1998 MITSUBISHI LANCER EVOLUTION IV oil

MANUAL TRANSMISSION OVERHAUL – Transfer22B-49
TRANSFER
DISASSEMBLY AND REASSEMBLY
10 2
114
8
7
9
5
3
1
6
Apply gear oil to all
moving parts before
installation.
23 {2.4}
Unit: Nm {kgf
m}
Disassembly steps

F1. Air breather
2. Dust seal guard

E3. Oil seal

D4. Oil seal

A5. O-ring

A6. O-ring

C7. Oil seal

B8. Oil seal

A9. O-ring
10. Transfer cover
11. Transfer

MANUAL TRANSMISSION OVERHAUL – Transfer22B-50
REASSEMBLY SERVICE POINTS

AO-RING INSTALLATION
Apply transmission oil to the O-ring.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

BOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

COIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

DOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

EOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.
MD998800
MB990938
MB990933
MB990891
MB990887
MD998304

27-1
REAR AXLE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 5. . . . . . . . . . . . .
ON-VEHICLE SERVICE
27. . . . . . . . . . . . . . .
1. Rear Axle Total Backlash Check 27. . . . . . .
2. Gear Oil Level Check 27. . . . . . . . . . . . . . . .
3. Gear Oil Change 28. . . . . . . . . . . . . . . . . . . . .
4. Fluid Level Check 29. . . . . . . . . . . . . . . . . . . .
5. Bleeding 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Differential Carrier Oil Seal
Replacement 30. . . . . . . . . . . . . . . . . . . . . . . . .
7. Speed Sensor Output Voltage
Measurement 31.
8. Action When Battery Runs Out 32. . . . . . . .
REAR HUB ASSEMBLY 33. . . . . . . . . . . . . . . .
KNUCKLE 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT 36. . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CARRIER
39.
DIFFERENTIAL CARRIER
41. . . . . . . . . . . . . . . . . . .
TORQUE TRANSFER DIFFERENTIAL
43. . . . . . . . . . . . . . .
LSD CASE ASSEMBLY
46. . . . . . . . . . .
HYDRAULIC UNIT
50. . . . . . . . . . . . . . .
SENSOR RELAY
52. . . . . . . . . . . . . . .
AYC-ECU 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE – Service Specifications / Lubricant / Sealant27-2
SERVICE SPECIFICATIONS

ItemsStandard valueLimit
Rear axle total backlash mm–5
Pressure generated by hydraulic unit MPa {kgf/cm2}0 – 1.6 {10.0 – 16.0}–
Wheel bearing axial play mm–0.05
Wheel bearing rotation starting torque Nm {kgf
cm}–1.0 {10.5} or less

ItemsStandard valueLimit
Right-to-left difference in combined thickness of friction plate and fric-
tion disc mm0 – 0.05–
Clearance between spring plate and differential case mm0.06 – 0.25–
LSD differential torque
Nm {kgf
m}
When new clutch plate is installed5 – 19 {0.5 – 1.9}–
Nm {kgf
m}
When existing clutch plate is installed2 – 19 {0.2 – 1.9}–
Distortion of friction plate and friction disc mm–0.08
Difference in thickness between friction plate, friction disc, and spring
plate mm–0.1
LUBRICANT

ItemsSpecified lubricantCapacity
Gear oilTorque
transfer
differential
DifferentialMITSUBISHI GENUINE DIA QUEEN SUPER
HYPOID GEAR OIL (GL-5)0.41 ± 0.02 dm3
{0.41 ± 0.02 }
differentialTorque transfer
mechanismMITSUBISHI GENUINE DIA QUEEN AYC FLUID0.700
0.05dm3
{0.700
0.05}
Hydraulic piping fluidMITSUBISHI GENUINE DIA QUEEN ATF-SPII1 dm3 {1 }
Torque transfer mechanism oil seal lipsVaselineAs required
SEALANT

ItemsSpecified sealant
Torque transfer differential vent plugSemi-drying sealant: THREEBOND 1281B (460 g)
Torque transfer mechanism cover

