specification MITSUBISHI LANCER EVOLUTION 2007 Service Workshop 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 -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 -Knuckle27B-28
KNUCKLE
REMOVAL AND INSTALLATION
Caution
1. 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.
2. With the part marked with *, first temporarily tighten it, then ground the vehicle and tighten
it to specification in unloaded condition.
Pre-removal Operation
Rear Hub Assembly Removal (Refer to P.27-25.)Post-installation Operation
DPress dust cover with a finger to check for crack
or damage in the dust cover.
DRear Hub Assembly Installation (Refer to P.27-25.)
1
2
3
4
5
6
25±6 N·m81±6 N·m
81±6 N·m*
88±10 N·m*
81±6 N·m
Removal steps
1. Vehicle speed sensor ABS or ACD>
AA"2. Knuckle and trailing arm connection
3. Knuckle and lower arm connectionAA"4. Knuckle and toe-control arm connec-
tion
AA"5. Knuckle and upper arm connection
6. Knuckle assembly
REMOVAL SERVICE POINT
AA"KNUCKLE AND TRAILING ARM/TOE-CONTROL
ARM/UPPER ARM DISCONNECTION
Caution
1. Use special tools to loosen the nut from the ball joint
instead of removing it.
2. Hang special tools with ropes to prevent them from
falling.
Nut
Cord
Ball joint
MB991113 or
MB990635

REAR AXLE -Drive Shaft27B-29
DRIVE SHAFT
REMOVAL AND INSTALLATION
Caution
1. 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.
2. With the part marked with *, first temporarily tighten it, then ground the vehicle and tighten
it to specification in unloaded condition.
Pre-removal Operation
DGear Oil Draining (Refer to P.27-17.)
DCenter Exhaust Pipe Removal (Refer to GROUP
15.)Post-installation Operation
DPress dust cover with a finger to check for crack
or damage in the dust cover.
DCenter Exhaust Pipe Installation (Refer to GROUP
15.)
DGear Oil Filling (Refer to P.27-17.)
DParking Brake Lever Stroke Check and Adjustment
DWheel Alignment Check and Adjustment (Refer to
GROUP 34 – On-vehicle Service.)
4
1
3
7
6510
2
8
9
11
12
225±25 N·m
54±5 N·m
88±10 N·m*
81±6 N·m*
81±6 N·m
25±6 N·m
Removal steps
AA"1. Rear brake caliper
2. Rear brake disc
3. Parking brake shoe & lining assembly
(Refer to GROUP 36 - Parking Brake
Drum.)
4. Clip
5. Parking brake cable connection
6. Split pinAB""BA7. Drive shaft nut
8. Vehicle speed sensor ABS or ACD>
9. Knuckle and trailing arm connection
10. Knuckle and lower arm connection
11. Knuckle and toe-control arm connec-
tion
AC""AA12. Rear drive shaft assembly

31-1
WHEEL AND TYRE
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
TROUBLESHOOTING 3.......................ON-VEHICLE SERVICE 6.....................
Tyre Inflation Pressure Check 6.................
Tyre Wear Check 6............................
Wheel Runout Check 6.........................
WHEEL AND TYRE 6........................

WHEEL AND TYRE -General Information/Service Specifications31-2
GENERAL INFORMATION
The wheels and tyres of the following specifications
have been established.
SPECIFICATIONS
ItemsRS (standard)RS (option), RS-II
WheelTypeSteel typeAluminium type
Size15×6JJ17×8JJ
Amount of wheel offset mm4638
Pitch circle diameter
(P.C.D.) mm114.3114.3
TyreSize205/65R15 94H235/45ZR17
Spare wheelTypeSteel typeSteel typep
Size16×4T17×4T
Amount of wheel offset mm4030
Pitch circle diameter
(P.C.D.) mm114.3114.3
Spare tyre (High pressure)SizeT125/70D16T125/70D17
SERVICE SPECIFICATIONS
ItemsLimit
Tread depth of tyre mm1.6
Wheel runout (Radial runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less
Wheel runout (Lateral runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less

WHEEL AND TYRE -Troubleshooting31-5
DIf the imbalance is 5 g or less, the zero
calibration is OK. Rebalance the wheel, then
go to Step 4 to check static balance.
DIf the imbalance is more than 5 g, go to Step
3.
3. Loosen the balancer wing nut, rotate the wheel
1/4 turn (90°), and retighten the nut. Recheck
the wheel balance.
DIf the imbalance is 5 g or less, the wheel may
not be centered on the balancer, or the
balancing cones, the cup, and/or wing nut are
damaged, dirty, or inappropriate for the wheel.
You may need to refer to the balancer
manufacturer’s instructions to verify the correct
attachments. after making the necessary
corrections, recheck the wheel balance. If OK,
then go to Step 4.
DIf the imbalance is more than 5 g, the balancer
requires calibration. Contact the balancer
manufacturer for calibration by their repair
representative.
4.<>
Attach a 5-g weight to the outer rim. Recheck
the balancer. The balancer should detect 5±2
g of imbalance 170°to 190°away from both the
inner and outer 5-g weights.DIf the imbalance is within specification, the static
balance calibration is correct. Go to Step 5
to check the dynamic balance.
DIf the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
5.<>
Attach a 5-g weight to the inner rim at 180°
opposite the 5-g weight that was added in step
4. Recheck the balance. The balancer should
detect 5±2g of imbalance 170°to 190°away
from both the inner and outer 5-g weights.
DIf the imbalance is within specification, the
dynamic balance calibration is correct. The
balancer calibration checks are complete.
DIf the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART
(Dynamic Balance Check)
(Static balance Check)
Balance wheel.
Rotate wheel 1/2 turn.Imbalance = more than 5 g
Imbalance = 5 g or lessRotate wheel 1/4 turn.Imbalance = more than 5 g
Imbalance = 5 g or less
Verify wheel is properly centered.
Verify cones, cup, & wing nut are clean,
undamaged, & appropriate for wheel.
Make necessary corrections, then
recheck wheel balance.
Attach a 5 g weight to the outer rim.
Is the imbalance 5±2 at 170°-190°
away from the 5-g weight?NOBalancer requires calibration.
Contact balancer manufacturer.
Balancer requires calibration.
Contact balancer manufacturer.
YES
Attach a 5-g weight to the inner rim at
180°opposite the weight on the outer
rim. Is the imbalance 5±2gat170°-190°
away from both 5-g weights?NOBalancer requires calibration.
Contact balancer manufacturer.
Rebalance wheel.
YES
Balancer dose not require calibration.

33A-1
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
SPECIAL TOOLS 3...........................
ON-VEHICLE SERVICE 4.....................
Wheel Alignment Check and Adjustment 4.......Ball Joint Dust Cover Check 5..................
STRUT ASSEMBLY 6.........................
LOWER ARM ASSEMBLY 9..................
STABILIZER BAR 12.........................
CROSSMEMBER BAR 15.....................