1998 MITSUBISHI LANCER EVOLUTION IV lock

MANUAL TRANSMISSION OVERHAUL – Center Differential22B-47
B
TAPER ROLLER BEARING REMOVAL
Use the special tools to remove the taper roller bearing.
REASSEMBLY SERVICE POINTS

ATAPER ROLLER BEARING INSTALLATION
Use the special tool to install the taper roller bearing.

BTAPER ROLLER BEARING INSTALLATION
Use the special tools to install the taper roller bearing.

CSPACER / SIDE GEAR / WASHER /
PINION/PINION HOLDER / PINION SHAFT /
LOCK PIN / FRONT OUTPUT SHAFT / SNAP
RING / CENTER DIFFERENTIAL FLANGE
INSTALLATION
(1) Install the side gear in the center differential case with
the spacer attached.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).
(2) Fit the washer on the back of each pinion. Engage the
4 pinions simultaneously in the side gear.
Rotate the gears to place them in position, then install
the pinion shaft holder.
(3) Insert the pinion shafts.
(4) Install the lock pins in the illustrated direction.
MD998917
MB990932
MB990937
MD998812
MD998823
Lock pin Differential case
Pinion shaft

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

REAR AXLE – On-vehicle Service 27-27
ON-VEHICLE SERVICE

1. REAR AXLE TOTAL BACKLASH CHECK
If the drive system roars or the vehicle vibrates, use the
following procedure to measure total backlash in the rear
axle. Based on the measurement taken, determine whether
the differential carrier assembly needs to be removed or not.
(1) Place the shift lever in the neutral position and operate
the parking brake.
(2) Turn the propeller shaft fully clockwise and make an
alignment mark on the companion flange dust cover and
gear carrier.
(3) Turn the propeller shaft fully counterclockwise and
measure the deviation between the alignment marks.
Limit: 5 mm
(4) If the backlash exceeds the limit, replace the differential
carrier assembly.
2. GEAR OIL LEVEL CHECK
2-1 DIFFERENTIAL
(1) Remove the filler plug.
(2) Check that the gear oil level is within the specified range
from the bottom end of the filler plug hole.
Standard value (A): 6 mm
(3) If the gear oil level exceeds the standard value, add the
specified gear oil up to the bottom end of the filler plug
hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER
HYPOID GEAR OIL (GL-5)
NOTE
10
C or more: #90, less than 10
C: #80
(4) Fit the filler plug and tighten it to the specified torque.
Alignment marks
Filler plug
49 Nm
{5.0 kgf
m}
Gear oil
Upper
limit
Lower
limit

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 27-31
7. SPEED SENSOR OUTPUT VOLTAGE
MEASUREMENT ABS>
(1) Lift up the vehicle and release the parking brake.
(2) Disconnect the AYC-ECU harness connector and take
measurements on the harness side connector.
Caution
Insert the probe from the harness side with the double
lock of the connector unlocked. Inserting it to the
terminal side could result in poor contact.
(3) Turn the wheel to be tested at about 1/2 to one
revolution/sec. and check for the output voltage using
a circuit tester (AC mV range) or oscilloscope.
Terminal nos.
Front LHFront RHRear LHRear RH
7698
20192221
Output voltage:
When circuit tester is used: 70 mV or more
When oscilloscope is used: 200 mVp-p or more
(4) If the output voltage is lower than the above value, it
is probably attributable to the following faults. Check or
replace the speed sensor as necessary.
Excessive clearance between the pole piece and rotor
of the speed sensor
Defective speed sensor
Waveform Check Using Oscilloscope
Check the harness and connector of the speed sensor for
connection. Then, use an oscilloscope to check for output
voltage waveform of each speed sensor as follows.
Start the engine and monitor the sensor by turning the wheel;
for a driving wheel, let it turn by shifting into the 1st gear
and for a driven wheel turn it manually at a constant speed.
NOTE
(1) Waveform may be observed by actually running the
vehicle.
(2) The output voltage is low when the wheel speed remains
low and builds up as the wheel speed increases.
AYC-ECU connector harness side
When turned manually
At idle (5 to 6 km/h)
1st gear

REAR AXLE – Rear Hub Assembly27-34
INSTALLATION SERVICE POINT
ADRIVE 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.
INSPECTION
1. REAR WHEEL BEARING ROTATION STARTING
TORQUE
(1) Install the special tool to the rear hub assembly and tighten
it to the specified torque.
(2) Using the special tool, measure the wheel bearing rotation
starting torque.
Limit: 1.0 Nm {10.5 kgf
cm}
(3) The wheel bearing starting torque should be within the
limit and the hub should be free of binding or rough motion
when turned.
2. WHEEL BEARING AXIAL PLAY CHECK
(1) Check the wheel bearing for axial play.
Limit: 0.05 mm
(2) If the specified torquing range (196 to 255 Nm {20.0
to 26.0 kgf
m}) does not bring the wheel bearing axial
play into the limit, replace the rear hub assembly.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}
MB990326 MB991000
(MB990998)
Wood block 196 – 255 Nm
{20.0 – 26.0 kfg
m} MB991017
Wood block
Wood block
MB991017

REAR AXLE – Torque Transfer Differential 27-43
TORQUE TRANSFER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
1 23
4 5
6
7 891011
12 1314
Unit: Nm {kgf
m}
186 {19.0}4
49 {5.0}
49 {5.0}9 {0.9}9 {0.9} 49 {5.0}
3
Disassembly steps
1. Drain plug
2. Packing
3. Filler plug
4. Gasket
5. Vent plug
6. Bleeder screw
7. Cover
A8. Self-locking nut
9. Washer
10. Companion flange11. Oil seal
B12. Oil seal
A13. Oil seal
14. Differential carrier assembly
Caution
(1) The differential carrier assembly is non-main-
tainable.
(2) No foreign matter should be allowed inside and
at the joints of the differential carrier assembly.

REAR AXLE – Torque Transfer Differential 27-45
DISASSEMBLY SERVICE POINT
ASELF-LOCKING NUT REMOVAL
ASSEMBLY SERVICE POINTS
AOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the specified grease to the oil seal lip.
Specified grease: Vaseline
BOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the multi-purpose grease to the oil seal lip.
MB990850
MD998812MD998829
MD998813
MB990938
MB991115