service MITSUBISHI LANCER EVOLUTION IV 1998 Manual Online

REAR AXLE – Rear Hub Assembly27-33
REAR HUB ASSEMBLY
REMOVAL AND INSTALLATION
12
3
4
56 7
8
Unit: Nm {kgf
m}
118 {12.0}
74 – 88
{7.5 – 9.0} 49 – 59
{5.0 – 6.0}196 – 255
{20.0 – 26.0}
Removal steps
A1. Caliper assembly
2. Brake disc
3. Shoe & lining assembly
(Refer to GROUP 36 – Parking
Brake.)
4. Clip
5. Parking brake cable connectionBA6. Drive shaft nut
C7. Rear hub assembly
8. Backing plate
Caution
Do not disassemble the rear hub assembly.
REMOVAL SERVICE POINTS
ACALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with a wire so that
it will not fall.
BDRIVE SHAFT NUT REMOVAL
CREAR HUB ASSEMBLY REMOVAL
(1) Using the special tool, remove the drive shaft from the
rear hub assembly.
(2) Remove the mounting bolts and remove the rear hub
assembly from the knuckle.
MB990767
MB990244 (3) MB990767
MB990242MB991354

REAR AXLE – Rear Hub Assembly27-34
INSTALLATION SERVICE POINT
ADRIVE SHAFT NUT INSTALLATION
(1) Install the washer on the drive shaft in the direction shown
on the left.
(2) Using the special tool, tighten the drive shaft nut to the
specified torque.
Caution
Before torquing the drive shaft nut to specification,
do not apply vehicle weight to the wheel bearing.
(3) If, at this time, the split pin holes are not aligned, tighten
the nut further (within 255 Nm {26.0 kgf
m}), insert the
split pin in the first matching holes, and bend it securely.
INSPECTION
1. REAR WHEEL BEARING ROTATION STARTING
TORQUE
(1) Install the special tool to the rear hub assembly and tighten
it to the specified torque.
(2) Using the special tool, measure the wheel bearing rotation
starting torque.
Limit: 1.0 Nm {10.5 kgf
cm}
(3) The wheel bearing starting torque should be within the
limit and the hub should be free of binding or rough motion
when turned.
2. WHEEL BEARING AXIAL PLAY CHECK
(1) Check the wheel bearing for axial play.
Limit: 0.05 mm
(2) If the specified torquing range (196 to 255 Nm {20.0
to 26.0 kgf
m}) does not bring the wheel bearing axial
play into the limit, replace the rear hub assembly.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}
MB990326 MB991000
(MB990998)
Wood block 196 – 255 Nm
{20.0 – 26.0 kfg
m} MB991017
Wood block
Wood block
MB991017

REAR AXLE – Knuckle27-35
KNUCKLE
REMOVAL AND INSTALLATION
Pre-removal Operation
Rear Hub Assembly and Backing Plate Removal
(Refer to P.27-33.)Post-installation Operation
(1) Check Each Ball Joint Dust Cover for Cracks or
Damage by Pushing It with Finger.
(2) Rear Hub Assembly and Backing Plate Installation
(Refer to P.27-33.)
1
23 45
6
Unit: Nm {kgf
m}
25 {2.6}
74 – 87
{7.5 – 8.9}
74 – 87
{7.5 – 8.9}*74 – 87
{7.5 – 8.9}
88 {9.0}*
Removal steps
1. Rear speed sensor connection

A2. Trailing arm connection
3. Lower arm connection
A4. Toe control arm connection
A5. Upper arm connection
6. KnuckleCaution
*: Indicates parts which should be temporarily
tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
REMOVAL SERVICE POINT
ATRAILING ARM / TOE CONTROL ARM / UPPER
ARM DISCONNECTION
Caution
(1) Use the special tool to loosen the nut only; do not
remove it from the ball joint.
(2) Tie the special tool with a cord not to let it fall off.
MB990635,
MB991113 or
MB991406
NutCord
Ball joint

REAR AXLE – Drive Shaft27-36
DRIVE SHAFT
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Gear Oil Draining (Refer to P.27-28.)
(2) Center Exhaust Pipe Removal
(Refer to GROUP 15.)Post-installation Operation
(1) Checking Each Ball Joint Dust Cover for Cracks
and Damages by Pressing Dust Cover with Finger
(2) Center Exhaust Pipe Installation
(Refer to GROUP 15.)
(3) Gear Oil Filling (Refer to P.27-28.)
(4) Parking Brake Lever Stroke Check and Adjustment
(Refer to GROUP 36 – On-vehicle Service.)
(5) Wheel Alignment Check and Adjustment
(Refer to GROUP 34 – On-vehicle Service.)
1
2 3
4
56 7
89 10 11
Unit: Nm {kgf
m}
25 {2.6}
74 – 87 {7.5 – 8.9}
74 – 87
{7.5 – 8.9}*88 {9.0}* 49 – 59 {5.0 – 6.0}
196 – 255 {20.0 – 26.0}
Removal steps
1. Caliper assembly
(Refer to P.27-33.)
2. Brake disc
3. Shoe & lining assembly (Refer to
GROUP 36 – Parking Brake.)
4. Clip
5. Parking brake cable connection
AB6. Drive shaft nut
7. Rear speed sensor coupling

