boot MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

CLUTCH –
General / Service Specifications /
Lubricants / On-vehicle Service21A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm163.5–166.5
Clutch pedal clevis pin play mm1–3
Clutch pedal free play mm6–13
Distance between the clutch pedal and the toeboard when
the clutch is disengaged mm85 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidBrake fluid DOT 3 or DOT 4As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMITSUBISHI genuine grease
Part No. 0101011
ON-VEHICLE SERVICE

CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height.
Standard value (A): 163.5 – 166.5 mm
3. If the height of the clutch pedal is outside the standard
value, loosen the locking nut and adjust the pedal height
to the standard value using the adjusting bolt or push
rod.
Clutch pedal height
A
Setting nutAdjusting bolt
Locking
nut
13 Nm

CLUTCH – Clutch Control21A-6
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
13 Nm
6 7
3
1
2
Piston repair kitClutch fluid:
Brake fluid DOT3 or DOT4
Grease: Rubber grease
2 5
4
413
44 8
Disassembly steps
1. Piston stopper ring
A2. Push rod assembly
3. Boot
4. Piston assembly
5. Reservoir cap
6. Spring pin
7. Reservoir tank
8. Clutch master cylinder bodyCaution
Do not disassemble piston assembly.
INSTALLATION SERVICE POINT
APUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of the clutch pedal easier.
122.5 mm

BASIC BRAKE SYSTEM – Disc Brake35A-9
DISC BRAKE

DISASSEMBLY AND REASSEMBLY
Front Brake
Seal & boot kit Shim set
Clip set Pad set
Brake caliper kit
1 23 4 5
6
7
8 9
10
1
23
43 41
2 56
55
7 9
9 7 9 7
8 6 6
10
21
Disassembly steps
1. Pin
2. Cross spring
3. Pad & wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
7. Piston boot
8. Piston
9. Piston seal
10. Caliper body

BASIC BRAKE SYSTEM – Disc Brake35A-10
Rear Brake
Seal & boot kit Shim set
Clip set Pad setBrake caliper kit
1
23 4 5
6
7 8
910
2
6
16
7
8 910 2
1
7
9 7 9
3
4
3 4
2
1
65
5
5
Disassembly steps
1. Pin
2. Cross spring
3. Pad & wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
7. Piston boot
8. Piston
9. Piston seal
10. Caliper body

STEERING – Power Steering Gear Box37A-17
INSPECTION
RACK CHECK

Check the rack tooth surfaces for damage or wear.

Check the oil seal contact surfaces for uneven wear.

Check the rack for bends.
PINION AND VALVE ASSEMBLY CHECK

Check the pinion gear tooth surfaces for damage or wear.

Check for worn or defective seal ring.
BEARING CHECK

Check for roughness or abnormal noise during bearing
operation.

Check the bearing for play.

Check the needle roller bearing for roller slip-off.
OTHER CHECK

Check the cylinder inner surface of the rack housing for
damage.

Check the boots for damage, cracking or deterioration.

Check the rack support for uneven wear or dents.

Check the rack bushing for uneven wear or damage.