1998 MITSUBISHI LANCER EVOLUTION IV clutch

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-43

COUTER RACE INSTALLATION

DOUTER RACE INSTALLATION

EOIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W
MB990935
MB990938
MB991445MB990938
MB990928
MB990938

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 Tools27-4
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 27-25
Terminal
No.Normally Check requirement Check item
18TPSIgnition switch:
ON
Accelerator pedal: Fully closed0.3 – 1.0 V
ON
Accelerator pedal: Fully open4.5 – 5.0 V
23Diagnosis data input/output1 V or less
24Idle position switchIgnition switch:
ON
Accelerator pedal: Fully closed2 V or less
ON
Accelerator pedal: Fully open4.5 – 5.0 V
25Accumulator pressure
switchIgnition switch:
ONAccumulator internal pressure:
Low2 V or less
Accumulator internal pressure:
HighBattery voltage
26ECU groundAt all times0 V
31AYC-ECU power supplyIgnition switch: ONBattery voltage
Ignition switch: OFF0 V
35AYC motor relayIgnition switch:
ON
When motor is energizedBattery voltage
ON
When motor is deenergized2 V or less
36AYC warning lampIgnition switch:
ON
When lamp is OFFBattery voltage
ON
When lamp is ON2 V or less
37Directional control valve
(right)
Ignition switch:
ON
Right clutch: ONBattery voltage
(right)ON
Right clutch: OFF0 V
38Proportioning valveIgnition switch:
ONAYC-ON0 V to battery volt-
age
AYC-OFF0 V
39ECU backup power supplyAt all timesBattery voltage
45Directional control valve
(left)
Ignition switch:
ON
Left clutch: ONBattery voltage
(left)ON
Left clutch: OFF0 V
46ECU groundAt all times0 V
NOTE
*1: Indicates the vehicles with ABS.

REAR AXLE – LSD Case Assembly 27-47
ASSEMBLY SERVICE POINTS
AINSTALLATION TO DIFFERENTIAL CASE B
Before starting the assembly procedure, perform the following
steps to adjust dimensional differences (clutch plate friction
force) in the axial direction of the components inside the
differential case and axial clearance of the differential side
gear.
(1) Place friction discs (two each) and friction plates (three
each) one on top of another as illustrated and, using
a micrometer, measure the thickness of each of the right
and left assemblies. Select different discs and plates so
that the difference between the right and left assemblies
falls within the specified range.
Standard value: 0 – 0.05 mm
NOTE
If a new part is used, note that the friction disc comes
in two thicknesses: 1.6 mm and 1.7 mm.
(2) Measure the thickness of each of the right and left spring
plates.
(3) Assemble the pressure ring internal parts (pinion shaft
and pressure ring), friction plates, and friction discs and,
using a micrometer, measure the overall width.
NOTE
When taking measurements, press the assembly from
both sides so that the pinion shaft makes a positive contact
with the groove in the pressure ring.
(4) Find value (A) which is the thickness measured in step
(3) added to the thickness of two spring plates.
(5) Find dimension (B) between the spring plate faying
surfaces when differential case A and B are assembled
together.
B = C + D – E
(6) If the clearance between the spring plate and differential
case (B – A) is outside the specified range, change the
friction discs and make adjustments.
Standard value: 0.06 – 0.25 mm
(7) Coat each part with the specified gear oil and mount
it in the specified direction and order into differential case
B.
Gear oil: DIA QUEEN LSD GEAR OIL
NOTE
Apply a careful coat of gear oil to the contacting and
sliding surfaces.
Groove
Differential
case ADifferential case B
Spring plate
Friction disc
Friction plate

REAR AXLE – LSD Case Assembly 27-48
BSCREW TIGHTENING
(1) Align the alignment mark on differential case A with that
on differential case B.
(2) Tighten the screws connecting differential case A and
B a uniform amount little by little in the diagonal order.
NOTE
If tightening the screws does not bring the two cases
properly together, spring plates are not probably
assembled properly. Reassemble from the start.
CLSD DIFFERENTIAL TORQUE CHECK
(1) Using the special tool, check for differential torque.
Standard value:
When new clutch plate is
installed Nm {kgf
m}When existing clutch plate is
reused Nm {kgf
m}
5 – 19 {0.5 – 1.9}2 – 19 {0.2 – 1.9}
NOTE
Before measuring the differential torque, first turn the
gears so they snug each other, then take measurements
during rotation.
(2) If the measurement falls outside the specified range,
disassemble the differential case assembly and repair
or replace defective parts.
INSPECTION
1. DIFFERENTIAL CASE INTERNAL PARTS
CONTACT/SLIDING SURFACE CHECK
(1) Clean the disassembled parts with cleaning oil and dry
them with compressed air.
(2) Check each plate, disc, and pressure ring for the following:
A. Friction and sliding surfaces of friction discs, friction
plates, and spring plates.
Replace a defective part with heat discoloration and
excessive wear with a new one, as it degrades locking
performance.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
B. Inner periphery and outer periphery protrusions of
friction discs, friction plates, and spring plates.
Replace a cracked or damaged part with a new one.
C. Friction and sliding surfaces between pressure rings
and friction discs.
MB990989MB990990
Friction disc
Friction plateSpring plate
Pressure ring

