torque MITSUBISHI LANCER EVOLUTION 2007 Service Workshop Manual

MANUAL TRANSMISSION - On-vehicle Service MANUAL TRANSMISSION - On-vehicle Service22A-40
ON-VEHICLE SERVICE
TRANSMISSION OIL CHECK
1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler plug
hole.
3. Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Tightening torque: 32±2 N·m
TRANSMISSION OIL REPLACEMENT
1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.
Tightening torque: 32±2 N·m
4. Fill with specified oil till the level comes to the lower portion
of oil filler plug hole.
Specified transmission oil:
Gear oil SAE 75W-90 or 75W-85W conforming to
API GL-4
Quantity: 2.8 L
5. Tighten the oil filler plug to the specified torque.
Tightening torque: 32±2 N·m
TRANSFER OIL CHECK
1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler plug
hole.
3. Check that the transfer oil is not noticeably dirty, and
that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Tightening torque: 32±2 N·m
TRANSFER OIL REPLACEMENT
1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.
Tightening torque: 32±2 N·m
Transmission oilFiller plug hole
Filler plug
Drain plug
Transfer oilFiller plug hole
Filler plug
Drain plug
Oil pan

MANUAL TRANSMISSION - On-vehicle Service22A-41
4. Fill with specified oil till the level comes to the lower portion
of oil filler plug hole.
Specified transfer 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
Quantity:
0.55 L ACD and AYC>
0.6 L and AYC>
5. Tighten the oil filler plug to the specified torque.
Tightening torque: 32±2 N·m
FLUID CHECK VEHICLES WITH ACD AND AYC>
1. Remove the maintenance lid located in the luggage
compartment.
2.
If the vehicle has been run, leave it for 90 min. or more
in an ordinary temperature (10_C–30_C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is 10_C or less, allow more
time to leave the vehicle to stand idle.

Set the MUT-IIto the 16-pin diagnosis connector. Turn ON
the ignition switch, perform MUT-IIactuator test (Item
No.03), forcibly drive the hydraulic unit and remove the
pressure in the accumulator.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
NOTE
(1) In the actuator test (Item No. 03: Oil Level Check
Mode), the directional valve of the hydraulic unit is
moved to the left and right for 20 times, and then
the differential is cleared automatically. Drive can also
be cleared forcibly using the Clear key of the MUT-II.
(2) If the function has been stopped by fail-safe, the
hydraulic unit cannot be cleared forcibly.
3. Check that the fluid level in the oil reservoir is in the
range between MAX and MIN.
4. If the fluid level is lower than MIN, add the specified
fluid.
Specified fluid: Dia Queen ATF SP III
5. Reinstall the maintenance lid.

MANUAL TRANSMISSION - On-vehicle Service22A-42
BLEEDING VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
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. Turn the ignition switch to the “ON” position.
4. Set the steering wheel in the straight-ahead position.
5. Perform the MUT-IIactuator test (Item No.02), and forcibly
drive the hydraulic unit.
NOTE
(1) The actuator test (Item No.01: Bleeding Mode) will
be performed for 5 minutes, after which it will be
cleared automatically. Drive can also be cleared during
forced driving using the clear key of the MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the hydraulic unit cannot be forcibly driven.
6. Remove the cap of the bleeder screw on the transfer,
and connect the vinyl hose.
7
.Slowly turn the steering wheel to the left or right from
the neutral state. Loosen the bleeder screw, and check
that air is discharged together with the fluid.
8
.After the air is discharged, tighten the bleeder screw,
and return the steering wheel to the neutral state.
Caution
During bleeding, replenish the fluid so that some
always remains in the oil reservoir.
9. Repeat steps 6 and 7 several 2 to 3 times, and after
checking that no more air mixes in, tighten the bleeder
screw at the specified torque.
Tightening torque: 5±1 N·m
10. After bleeding, check the fluid level. (Refer to P. 22A-41.)
Caution
If bleeding is not performed completely, noise may
be produced from the hydraulic unit, or the durability
of the pump, etc. may drop.
11. On vehicles with AYC, perform bleeding when the
hydraulic unit is removed. (Refer to GROUP 27B -
On-vehicle Service.)
ACD OPERATION CHECK ACD OR VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
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.
Bleeder screw
Front exhaust pipe

