1998 MITSUBISHI LANCER EVOLUTION IV differential

REAR AXLE – On-vehicle Service 27-29
3-2 TORQUE TRANSFER MECHANISM
(1) Remove the drain plug to discharge the gear oil.
(2) Fit the drain plug and tighten it to the specified torque.
(3) Remove the filler plug and add the specified gear oil
up to the bottom end of the filler plug hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
Quantity used: 0.70
0
0.05dm3{0.700
0.05}
(4) Fit the filler plug and tighten it to the specified torque.
4. FLUID LEVEL CHECK
(1) Remove the maintenance lid located in the luggage
compartment.
(2) If the vehicle has been run, leave it for 5 min. or more
in an ordinary temperature (10
C to 30
C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is less than 10
C or less,
allow more time to leave the vehicle to stand idle.
(3) Check that the fluid level in the oil reservoir is in the
range between MAX and MIN.
(4) If the fluid level is lower than MIN, add the specified
fluid.
Specified fluid: MITSUBISHI DIA QUEEN ATF-SPII
(5) Reinstall the maintenance lid.
5. BLEEDING
(1) Lift up the vehicle.
(2) Remove the cap of the left bleeder screw on the torque
transfer differential and connect a vinyl hose.
(3) Gradually turn the steering wheel clockwise from the
straight-ahead position. At this time, loosen the left bleeder
screw and check that fluid is discharged with air.
(4) After air has been completely discharged, tighten the
bleeder screw.
Caution
While the system is being bled of air, add fluid as
necessary to ensure that it is left in the oil reservoir
during the entire procedure.
(5) Repeat steps (3) and (4) two to three times until no air
bubbles are recognized in the fluid that comes out. Then,
tighten the bleeder screw to the specified torque.
Tightening torque: 9 Nm {0.9 kgf
m}
(6) Perform steps (2) through (5) for the right bleeder screw.
Note, however, that the steering wheel should be turned
counterclockwise.
Filler plug
49 Nm {5.0 kgf
m}
Gear oil
Drain plug
49 Nm
{5.0 kgf
m}
Bleeder
screws Vinyl hose

REAR AXLE – On-vehicle Service 27-30
(7) After the system has been completely bled of air, check
for the fluid level.
Caution
If the system is not completely bled of air, the hydraulic
unit could generate noise, degrading pump durability.
6. DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
6-1 DIFFERENTIAL
(1) Remove the drive shaft. (Refer to p. 27-36.)
(2) Remove the oil seal from the differential carrier.
(3) Using the special tool, drive a new oil seal all the way
into position.
(4) Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with multi-purpose grease.
(5) Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier. (Refer to P.27-36.)
(6) Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)
6-2 TORQUE TRANSFER MECHANISM
(1) Remove the drive shaft. (Refer to p. 27-36.)
(2) Remove the oil seal from the differential carrier.
(3) Using the special tool, drive a new oil seal all the way
into position.
(4) Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with the specified grease.
Specified grease: Vaseline
(5) Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier. (Refer to P.27-36.)
(6) Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)MB990938
MB991115
MD998829
MD998812
MD998813

REAR AXLE – Drive Shaft27-37
REMOVAL SERVICE POINTS
ADRIVE SHAFT NUT REMOVAL
Caution
Do not apply the vehicle weight to the wheel bearing
with the drive shaft nut loosened.
BDRIVE SHAFT REMOVAL
(1) Using the special tool, drive the drive shaft out of the
hub.
(2) Apply a lever to the protrusion of the drive shaft and
remove the drive shaft from the differential carrier.
Caution
(1) Be sure to remove the drive shaft from the
differential side using a lever. Removing it from
the BJ side could damage the parts.
(2) Do not apply the vehicle weight to the wheel
bearing with the drive shaft removed. If it is
unavoidable to apply the weight for reasons of
moving the vehicle, use the special tool to
temporarily secure it in position.
(3) To prevent entry of foreign matter into the
differential carrier, use the special tool as a cover.