8. Trailing arm coupling
9. Lower arm coupling
10. Toe control arm coupling
BA11. Drive shaftCaution
(1) With the part marked with *, first temporarily
tighten it, then ground the vehicle and tighten
it to specification in unloaded condition.
(2) When removing the drive shaft from, and
reinstalling it to, a vehicle with AYC, use care
not to damage the rotor mounted on the BJ outer
race.

REAR AXLE – Drive Shaft27-37
REMOVAL SERVICE POINTS
ADRIVE SHAFT NUT REMOVAL
Caution
Do not apply the vehicle weight to the wheel bearing
with the drive shaft nut loosened.
BDRIVE SHAFT REMOVAL
(1) Using the special tool, drive the drive shaft out of the
hub.
(2) Apply a lever to the protrusion of the drive shaft and
remove the drive shaft from the differential carrier.
Caution
(1) Be sure to remove the drive shaft from the
differential side using a lever. Removing it from
the BJ side could damage the parts.
(2) Do not apply the vehicle weight to the wheel
bearing with the drive shaft removed. If it is
unavoidable to apply the weight for reasons of
moving the vehicle, use the special tool to
temporarily secure it in position.
(3) To prevent entry of foreign matter into the
differential carrier, use the special tool as a cover.

MB990767
MB990244 (3) MB990767
MB990242 MB991354
MB991000
(MB990998)
MB991017
MB991460

REAR AXLE – Drive Shaft27-38
INSTALLATION SERVICE POINTS
ADRIVE SHAFT INSTALLATION
Caution
Use care not to allow the drive shaft splines to damage
the oil seal of the differential carrier.
BDRIVE SHAFT NUT INSTALLATION
(1) Install the washer on the drive shaft in the direction shown
on the left.
(2) Using the special tool, tighten the drive shaft nut to the
specified torque.
Caution
Before torquing the drive shaft nut to specification,
do not apply vehicle weight to the wheel bearing.
(3) If, at this time, the split pin holes are not aligned, tighten
the nut further (within 255 Nm {26.0 kgf
m}), insert the
split pin in the first matching holes, and bend it securely.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}

REAR AXLE – Differential Carrier 27-40
REMOVAL SERVICE POINT
AREAR 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
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY
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.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
442
5
5

REAR AXLE – Differential Carrier 27-42
REMOVAL SERVICE POINTS
APROPELLER SHAFT DISCONNECTION
Make an alignment mark on the companion flange and flange
yoke, then disconnect the propeller shaft from the companion
flange.
Caution
Suspend the propeller shaft from the body with a wire
to prevent the bend at the joint from catching and
damaging the joint boot.
BREAR 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
AREAR 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.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the companion flange with that
of the flange yoke at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 105
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 70
13
3
442
5
5

REAR AXLE – Torque Transfer Differential 27-45
DISASSEMBLY SERVICE POINT
ASELF-LOCKING NUT REMOVAL
ASSEMBLY SERVICE POINTS
AOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the specified grease to the oil seal lip.
Specified grease: Vaseline
BOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the multi-purpose grease to the oil seal lip.
MB990850
MD998812MD998829
MD998813
MB990938
MB991115

REAR AXLE – LSD Case Assembly 27-46
LSD CASE ASSEMBLY
DISASSEMBLY AND REASSEMBLY
1
2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20
Differential gear set
1011
1110
Disassembly steps
CLSD differential torque check
AB1. Screw
2. Differential case A
3. Spring plate
4. Friction plate
5. Friction disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Pressure ring
10. Side gear11. Pinion gear
12. Pinion shaft
13. Pressure ring
14. Friction plate
15. Friction disc
16. Friction plate
17. Friction disc
18. Friction plate
19. Spring plate
A20. Differential case B
DISASSEMBLY SERVICE POINT
ASCREW REMOVAL
(1) Check out the alignment marks.
(2) Loosen a uniform amount little by little the screws securing
differential case A to B.
(3) Separate differential case B from differential case A and
remove their components.
Keep the removed spring plates, friction plates, and friction
discs organized in the order of removal and for right and
left use.