1998 MITSUBISHI LANCER EVOLUTION IV torque

Snap Rings, Spacers and Thrust Plates
for Adjustment / Torque Specifications MANUAL TRANSMISSION
OVERHAUL –22B-9
Part namePart No. Identification symbol Thickness mm
Spacer
(For adj stment of center differential case
1.19LMD710456
(For adjustment of center differential case
preload)1.22GMD700271p
1.25MMD710457
1.28NMD710458
1.31EMD706574
Spacer
(For adj stment of center differential case pinion
0.6–MD748362
(For adjustment of center differential case pinion
backlash)0.7–MD748363
0.8–MD748364
0.9–MD748365
1.0–MD748366
1.1–MD748367
TORQUE SPECIFICATIONS
TRANSMISSION
ItemsNm {kgf
m}
Under cover mounting bolt6.9 {0.7}
Interlock plate bolt30 {3.1}
Clutch housing-transmission case mounting bolt44 {4.5}
Clutch release bearing retainer mounting bolt9.8 {1.0}
Control housing mounting bolt18 {1.9}
Shift cable bracket mounting bolt18 {1.9}
Speedometer gear mounting bolt3.9 {0.4}
Stopper bracket mounting bolt18 {1.9}
Select lever mounting bolt18 {1.9}
Select lever mounting nut11 {1.2}
Center differential drive gear mounting bolt132 {13.5}
Back-up lamp switch32 {3.3}
Poppet spring plug32 {3.3}
Reverse idler gear shaft mounting bolt48 {4.9}
Roll stopper bracket mounting bolt69 {7.0}

Torque Specifications /
Special toolsMANUAL TRANSMISSION OVERHAUL – 22B-10
TRANSFER
ItemsNm {kgf
m}
Transfer cover mounting bolt23 {2.4}
Transmission-transfer mounting bolt69 {7.0}
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bushing
remover & installer
ringInstallation of transfer oil seal
MB990891Bushing remover &
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller bearing
MB990933Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing outer race
MB990937Installer adapterInstallation of differential case taper roller
bearing

MANUAL TRANSMISSION OVERHAUL – Transmission22B-17
(3) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the transmission case at the positions
shown in the illustration.
(4) Install the bearing outer race.
(5) Install the transmission case and tighten the bolts to the
specified torque.
(6) Remove the transmission case. If the solder is not crushed,
repeat the steps (2) through (5) using the solder with
larger diameter.
(7) Measure the thickness of the crushed solder with a
micrometer and select spacers that will provide the
standard end play/preload value.
Standard value:
Input shaft end play 0 – 0.17 mm . . . . . . . . . .
Output shaft end play 0.13 – 0.18 mm . . . . . . . .
Center differential preload 0.05 – 0.11 mm . . . .
REASSEMBLY SERVICE POINTS

AINPUT SHAFT / OUTPUT SHAFT / CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and differential as a unit.

B5TH-REVERSE SPEED SHIFT FORK /
5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
RAIL INSTALLATION
(1) Install the 3rd-4th speed shift rails and fork, and
5th-reverse speed shift rail and fork.
Solders
Solders
Output shaft
Center
differentialInput
shaft
3rd-4th speed
shift fork
5th-reverse
speed shift fork5th-reverse
speed shift rail
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL – Center Differential22B-48
(5) Install the front output shaft to the side gear and fit the
snap ring.
(6) Attach the spacer on the other side gear, then install
the side gear in the center differential case.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).
(7) Install the center differential flange on the case while
aligning the mating marks, then secure it temporarily with
machine screw.
(8) Measure the backlash between the side gear and the
pinion.
Standard value: 0.025 – 0.150 mm
(9) If the measurement deviates from the standard value,
correct the backlash using a spacer of different thickness
and check it again.
NOTE
The backlash must be the same on both sides.

DCENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Apply sealant to the entire threaded portion of the bolt.
Specified sealant:
THREEBOND 1303 or LOKTITE 648
(2) Tighten the bolts to the specified torque in the illustrated
sequence.
1
8
7
6
5
4
3
2
10
9

FRONT AXLE – Service Specifications / Special Tools26-2
SERVICE SPECIFICATIONS
ItemsLimit
Hub axial play mm0.05
Hub rotation starting torque Nm {kgf
m}1.8 {1.8}
SPECIAL TOOLS
ToolNumberNameUse
MB990635 or
MB991113Steering linkage
pullerBall joint disconnection
MB990767End holderFixing of hub
MB991354Puller bodyRemoval of drive shaft
AB
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller bar
A: MB991017
B: MB990998
C: MB991000A, B: Front hub
remover &
installer
C: Spacer
Temporary fixing of unit bearing

Measurement of hub rotation starting
torque

Measurement of hub axial play
Use MB991000 (component of
MB990998) for the spacer.
MB990326Preload socketMeasurement of hub rotation starting torque

FRONT AXLE – Axle Hub and Knuckle26-5
INSPECTION
1. HUB ROTATION STARTING TORQUE CHECK
(1) Install the special tool to the front hub assembly and
tighten the nut to the specified torque.
(2) Use the special tool to measure the hub rotation starting
torque.
Limit: 1.8 Nm {18.0 kgf
cm}
(3) The hub rotation starting torque should be within the limit
value range, and there should be no engagement or
feeling of roughness.
2. HUB AXIAL PLAY CHECK
(1) Measure the hub play in the axial direction.
Limit: 0.05 mm
NOTE
Measure the hub play while clamping the hub in a vice
with wooden blocks against the bearing section.
(2) If the limit value of hub axial play cannot be obtained
with the nut tightened to the specified torque (177 to
275 Nm {18.0 to 28.0 kgf
m}), replace the front hub
assembly.MB991000
(MB990998)
MB990326
177 – 275 Nm
{18.0 – 28.0 kgf
m}
MB991017
MB991017
Wooden blocks
Wooden blocks

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