MB990767
MB990244 (3) MB990767
MB990242 MB991354
MB991000
(MB990998)
MB991017
MB991460

REAR AXLE – Drive Shaft27-38
INSTALLATION SERVICE POINTS
ADRIVE SHAFT INSTALLATION
Caution
Use care not to allow the drive shaft splines to damage
the oil seal of the differential carrier.
BDRIVE SHAFT NUT INSTALLATION
(1) Install the washer on the drive shaft in the direction shown
on the left.
(2) Using the special tool, tighten the drive shaft nut to the
specified torque.
Caution
Before torquing the drive shaft nut to specification,
do not apply vehicle weight to the wheel bearing.
(3) If, at this time, the split pin holes are not aligned, tighten
the nut further (within 255 Nm {26.0 kgf
m}), insert the
split pin in the first matching holes, and bend it securely.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}

REAR AXLE – Differential Carrier 27-39
DIFFERENTIAL CARRIER

REMOVAL AND INSTALLATION

Pre-removal Operation
(1) Hydraulic Piping Fluid Draining
(2) Gear Oil Draining (Refer to P.27-28.)
(3) Lower Arm Assembly Removal
(Refer to GROUP 34.)
(4) Rear Stabilizer Removal (Refer to GROUP 34.)
(5) Drive Shaft Removal (Refer to P.27-36.)Post-installation Operation
(1) Drive Shaft Installation (Refer to P.27-36.)
(2) Rear Stabilizer Installation (Refer to GROUP 34.)
(3) Lower Arm Assembly Installation
(Refer to GROUP 35.)
(4) Gear Oil Filling (Refer to P.27-28.)
(5) Hydraulic Piping Fluid Filling and Bleeding
(Refer to P.27-29.)
1
23
4 5
6
7
8
910
11
Unit: Nm {kgf
m}
12 {1.2}
29 – 34
{3.0 – 3.5}
88 {9.0}
88 {9.0}88 {9.0}44 {4.5} 88 {9.0}
34 {3.5}
3108 – 127 {11.0 – 13.0}
988 {9.0}
Removal steps
1. Hydraulic unit hose assembly con-
nection
B2. Propeller shaft connection
3. Differential support member mount-
ing bolt
AA4. Rear crossmember and differential
carrier assembly5. Differential support member
6. Upper stopper
7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential mount bracket
11. Differential carrier

REAR AXLE – Differential Carrier 27-40
REMOVAL SERVICE POINT
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY REMOVAL
(1) Using a jack, support the differential carrier from its
underside.
(2) Remove the rear crossmember mounting bolts and
remove the differential carrier, where it is attached to
the rear crossmember, from the vehicle.
INSTALLATION SERVICE POINTS
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY
Tighten the rear crossmember mounting bolts in the numerical
order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the rear crossmember mounting holes have
different diameters between front and rear. This is the reason
for specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
442
5
5

REAR AXLE – Differential Carrier 27-41
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Differential Gear Oil Draining
(2) Lower Arm Assembly Removal
(3) Rear Stabilizer Removal
(4) Drive Shaft RemovalPost-installation Operation
(1) Drive Shaft Installation
(2) Rear Stabilizer Installation
(3) Lower Arm Assembly Installation
(4) Differential Gear Oil Filling
12
3
4 5
6
78
9 10
Unit: Nm {kgf
m}
29 – 34
{3.0 – 3.5}88 {9.0} 108 – 127
{11.0 – 13.0}
3
6
9
7 2
108 – 127
{11.0 – 13.0}108 – 127
{11.0 – 13.0}
88 {9.0}88 {9.0} 88 {9.0}
69 {7.0}
108 – 127
{11.0 – 13.0}
3
3
69 {7.0}
88 {9.0}
Removal steps
AB1. Propeller shaft connection
2. Toe control bar
3. Differential support member mount-
ing bolt and nut
BA4. Rear crossmember and differential
carrier assembly5. Differential support member
6. Upper stopper
7. Lowe
r stopper
8.Differential support arm
9.Differential mount bracket
10.Differential carrier

REAR AXLE – Differential Carrier 27-42
REMOVAL SERVICE POINTS
APROPELLER SHAFT DISCONNECTION
Make an alignment mark on the companion flange and flange
yoke, then disconnect the propeller shaft from the companion
flange.
Caution
Suspend the propeller shaft from the body with a wire
to prevent the bend at the joint from catching and
damaging the joint boot.
BREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY REMOVAL
(1) Using a jack, support the differential carrier from its
underside.
(2) Remove the rear crossmember mounting bolts and
remove the differential carrier, where it is attached to
the rear crossmember, from the vehicle.
INSTALLATION SERVICE POINTS
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY INSTALLATION
Tighten the rear crossmember mounting bolts in the numerical
order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the rear crossmember mounting holes have
different diameters between front and rear. This is the reason
for specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the companion flange with that
of the flange yoke at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 105
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 70
13
3
442
5
5