MANUAL TRANSMISSION - On-vehicle Service22A-44
(2) If the hydraulic unit function has been stopped by
fail-safe, the hydraulic unit cannot be forcibly driven.
6. Check that the generated oil pressure of the hydraulic
unit satisfies the standard value.
Standard value: 1.0 – 1.6 MPa
Caution
While the oil pressure is checked, add fluid as
necessary to ensure that it is left in the oil reservoir
during the entire procedure.
7. If the measured value exceeds the standard value, replace
the hydraulic unit.
8. Connect the hydraulic unit and transfer connector
assembly, and tighten the flare nut at the specified torque.
Tightening torque: 34±5 N·m (when screw is dry)
26±4 N·m (when screw is applied with oil)
9. Supply the specified fluid up to the MAX level of the
oil reservoir, and bleed the oil pressure pipes.
Specified fluid: DIA QUEEN ATF SP III
Quantity:
0.9 dm
3
1.0 dm3
WHEEL SPEED SENSOR OUTPUT VOLTAGE
MEASUREMENT (VEHICLES WITHOUT AYC)>
1. Lift the vehicle, and release the parking brake.
2. Disconnect the 4WD-ECU connector, and measure at
the connector of the harness.
Caution
Insert the probe from the harness of the connector.
Inserting in the terminal side may cause contact fault.
3. Rotate the measured wheel by about 1/2 to 1
rotations/second, and check the output voltage between
the following terminals using a circuit tester (AC mV range)
or oscilloscope.
Terminal No.
Front leftFront rightRear leftRear right
6987
19222120

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 6..........................
SERVICE SPECIFICATIONS 6.................
SEALANTS 7................................
LUBRICANTS 8..............................
SNAP RINGS, SPACERS AND THRUST
PLATES FOR ADJUSTMENT 9................
TIGHTENING TORQUE 11....................
SPECIAL TOOLS 12..........................
TRANSMISSION 15...........................
INPUT SHAFT 22............................OUTPUT SHAFT 29..........................
REVERSE IDLER GEAR 37...................
SPEEDOMETER GEAR 38....................
SELECT LEVER 39...........................
CONTROL HOUSING 40......................
CLUTCH HOUSING 43........................
TRANSMISSION CASE 46....................
CENTER DIFFERENTIAL 48..................
TRANSFER 51...............................

MANUAL TRANSMISSION OVERHAUL -Tightening Torque22B-11
TIGHTENING TORQUE
TRANSMISSION
ItemsTightening torque N•m
Under cover mounting bolt6.9±1
Interlock plate bolt30±3
Clutch housing and transmission case tightening bolt44±5
Clutch release bearing retainer mounting bolt9.8±2
Control housing mounting bolt18±3
Shift cable bracket mounting bolt18±3
Speedometer gear mounting bolt3.9±1
Stopper bracket mounting bolt18±3
Select lever mounting bolt18±3
Select lever mounting nut11±1
Center differential drive gear mounting bolt132±5
Backup light switch32±2
Poppet spring32±2
Reverse idler gear shaft mounting bolt48±5
Roll stopper bracket mounting bolt69±9
TRANSFER
ItemsTightening torque N•m
Transfer cover mounting bolt23±3
Transmission and transfer tightening bolt69±9