REAR AXLE – Special Tools27-3
SPECIAL TOOLS
ToolNumberNameUse
MB991529Diagnosis code
check harnessInspection of AYC (diagnosis display by AYC
warning lamp)
MD998330
(MD998331)Oil pressure
gauge
(2,942 kPa
{30 kgf/cm
2})
Hydraulic pressure measurement with AYC>
MB991705Hose adapter
MB990925Bearing & oil seal
installer setPressfitting of oil seal
MB991115Oil seal installerPressfitting of oil seal (used in
combination with MB990938)
MD998812Installer capPressfitting of oil seal nism of vehicles with AYC>
MD998813Installer 100
MD998829Installer adapter
(60)
MB990767End yoke holderFixing of hub

REAR AXLE – Special Tools27-4
Tool UseName Number
AB
MB990241
A: MB990242
B: MB990244Rear axle shaft
puller
A: Puller shaft
B: Puller bar
Removal of drive shaft

Removal of rear hub assembly
MB991354Puller body
A: MB991017
B: MB990998
C: MB991000A, B: Front hub
remover &
installer
C: Spacer
Temporary fixing of unit bearing

Measurement of wheel bearing rotation
starting torque

Measurement of wheel bearing axial play
Use MB991000 (component
of MB990998) for the spacer.
MB990326Preload socket
Measurement of wheel bearing rotation
starting torque

Measurement of drive pinion preload
MB991406,
MB990635, or
MB991113Steering linkage
puller
Disconnection of ball joint

Removal of hub bolt
MB991460PlugPrevention of differential oil from being dis-
charged and entry of foreign matter tial>
MB990988Side gear holding
tool setMeasurement of clutch plate preload without AYC>
MB990850End yoke holderRemoval and installation of companion flange

REAR AXLE – Troubleshooting 27-18
Code No. 81: AYC relay systemProbable cause
This code is output when the coil circuit of the AYC relay is open- or short-circuited.
Defective AYC relay

Defective harness or connector

Defective AYC-ECU
NG
Check and repair the harness between
AYC relay and body ground.
OK
Check the trouble symptom.
OK
Replace AYC-ECU.
NG
Check the harness between AYC relay
and AYC-ECU.NG
Repair
NG
Check the trouble symptom.
OK
Check the following connectors:
B-96, B-126NG
Repair
OK
Measure at A-126 AYC relay connec-
tor.

Disconnect the connector and
measure at the harness side.

Continuity across 1 and body
ground
OK:ConductingNGCheck the following connector:
A-126NG
Repair
Check the AYC relay.
(Refer to P.27-52.)NGReplace the AYC relay.

REAR AXLE – Troubleshooting 27-19
Code No. 82: Electric pump systemProbable cause
This code is output if the pressure switch is not set to high-pressure position despite
the AYC-ECU’s command to drive the AYC relay for a given period of time.
Low hydraulic oil level

Oil leak

Defective fusible link

Defective AYC relay

Defective harness or connector

Defective AYC motor

Defective accumulator pressure switch

Defective AYC-ECU
OK
Replace AYC-ECU.
Check the harness
between AYC relay and
AYC motor, and between
AYC motor and body
ground.NG
Replace
NG
OK
Check the trouble symptom.
OK
Check the following
connectors:
A-126, B-94, B-27, F-32NG
Repair
OK
Replace AYC-ECU.
NG
Check the harness
between AYC-ECU and
accumulator pressure
switch.NG
Repair
NG
Check and repair the har-
ness between fusible link
no. 10 and AYC relay.
OK
Check the trouble symp-
tom.
OK
Replace the hydraulic unit
for a defective accumula-
tor pressure switch.
NO
Repair the leak.
OK
Check the trouble symptom.
NG
Check the following
connector: A-126NG
Repair
YES
Add hydraulic oil.
Is the hydraulic oil level correct in the reservoir tank?
(Refer to P.27-29.)NOIs there a hydraulic oil leak?
Measure at A-126 AYC relay connector.

Disconnect the connector and measure at the harness side.

Voltage across 5 and body ground
OK: Battery voltage
NG
NO
Can pump be operated?YESMeasure at F-31 accumulator pressure switch connector.

Disconnect the connector and measure at the harness side.

Ignition switch: ON

Voltage across 2 and body ground
OK:Battery voltage
YES
Is diagnosis code no. 81 output?YESCheck the AYC relay system. (Refer to P.27-18.)
NG
Check the following
connectors: B-95, B-94,
D-06, F-30, F-31NG
Repair
OK

Check AYC relay for
continuity.
(Refer to P.27-52.)

Check AYC motor for
operation.NG
Repair