
A: MB991237
B: MB991238A: Spring
compressor
body
B: Arm setCoil spring compression
BAMB991680
A: MB991681
B: MB991682Wrench set
A: Wrench
B: SocketStrut assembly disassembly and reassembly
MB991006Preload socketLower arm ball joint rotation starting torque
measurement
MB990326Preload socketLower arm pillow ball bushing rotation starting
torque measurement

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