1998 MITSUBISHI LANCER EVOLUTION IV check oil

22A-1
MANUAL
TRANSMISSION
CONTENTS
LUBRICANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . .
1. Transmission Oil Check 3. . . . . . . . . . . . . . . .
2. Transmission Oil Replacement 3. . . . . . . . . .
3. Transfer Oil Check 3. . . . . . . . . . . . . . . . . . . .
4. Transfer Oil Replacement 3. . . . . . . . . . . . . .
TRANSMISSION CONTROL* 4. . . . . . . . . . . . .
Shift Lever Assembly 6. . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION ASSEMBLY 7. . . . . . . . . . . . .
TRANSFER ASSEMBLY 10. . . . . . . . . . . . . . . .
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1) Thoroughly review this manual, especially GROUP 52B – Supplemental Restraint System (SRS) before beginning any
service or maintenance of any component of the SRS or any SRS-related component.
(2) When removing or installing the components indicated in the table of contents by an asterisk (*), use special care not
to apply shocks to SRS-related components.

MANUAL TRANSMISSION – On-vehicle Service22A-3
ON-VEHICLE SERVICE
1. TRANSMISSION OIL CHECK
(1) Remove the oil filler plug.
(2) Oil level should be at the lower portion of the filler plug
hole.
(3) Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
2. TRANSMISSION OIL REPLACEMENT
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transmission oil
Specified oil:
MITSUBISHI genuine “Dia-Queen” multi gear oil
<75W/85W>
Quantity: 2.8 dm
3 (2.8
)
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
3. TRANSFER OIL CHECK
(1) Remove the oil filler plug.
(2) Oil level should be at the lower portion of the filler plug
hole.
(3) Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
4. TRANSFER OIL REPLACEMENT
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transfer oil
Specified oil:
MITSUBISHI genuine “Dia-Queen Super” hypoid
gear oil (GL-5)
Quantity: 0.62 dm
3 (0.62
)
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
Transmission oilFiller plug hole
Filler plug
Drain plug
Filler plug
Drain plug
Transfer oil

MANUAL TRANSMISSION – Transmission Assembly22A-7
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Transmission Oil Draining (Refer to P.22A-3.)
(2) Transfer Oil Draining (Refer to P.22A-3.)
(3) Under Cover Removal
(4) Front Exhaust Pipe Removal (Refer to GROUP 15.)
(5) Battery and Battery Tray Removal
(6) Air Cleaner Assembly RemovalPost-installation Operation
(1) Air Cleaner Assembly Installation
(2) Battery and Battery Tray Installation
(3) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(4) Under Cover Installation
(5) Transfer Oil Supplying (Refer to P.22A-3.)
(6) Transmission Oil Supplying (Refer to P.22A-3.)
(7) Shift Lever Operation Check
(8) Speedometer Operation Check
1
2
34 5
6
7
8 8
Unit: Nm {kgfm}
49 {5.0} 98 {10.0}*
88 {9.0}19 {1.9}
48 {4.9}19 {1.9}
Removal steps
1. Shift cable and select cable con-
nection
2. Backup lamp switch connector
3. Vehicle speed sensor connector
A4. Starter motor
5. Clutch release cylinder connection
6. Transmission assembly upper part
coupling bolts7. Transmission mount bracket
8. Transmission mount stopper

Engine assembly supporting
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.

MANUAL TRANSMISSION OVERHAUL – Sealants and Adhesives22B-5
SEALANTS AND ADHESIVES
TRANSMISSION
ItemsSpecified sealants and adhesives
Clutch housing-transmission case mating surfaceTHREEBOND 1216
Control housing-transmission case mating surface
Under cover-transmission case mating surface
Air breatherTHREEBOND 1501
Center differential drive gear boltTHREEBOND 1303 or LOKTITE 648
TRANSFER
ItemsSpecified sealants and adhesives
Air breatherTHREEBOND 1501
FORM-IN-PLACE GASKET
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that
the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
SURFACE PREPARATION
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 10 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

MANUAL TRANSMISSION OVERHAUL – Transmission22B-19

GCONTROL HOUSING INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.

HSPEEDOMETER GEAR INSTALLATION
Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

ISELECT LEVER INSTALLATION
Apply grease to the control shaft sliding portion of the select
lever shoe.
Specified grease: MOLYWHITE TA No.1 or No.2

JO-RING INSTALLATION
Lubricate O-ring with transmission oil.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W
INSPECTION
BACK-UP LAMP SWITCH
Check for continuity between terminals.
Switch conditionContinuity
PressedNot exist
ReleasedExists

2 mm
Control shaft
Select
lever
shoe

MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear22B-35
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
5
4321
TFM0807
Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the shaft and gear are combined
and made to rotate, they rotate smoothly without looseness
and noise.
(2) Check to ensure that the cage is not deformed.

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 – 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