torque MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

REAR AXLE -On-vehicle ServiceREAR AXLE -On-vehicle Service27B-18
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
Quantity: 0.55 L
4. Fit the filler plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m

Differential part
1. Remove the drain plug to discharge the gear oil.
2. Fit the drain plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m
3. Remove the filler plug and add the specified gear oil
up to the bottom end of the filler plug hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W
Quantity: 0.55±0.02 L
NOTE
10_C or more: SAE90, less than 10_C: SAE80W
4. Fit the filler plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m
Torque transfer mechanism part
1. Remove the drain plug to discharge the gear oil.
2. Fit the drain plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m
3. Remove the filler plug.
4. Using the oil suction gun (general service tool), between
the body and differential support arm, apply the specified
gear oil up to the under of the filler plug hall.
Specified gear oil: ATF-SP III
Quantity: 0.65 - 0.7 L
5. Fit the filler plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m
Gear oil
Filler plug
Drain plug
Upper limit
Lower limitGear oil
6mm
Filler plug
Drain plug
Oil suction gun
(general service tool)

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-21
5. Operate the MUT-II, drive the torque transfer differential
(item No.06 and 07) forcibly.
NOTE
(1) Drive the clutch operating mode forcibly for 1 minutes,
release the operation automatically. Drive can also
be cleared forcibly using the Clear key of MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the torque transfer differential cannot be
forcibly driven.
6. Operating the MUT-II, by service data (item no.07 and 08),
check the condition of the wheel speed below.

The left rear wheel is faster 2km/h than right rear wheel.

The right rear wheel is faster 2km/h than left rear wheel.
NOTE
If the above are not satisfied, check the oil pressure as
the system may be faulty.
OIL PRESSURE CHECK
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 ON.
4. Disconnect the hydraulic unit and the hydraulic unit hose
assembly, connect the special tool to L port, put the lid
to R port or connect the hydraulic unit hose assembly
disconnected from L port to R port.
5. Operating the MUT-II, drive the hydraulic unit forcibly
(item No.02).
NOTE
(1) Drive the operation check mode of the clutch left
side for 1 minutes, release the operation automatically.
Drive can also be cleared forcibly using the Clear
key of MUT-II.
(2) If the function has been stopped by fail safe, the
hydraulic unit cannot be cleared forcibly.
6. Check that the generated oil pressure of the hydraulic
unit satisfies the standard value.
Standard value: 0.9 – 1.1 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. Check the oil pressure of the clutch right side following step
4 through 6. Connect the special tool to R port, put the lid
to L port or hydraulic unit hose assembly disconnected
from R port to L port, use the MUT-IIdrive item No.07
(operation check mode of clutch right side) forcibly.
MD998330
MB991705

REAR AXLE -On-vehicle Service27B-22
8. If the measured value exceeds the standard value, replace
the hydraulic unit.
9. Connect the hydraulic unit and the hydraulic unit hose
assembly, and connect the torque transfer differential and
hydraulic unit hose assembly, tighten the flare nut in
specified torque.
Tightening torque: 34±5 N·m (Thread is not lubricated)
26±4 N·m (Thread is lubricated)
10. Supply the specified fluid up to the MAX level of the
oil reservoir, and bleed.
Specified fluid: ATF-SP III
Quantity: 1 L
WHEEL BEARING AXIAL PLAY CHECK
1. Remove the brake caliper and brake disc.
2. Check the bearing’s axial play.
Place a dial gauge against the hub surface; then move
the hub in the axial direction and check whether or not
there is axial play.
Limit: 0.05 mm
3. If the axial play exceeds the limit, the castle nut should
be tightened to the specified torque 225±25 N·m and
check the axial play again.
4. Replace the rear hub assembly if an adjustment cannot
be made to within the limit.
WHEEL BEARING ROTARY-SLIDING
RESISTANCE CHECK
1. Remove the brake caliper and brake disc.
2. After turning the hub a few times to seat the bearing,
wind a rope around the hub bolt and turn the hub by
pulling at a 90_angle with a spring balance. Measure
to determine whether or not the rotary-sliding resistance
of the rear hub is at the limit value.
Limit: 22 N or less

REAR AXLE -On-vehicle Service27B-23
3. If the limit value is exceeded, loosen the flange nut and
then tighten it to the specified torque 225±25 N·m and
check the rear hub rotary sliding resistance again.
4. Replace the rear hub assembly if an adjustment cannot
be made to within the limit.
HUB BOLT REPLACEMENT
1. Remove the brake caliper and brake disc.
2. Use the special tools to remove the hub bolts.
NOTE
To retain a space for removing the hub bolts, remove
near the retainer spring mounting position.
3. Install the plain washer to the new hub bolt, and install
the bolt with a nut.
DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
Differential 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 multi-purpose grease.
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.)
MB991618MB990767
Plain
washerMB990767
MB990938
MB991115

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

REAR AXLE -Rear Hub Assembly27B-27
INSPECTION
WHEEL BEARING ROTATION STARTING TORQUE
CHECK
1. Tighten special tools in rear hub assembly to the specified
torque.
2. Hold rear hub assembly in a vice by way of wooden
block.
3. Measure the wheel bearing rotation torque with special
tools.
Limit: 1.0 N
·m
4. Hub rotation starting torque must be under the limit value
and there should be no stickiness or roughness when
rotating the hub.
WHEEL BEARING AXIAL PLAY CHECK
1. Check the wheel bearing axial play.
Limit: 0.05 mm
2. If the wheel bearing axial play exceeds the limit value
at the specified torque of (225±25 N
·m), replace the
rear hub assembly.
Wooden
block
MB991000
(MB990998)MB991017
225±25 N·m
MB990326
Wooden
block
Wooden
block

REAR AXLE -Differential Carrier 27B-40
2. Insert the brass between the differential carrier and the
differential case, and then rotate the companion flange
by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque (approximate 2.5 -
3.0 N·m) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.
Standard tooth contact patternProblemSolution
1 Narrow tooth side
2 Drive-side tooth surface (the
side applying power during
forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the
side applying power during
reverse movement)
1
2
34
Tooth contact pattern resulting from
excessive pinion height
The drive pinion is positioned too far
from the centre of the drive gear.
1 2
34
Increase the thickness of the drive
pinion rear shim, and position the
drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.
1 2
34
Tooth contact pattern resulting from
insufficient pinion height
The drive pinion is positioned too
close to the centre of the drive gear.
1 2
34
Decrease the thickness of the drive
pinion rear shim, and position the
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.
1
2
34
NOTE
Checking the tooth contact pattern is the way to
confirm that the adjustments of the pinion height
and backlash have been done properly. Continue
to adjust the pinion height and backlash until the
tooth contact pattern resembles the standard
pattern.If, even after adjustments have been made, the
correct tooth contact pattern cannot be obtained,
it means that the drive gear and the drive pinion
have become worn beyond the allowable limit.
Replace the gear set.
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-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