CHASSIS ELECTRICAL – Combination MetersCHASSIS ELECTRICAL – Combination Meters54-27
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
1. Adjust the pressure of the tyres to the specified level.
2. Set the vehicle onto a speedometer tester and use wheel
chocks to hold the rear wheels.
3. Pull the parking brake lever firmly.
4. To prevent the front wheel from moving from side to side,
attach tension bars to the tie-down hook, and secure
both ends to anchor plates.
5. To prevent the vehicles from starting, attach a chain or
wire to the rear towing hook, and secure the other end
of the chain or wire firmly to an unmovable body.
6. Check if the speedometer indication range is within the
standard values and if the pointer fluctuation is within
the limits.
Caution
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
Standard values:
Vehicle speed km/hSpeedometer indication
allowable errors km/h
4037 – 45
8075 – 88
120113 – 132
160150 – 176
Limit: Pointer fluctuation
(at vehicle speeds of higher than 35 km/h) ±3 km/h
TACHOMETER CHECK
1. Insert a paper clip in the engine speed detection connector
from the harness side, and attach the engine
speedometer.
2. Compare the readings of the engine speedometer and
the tachometer at every engine speed, and check if the
variations are within the standard values.
Standard values:
700 r/min : ±100 r/min
3,000
*1 r/min : ±150 r/min
3,000*2 r/min : +225 to –100 r/min
5,000*1 r/min : ±250 r/min
5,000*2 r/min : +325 to –125 r/min
6,000*1 r/min : ±300 r/min
7,000*2 r/min : +400 to –100 r/min
8,000*3 r/min : +400 to 0 r/min
NOTE
*1: Tachometer measurable up to 8,000 r/min
*2: Tachometer measurable up to 9,000 r/min and one measurable up to 10,000 r/min
*3: Tachometer measureble up to 10,000 r/min
Wheel chocks
Tension bar
Tie-down hook
Front
Anchor plate
Engine speed detection
connector

CHASSIS ELECTRICAL – Radio and Tape Player54-45
RADIO AND TAPE PLAYER
TROUBLESHOOTING
There is noise when the engine is running.
Kind of Noise (Parenthe-
sized is how noise
sounds.)SymptomCauseRemedy
AM, FM: Ignition noise
(Popping, snapping,
crackling, buzzing)
Popping sound becomes
faster with the increase
of engine speed.

The noise is lost with
ignition switch turned to
ACC.
Mainly due to the
spark plugs.

Due to noise circula-
tion from elsewhere

Noise from the engineCheck the noise capacitor
and earth cable and
replace if necessary. (See
Fig. 1 and Fig. 2.)
AM, FM: Defogger noise
(1) (Murmuring)Occurs when the defogger
switch is turned to ON and
OFF.Noise produced by spark-
ing when the defogger
switch is turned to ON/
OFF enters the glass
antenna.Check the noise capacitor
and replace if necessary.
(See Fig. 1.)
AM, FM: Defogger noise
(2) (Snapping noise)Occurs when the defogger
switch is turned to ON.Noise produced by current
flowing in the defogger
enters the glass antenna.Check the choke coil and
replace if necessary.
(See Fig. 3.)
AM, FM: Defogger noise
(3) (Scratching, gaggling)Occurs when the defogger
switch is turned to ON with
print heater wire broken.Noise produced by spark-
ing where print heater is
broken enters the glass
antenna.Repair the print heater.
AM, FM: Wiper motor
noise (Humming, wheez-
ing)Sound becomes faster with
the increase of wiper speed
and is lost when the wiper is
stopped.Caused by sparking in
wiper motor brush.Replace the wiper motor.
FM: Mirror motor noise
(Humming, wheezing)Occurs when electric mirror
operates.Caused by sparking in
mirror motor brush.Replace the electric
motor.
Other electrical compo-
nents–Noise is emitted by some
electrical components in
long use.Repair or replace electri-
cal components.
Static electricity (Crack-
ling, crinkling)
Noise is stopped when
the vehicle comes to a
complete stop.

Noise becomes louder
when the clutch is
released.Occurs when parts or
wiring move for some
reason and contact metal
parts of the body.Put parts or wiring into
position.
Various noises are produced
by body parts.Due to electrical detach-
ment of the hood, exhaust
pipe and muffler, suspen-
sion, etc. from the body.Tighten mounting bolts
securely. In many cases,
remedy of one part does
not eliminate the problem
due to incomplete earthing
elsewhere.
Caution
(1) Never let the noise filter contact a high tension cable. The noise filter could break down.
(2) Check that there is no external noise. This check is necessary to prevent misidentification of noise
sources.
(3) Noise prevention should be performed by eliminating noise sources in the descending order of loudness.