engine MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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

REAR AXLE -Special Tools/Troubleshooting 27B-8
NumberNameO.D.mm
BoxMB990551Box–
CBaseMB990989Base–
ABCBase
MB990990Tool A25A
Tool
MB990991Tool B28
ToolMB990992Tool C31
Installer adapterBrass bar
Bar (one-touch type) AB
C
Toolbox
Tool numberO.D.mmTool numberO.D.mm
AMB99092639AMB99093363.5
MB99092745MB99093467.5
MB99092849.5MB99093571.5
MB99092951MB99093675.5
MB99093054MB99093779
MB99093157BMB990938-
MB99093261CMB990939-
TROUBLESHOOTING
BASIC TROUBLESHOOTING CONDITIONS
Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.
NOTE
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.
DThe correct steering wheel has been properly installed in the neutral position of the steering column
shaft.
DTire and wheel sizes are correct with correct specifications. Inflation pressure, balance, and wear
conditions are okay.
DWheel alignment is correct.
DThe engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
DIAGNOSIS FUNCTION
READING THE DIAGNOSIS CODES
Read the diagnosis code using MUT-IIor ACD mode indicator
lamp. (Refer to GROUP 00 – How to Use Troubleshooting/
Inspection Service Points.)
NOTE
Connect the MUT-IIto the 16-pin diagnosis connector.

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 -On-vehicle Service27B-20
6. Remove the cap of the left bleeder screw on the torque
transfer differential and connect a vinyl hose.
7. Gradually turn the steering wheel clockwise from the
straight-ahead position. At this time, loosen the left bleeder
screw and check that fluid is discharged with air.
8. After air has been completely discharged, tighten bleeder
screw and turn the steering wheel in the straight-ahead
position.
Caution
While the system is being bled of air, add fluid as
necessary to ensure that it is left in the oil reservoir
during the entire procedure.
9. Repeat steps 6 and 7 two to three times until no air
bubbles are recognized in the fluid that comes out. Then,
tighten the bleeder screw to the specified torque.
Tightening torque: 9±1 N·m
10. Perform steps 5 through 8 for the right bleeder screw.
Note, however, that the steering wheel should be turned
conterclockwise.
11. When removing the hydraulic unit, bleed the fluid line
in ACD side. (Refer to GROUP 22 – On-vehicle Service.)
12. After the system has been completely bled of air, check
for the fluid level. (Refer to P. 27B-19.)
Caution
If the system is not completely bled of air, the hydraulic
unit could generate noise, degrading pump durability.
AYC OPERATION CHECK
1. Lift up the vehicles.
2. Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the LOCK (OFF) position
before connecting or disconnecting the MUT-II.
3. Start the engine.
4. Set the gear to the 2nd gear or above, operate MUT-II,
and check from the service data (Item No.09) that the
wheel speed is within 10 km/h to 20 km/h.
NOTE
(1) Set the steering wheel to the neutral position.
(2) When turning the steering wheel, AYC operates
continually (operation sound from the torque transfer
differential), but it is not system fault. In this case,
set the steering wheel to the neutral position, and
perform the following operations in order to stop the
ACD.
DRelease the clutch.
DSet the gear to ”Neutral”.
DStop the engine.
Bleeder
screw
Vinyl hose

REAR AXLE -On-vehicle Service27B-24
Torque transfer mechanism part
1. Remove the drive shaft. (Refer to P. 27B-29.)
2. Remove the oil seal from the differential carrier.
3. Using the special tool, drive a new oil seal all the way
into position.
4. Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with the specified grease.
Specified grease: Vaseline
5. Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier. (Refer to P.
27B-29.)
6. Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)
ACTION WHEN BATTERY RUNS OUT
When the engine is started using a booster cable where the
battery has completely run down and you attempt to start
the vehicle without waiting for the battery to recover a certain
charge, the engine can misfire and you just cannot start to
move it. In such cases, charge the battery sufficiently; or,
remove the AYC battery cable from the battery fuse assembly
to make AYC inactive before attempting to start the vehicles.
When the battery cable is removed, the ACD mode indicator
lamp lights up. After the battery has been recharged, fit the
battery cable back again and start the engine to ensure that
the ACD mode indicator lamp is off.
MD998829
MD998813 MD998812
Battery fuse assembly
Battery cable
for AYC

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 - General Information32-2
GENERAL INFORMATION
Inertia principal axes system is incorporated into
the engine mount system.Upper installation of roll mount reduces engine
rolling, and increase of insulator bore also reduces
idle vibration.
CONSTRUCTION DIAGRAM

Transmission mount Engine mount

Rear roll rod bracket
Front roll stopper
Front roll mount bracketRear roll mount bracket
Crossmember
Crossmember bar
CentermemberRear roll rod assembly

POWER PLANT MOUNT - General Information/Special Tool32-3

Front roll stopper Front roll mount bracketRear roll stopper Rear roll mount bracket
Crossmember
Crossmember bar
Centermember
SPECIAL TOOL
ToolNumberNameUse
MB990635,
MB991113 or
MB991406
Steering linkage
pullerTie rod end disconnection

POWER PLANT MOUNT - Engine Mounting32-4
ENGINE MOUNTING
REMOVAL AND INSTALLATION
Caution
*: 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.
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to
GROUP 51 - Front Bumper.)DRaise the engine and transmission assembly until
its weight is not applied to the insulator, and support
it securely.
98±10 N·m*
67±7 N·m*
1
2
12±2 N·m
3 44
Removal steps
1. Power steering pressure hose as-
sembly
2. Engine mounting connecting bolt3. Engine mounting bracket
"AA4. Engine mounting insulator
INSTALLATION SERVICE POINT
"AAENGINE MOUNTING INSULATOR INSTALLATION
Arrow marks on the engine mount insulator should face the
shown direction.
NOTE
Disregard F and R stamped as a shared part.
Engine sideEngine side
Engine mounting insulator
>

POWER PLANT MOUNT - Transmission Mounting32-5
TRANSMISSION MOUNTING
REMOVAL AND INSTALLATION
Caution
*: 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.
Pre-removal Operation
DUnder Cover Removal (Refer to GROUP 51 - Front
Bumper.)
DRaise the engine and transmission assembly until
its weight is not applied to the insulator, and support
it securely.
DBattery and Battery Tray Removal
DAir Cleaner Removal (Refer to GROUP 15.)
DRadiator Removal (Refer to GROUP 14.)
DAir Pipe C, Air By - pass Hose, Air Hose D Removal
(Refer to GROUP 15 - Inter Cooler.)
DRear Roll Stopper Removal (Refer to P.32-6.)Post-installation Operation
DRear Roll Stopper Installation (Refer to P.32-6.)
DAir Pipe C, Air By - pass hose, Air Hose D Installation
(Refer to GROUP 15.)
DRadiator Installation (Refer to GROUP 15.)
DAir Cleaner Installation (Refer to GROUP 15.)
DBattery and Battery Tray Installation
DUnder Cover Installation (Refer to GROUP 51 -
Front Bumper.)
47±7 N·m*
3
3
82±7 N·m*
2
1
Removal steps
1. Transmission mounting connecting
bolt2. Transmission mounting
"AA3. Transmission mounting stopper
INSTALLATION SERVICE POINT
"AATRANSMISSION MOUNT STOPPER
INSTALLATION
Install the transmission mount stopper so that its arrow points
upward.
INSPECTION
Check the transmission mounting insulator for cracks,
separation or deformation.
Engine side
Transmission
mount bracketTransmission
mount stopper