MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

REAR AXLE -Differential Carrier 27B-35
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation
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.)
12
765
4 8 910
32¶2Nm
2
3
3 3
3
76
9
120±10 N·m
88±10 N·m
69±9 N·m
88±10 N·m
88±10 N·m
88±10 N·m
120±10 N·m
120±10 N·m
120±10 N·m
69±9 N·m
88±10 N·m
Removal steps
AA"1. Propeller shaft connection (Refer to
GROUP 25.)
2. Toe control bar
3. Differential support member mount-
ing boots and nuts
AB""AA4. Rear crossmember and differential
carrier assembly5. Differential support member
6. Upper stopper
7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential carrier assembly

REAR AXLE -Differential Carrier 27B-36
REMOVAL SERVICE POINTS
AA"PROPELLER SHAFT DISCONNECTION
Suspend the removed propeller shaft from the body with a
wire to prevent bending.
AB"REAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY REMOVAL
1. Using a jack, support the differential carrier from its
underside.
2. Remove the rear crossmember mounting bolts and
remove the differential carrier, where it is attached to
the rear crossmember, from the vehicle.
INSTALLATION SERVICE POINTS
"AAREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY INSTALLATION
Tighten the rear crossmember mounting bolts in the numerical
order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the rear crossmember mounting holes have
different diameters between front and rear. This is the reason
for specifying the tightening sequence of the mounting bolts.
No.Bolt typeBolt size(thread
dia.×length)mm
1, 2, 3Flange bolt(with washer)12×105
4Bolt(with spring washer and
washer)12×152
5Flange bolt(with washer)12×70
5
Front of vehicle
1
3
442
3

REAR AXLE -Differential Carrier 27B-37
BUSHING REPLACEMENT
1. Remove and press fit the bush with special tool. (About
removal and press fitting the bush of the differential
support arm, refer to P. 27B-57.)
2. Press fit the bush so that the hollow of the bush is on
the position shown as the illustration.
3. Press fill the bush until the surface of the outer sleeve
of the bush, differential mounting bracket.
MB990641 Bush
Differential
mount
bracket
Steel block
Hollow

REAR AXLE -Differential Carrier 27B-38
DISASSEMBLY
19
2
6
8
20
22
26
5
113
4
9
12
15
16
1314
10
21
1
23
24
25
18
17
7
897
Disassembly steps
AA"DInspection before disassembly
1. Filler plug
2. Drain plug
3. Differential cover assembly
4. Vent plug
5. Bearing cap
AB"6. Differential case assembly
AB"7. Side bearing spacer
AB"8. Side bearing outer race
AC"9. Side bearing inner race
AD"10. Drive gear
11. Limited slip differential case assembly*
AE"12. Self-locking nut
13. Washer
AF"14. Drive pinion assemblyAF"15. Companion flange
16. Drive pinion front shim (For adjusting
preload of drive pinion)
17. Drive pinion spacer
AG"18. Drive pinion rear bearing inner race
19. Drive pinion rear shim (For adjusting
drive pinion height)
20. Drive pinion
AH"21. Oil seal
AH"22. Drive pinion front bearing inner race
AH"23. Drive pinion front bearing outer race
AI"24. Drive pinion rear bearing outer race
25. Oil seal
26. Differential carrier

REAR AXLE -Differential Carrier 27B-39
DISASSEMBLY SERVICE POINTS
AA"INSPECTION BEFORE DISASSEMBLY
1. Remove the cover.
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.
DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.
Standard value: 0.11 - 0.16 mm
2. If the backlash is not within the standard value, adjust
the final drive gear backlash. (Refer to P.27B-49.)
3. After the adjustment, inspect the drive gear tooth contact.
DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.
DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.MB990909 and
MB991116

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-41
AB"DIFFERENTIAL CASE ASSEMBLY/ SIDE BEARING
SPACER/SIDE BEARING OUTER RACE REMOVAL
Use the handle of a hammer to remove the differential case
assembly, side bearing spacers and side bearings.
Caution
When taking out the differential case assembly, be careful
not to drop and damage the side bearing spacers or
the side bearing outer races.
NOTE
Keep the right and left side bearings and side bearing outer
race separate, so that they do not become mixed at the time
of assembly.
AC"SIDE BEARING INNER RACE REMOVAL
Use special tools to pull out the side bearing inner race.
NOTE
There are two notches provided (at the differential case side)
for the claw part of the special tool; use the special tool at
that position.
If notches of special tools touch the end of differential case
and fail to hook with inner race, file the notches to be able
to hook with inner race.
AD"DRIVE GEAR REMOVAL
1. Make the mating marks to the differential case and the
drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
AE"SELF-LOCKING NUT REMOVAL
Use special tool to hold the companion flange, and then
remove the companion flange self-locking nut.
MB990810
Socket
wrench
Mating marks
MB990850

REAR AXLE -Differential Carrier 27B-42
AF"DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
1. Make the mating marks to the drive pinion and companion
flange.
Caution
Do not make mating marks on the contact surfaces
of the companion flange and propeller shaft.
2. Use special tools to pull out the companion flange.
AG"DRIVE PINION REAR BEARING INNER RACE
REMOVAL
Use special tools to pull out the front bearing inner race.
AH"OIL SEAL/DRIVE PINION FRONT BEARING
INNER RACE/DRIVE PINION FRONT BEARING
OUTER RACE REMOVAL
Use special tool to remove drive pinion front bearing outer
race.
AI"DRIVE PINION REAR BEARING OUTER RACE
REMOVAL
Use special tool to remove the drive pinion rear bearing outer
race.
Companion
flange
MB990810
MB990339
MB990648
Drive pinion
front bearing
outer race
Oil seal
MB990939
Drive pinion
rear bearing
outer race
Drive pinion
front bearing
inner race
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-44
Lubrication and Adhesive Points
Vent plug
2 - 3mm
(bead diameter)
Adhesive: 3M Stud Locking
4170 or equivalentSealant: 3M ATD Part No.8661, 8663
or equivalent
REASSEMBLY SERVICE POINTS
"AAOIL SEAL PRESS-FITTING
MB990938
MB991115