MANUAL TRANSMISSION OVERHAUL -Transmission22B-19
(3) Set solder (10 mm long, 1.6 mm diameter) on the
transmission case at the position shown in the illustration.
(4) Install the outer race onto the transmission case.
(5) Install the transmission case, and tighten the bolt with
the specified torque.
(6) If the solder has not been crushed, carry out steps (2) to (5) with
solder having a larger diameter.
(7) Using a micrometer, measure the thickness of the crushed solder,
and select a spacer so that the end play and preload are at the
standard values.
Standard value:
Input shaft end play
0.05mm loose to 0.17mm loose
Output shaft preload
0.13mm tight to 0.18mm tight
Center differential preload
0.05mm tight to 0.11mm tight
REASSEMBLY SERVICE POINTS
"AAINPUT SHAFT/OUTPUT SHAFT/CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and center differential onto
the clutch housing at the same time.
"BA5TH-REVERSE SPEED SHIFT
FORK/5TH-REVERSE SPEED SHIFT
RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH
SPEED SHIFT RAIL INSTALLATION
(1) Assemble the 3rd-4th speed shift rail, fork and the
5th-reverse speed shift rail and fork.
Solder
Solder
Output shaft
Center differentialInput
shaft
3rd-4th speed
shift rail
5th-reverse
speed shift rail 5th-reverse
speed shift
fork
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-50
(5) Install the front output shaft onto the side gear, and install
the snap ring.
(6) After assembling the side gear into the center differential
case, install the spacer onto the side gear.
(7) Match the alignment marks, install the center differential
flange, and temporarily fix the machine screw.
(8) Measure the backlash between the side gear and pinion.
Standard value: 0.025 - 0.150 mm
(9) If the backlash is not within the standard value, select
a spacer, and measure the backlash again.
NOTE
Adjust so that the backlash on both sides is even.
"DACENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Confirm that rust-proofing oil is applied, and then apply
sealant on all of the bolt threads.
Sealant
Specified sealant:
3M STUD Locking No.4170 or equivalent
(2) Tighten with the specified torque following the order shown
in the illustration.

FRONT AXLE -Service Specifications/Lubricants/Special Tools26-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Wheel bearing axial play mm-0.06
WheelbearingrotationstartingtorqueN·m-103orlessWheelbearing rotation startingtorqueN·m-1.03orless
Setting of T.J. boot length mm85±3-
Opening dimension of the
special tool (MB991561) mmWhen the B.J.boot band
(small) is crimped.2.9-
When the B.J.boot band
(big) is crimped.3.2-
Crimped width of the B.J.boot band mm2.4 - 2.8-
LUBRICANTS
ItemsSpecified lubricantsQuantity g
T.J. boot greaseRepair kit grease120±10
B.J.boot greaseRepair kit grease11 0±10
SPECIAL TOOLS
ToolNumberNameUse
MB990767End yoke holderFixing of the hub
MB991618Hub bolt removerRemoval of the hub bolt
MB991113 or
MB990635Steering linkage
pullerDisconnection of ball joint
A
B
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller barDRemoval of the drive shaft
DRemoval of the hub
MB991354Puller bodyDRemoval of the drive shaft
DRemoval of the hub

FRONT AXLE -Special Tools26-4
Tool UseName Number
MB990685Torque wrenchMeasurement of wheel bearing rotation
starting torque
MB990326Preload socketMeasurement of wheel bearing rotation
starting torque
A
B
C
A: MB991017
B: MB990998
C: MB991000A,B: Front hub
remover and
installer
C: SpacerDProvisional holding of the wheel bearing
DMeasurement of wheel bearing rotation
starting torque
DMeasurement of wheel bearing axial play
MB991000, which belongs to MB990998,
should be used as a spacer.
MB991721Sliding hammerOutput shaft removal
MB991561Boot band clipping
toolResin boot band installation
MB990925
Brass bar
Installer adapterTool box
Bar (snap-in type) ACB
TypeTool numberO.D. mmTypeTool numberO.D. mm
MB99092639MB99093363.5
MB99092745MB99093467.5
MB99092849.5AMB99093571.5
AMB99092951MB99093675.5
MB99093054MB99093779
MB99093157BMB990938-
MB99093261CMB990939-