1998 MITSUBISHI LANCER EVOLUTION IV Workshop Manual

FRONT AXLE – Axle Hub and Knuckle26-4
REMOVAL SERVICE POINTS
ACALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, so that it
does not fall.
BDRIVE SHAFT NUT REMOVAL
Caution
Do not apply the vehicle weight to the wheel bearing
while loosening the drive shaft nut.
CTIE ROD END DISCONNECTION
Use the special tool to disconnect the ball joint.
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.
DDRIVE SHAFT REMOVAL
INSTALLATION SERVICE POINT
ADRIVE SHAFT NUT INSTALLATION
(1) Install the drive shaft washer in the specified direction.
(2) Using the special tool, tighten the drive shaft nut.
Caution
Before securely tightening the drive shaft nuts, make
sure there is no load on the wheel bearings.
(3) If the position of the split pin holes does not match, tighten
the nut up to the first matching holes.
Install the split pin and bend it securely.
MB990767
MB990635 or
MB991113
Ball joint
CordNut
MB990767
MB990242MB991354
MB990244 (3)
177 – 275 Nm
{18.0 – 28.0 kgf
m}
Washer
MB990767

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

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 – Special Tools / Troubleshooting 27-5
MB990988NumberNameO.D. mm
1MB990551Box–
2MB990989Base–
3(MB990990)Tool A25
(MB990991)Tool B28
(MB990992)Tool C31
MB990925
Brass bar
Bar (one-touch type)Toolbox
Installer adapter
Tool number (MB990925)O.D. mmTool number (MB990925)O.D. mm
AMB99092639.0AMB99093363.5
MB99092745.0MB99093467.5
MB99092849.5MB99093571.5
MB99092951.0MB99093675.5
MB99093054.0MB99093779.0
MB99093157.0BMB990938–
MB99093261.0CMB990939–
TROUBLESHOOTING
1. BASIC TROUBLESHOOTING CONDITIONS
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.

The correct steering wheel has been properly installed in the neutral position of the steering column
shaft.

Tire and wheel sizes are correct with correct specifications. Inflation pressure, balance, and wear
conditions are okay.

Wheel alignment is correct.

The engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
2. DIAGNOSIS FUNCTION
READING THE DIAGNOSIS CODE
Read the diagnosis code using AYC warning lamp.

REAR AXLE – Troubleshooting 27-6
3. INSPECTION CHART FOR DIAGNOSIS CODE
Diagnosis
code No.Diagnosis itemsRef. page
12Power supply voltage (valve power supply) system (open- or short-circuit)27-7
21FR wheel speed sensor system (open- or short-circuit)27-7
22FL wheel speed sensor system (open- or short-circuit)27-7
23RR wheel speed sensor system (open- or short-circuit)27-7
24RL wheel speed sensor system (open- or short-circuit)27-7
25Wrong-diameter tire27-9
26Faulty wheel speed sensor27-10
31Steer sensor (ST-1, ST-2, ST-N) system (open-circuit)27-11
32Steer sensor (ST-N) system (short-circuit)27-11
33Steer sensor (ST-N) system27-12
34Steer sensor (ST-1, ST-2) system (short-circuit)27-12
41TPS system (open- or short-circuit)27-13
51Longitudinal acceleration sensor system (open- or short-circuit)27-13
52Longitudinal acceleration sensor27-14
56Lateral acceleration sensor system (open- or short-circuit)27-13
61Stop lamp switch system (open-circuit)27-14
65ABS monitor system (open-circuit or defective ABS)27-15
71Proportioning valve system (open- or short-circuit)27-15
72Directional control valve (right) system (open- or short-circuit)27-16
73Directional control valve (left) system (open- or short-circuit)27-17
81AYC relay system (open- or short-circuit)27-18
82Electric pump system27-19
83Electric pump system27-20