1999 MITSUBISHI LANCER EVOLUTION VI oil

REAR AXLE – On-vehicle Service 27-33
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.
4. Pour the specified gear oil up to the bottom end of the
filler plug hole using an oil syringe (recommended tool)
through the gap between the body and the differential
support arm.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
Quantity used: 0.70
0
0.05

5. Fit the filler plug and tighten it to the specified torque.
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 (10C to 30C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is less than 10C or less,
allow more time to leave the vehicle to stand idle.

Connect the MUT-II to the 16-pin diagnosis connector.
Turn on the ignition switch. Operate the MUT-II (Item
No.11) to activate the hydraulic unit forcibly for removing
the pressure from inside the accumulator.
Caution
Before connecting or disconnecting the MUT-II,
always turn off the ignition switch.
NOTE
(1) The forced activation (oil level check mode) will be
automatically canceled as soon as the directional
valve in the hydraulic unit is activated to the left and
right 20 times.
It can also be canceled forcibly by operating the clear
key on the MUT-II.
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
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: Dia Queen ATF SP II or equivalent
5. Reinstall the maintenance lid.
Gear oil
Drain plug
49 Nm
Oil syringe
(Recommended tool)
Filler plug
49 Nm

REAR AXLE – On-vehicle Service REAR AXLE – On-vehicle Service 27-34
BLEEDING
1. Lift up the vehicle.
2. Connect the MUT-II to the 16-pin diagnosis connector.
Caution
Before connecting or disconnecting the MUT-II,
always turn off the ignition switch.
3. Turn on the ignition switch.
4. Operate the MUT-II (Item No.10) to activate the hydraulic
unit forcibly.
NOTE
(1) The forced activation (air bleeding mode) will be
automatically canceled after 5 minutes operation. It
can also be canceled forcibly by operating the clear
key on the MUT-II.
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
5. Remove the cap of the left bleeder screw on the torque
transfer differential and connect a vinyl hose.
6. 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.
7. 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.
8. Repeat steps (6) and (7) 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
9. Perform steps (5) through (8) for the right bleeder screw.
Note, however, that the steering wheel should be turned
counterclockwise.
10. After the system has been completely bled of air, check
for the fluid level. (Refer to P.27-33.)
Caution
If the system is not completely bled of air, the hydraulic
unit could generate noise, degrading pump durability.
AYC OPERATION CHECK
1. Lift up the vehicle.
2. Connect the MUT-II to the 16-pin diagnosis connector.
Caution
Before connecting or disconnecting the MUT-II, always
turn off the ignition switch.
3. Start the engine.
4. Operate the MUT-II with the transmission in 2nd or a
higher gear and check to ensure that the vehicle speed
is higher than 10 km/h using the Data List (Item 10).
Bleeder
screws Vinyl hose

REAR AXLE – On-vehicle Service 27-36
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
6. Check to ensure that the hydraulic pressure generated
by the hydraulic unit conforms to the standard value.
Standard value: 1.0 – 1.6 MPa
NOTE
During checking the hydraulic pressure, occasionally
replenish the oil reservoir with fluid so that it does not
become empty.
7. Check the hydraulic pressure of the clutch right side by
repeating the steps (4) through (6). At this time, however,
the special tool must be connected to the R port and
the blind plug or the R port of the removed hydraulic
unit hose assembly must be attached to the L port. Further,
the MUT-II must be operated in the forced activation mode
Item No. 14 (clutch right side operation check mode).
8. If the measured value exceeds the standard value, replace
the hydraulic unit.
9. Connect the hydraulic unit hose assembly to the hydraulic
unit and to the torque transfer differential and tighten
the flare nuts to the specified torque.
Specified torque: 34 Nm
10. Pour the specified fluid in the oil reservoir up to the MAX
mark. Then, bleed the system.
Specified fluid: Dia Queen ATF SP II or equivalent
Fluid amount used: Approx. 1

DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
DIFFERENTIAL
1. Remove the drive shaft.
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.
6. Check for correct wheel alignment.
TORQUE TRANSFER MECHANISM
1. Remove the drive shaft.
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.
6. Check for correct wheel alignment.
MB990938
MB991115
MD998829
MD998812
MD998813

REAR AXLE – Hydraulic Unit 27-39
HYDRAULIC UNIT
REMOVAL AND INSTALLATION
Caution
(1) When connecting the return hose and suction hose, do not apply lubricant.
(2) No foreign matter should be allowed in the hydraulic piping and joints.
Pre-removal Operation

Trunk Side Trim Removal

Hydraulic Piping Fluid DrainingPost-installation Operation

Hydraulic Piping Fluid Filling and Bleeding
(Refer to P.27-32, 34.)

Trunk Side Trim Installation
1 23 45
6
7 8 9
10 11 12
1314
12 Nm
4
12 Nm
18 Nm
12 Nm
12 Nm 18 Nm
34 Nm
34 Nm
Removal steps
1. Dust guard
2. Suction hose and return hose con-
nection
3. Hydraulic unit hose assembly con-
nection
4. Hydraulic unit and bracket assem-
bly mounting bolt
C5. Hydraulic unit and bracket assem-
bly
A6. Hydraulic unit7. Hydraulic unit bracket
8. AYC harness
9. Hydraulic unit bracket
10. Hydraulic unit hose assembly
B11. Return hose
B12. Suction hose
A13. Grommet
14. Oil reservoir

STEERING – Power Steering Gear Box37A-8
DISASSEMBLY AND REASSEMBLY
Steering gear seal set
Flare nut
1
3 4
5
6 7
8
910
11
12 13 14
15 17
1921
24
25
26 29
32
33
35
2
22
3416
27
28 31
3013 Nm
1
20
36 3718
25 Nm
49 – 59 Nm
88 Nm27
28
309 20
62
9 6 35
59 Nm
15
59 Nm
21 Nm
2
311823 23
Disassembly steps
1. Feed pipe
2. O-ring
N3. Tie-rod end locking nut
N4. Tie-rod end
5. Bellows clip
M6. Bellows band
7. Bellows
L8. Tie-rod
L9. Tab washer
K
Total pinion torque adjustment
10. Locking nut
A11. Rack support cover
12. Rack support spring
13. Rack support
J14. End plug
15. Self-locking nut
16. Bolt
17. Valve assembly
BI18. Oil sealB19. Pinion and valve assembly
CH20. Seal ring
21. Valve housing assembly
DG22. Ball bearing
DG23. Oil seal
EF24. Circlip
F25. Rack stopper
FE26. Rack bushing
GE27. Oil seal
28. O-ring
FD29. Rack
30. Piston ring
31. O-ring
32. Rack housing assembly
HC33. Ball bearing
IC34. Needle roller bearing
JB35. Oil seal
36. Gear housing mounting bushing
A37. Gear housing mounting rubber

STEERING – Power Steering Gear Box37A-10
DISASSEMBLY SERVICE POINTS
ARACK SUPPORT COVER REMOVAL
Use the special tool to remove the rack support cover from
the gear box.
BOIL SEAL / PINION AND VALVE ASSEMBLY
REMOVAL
Using a plastic hammer, gently tap the pinion to remove it.
CSEAL RING REMOVAL
Cut the seal ring and remove it from the pinion and valve
assembly and the rack.
Caution
When cutting the seal ring, be careful not to damage
the pinion and valve assembly or the rack.
DBALL BEARING / OIL SEAL REMOVAL
Use a socket, remove the oil seal and the ball bearing from
the valve housing assembly simultaneously.
ECIRCLIP REMOVAL
1. Turn the rack stopper clockwise until the end of the circlip
comes out of the slot in the rack housing.
2. Turn the rack stopper anticlockwise to remove the circlip.
Caution
Note that if the rack stopper is first turned
anticlockwise, the circlip will get caught in the slot
in the housing and the rack stopper will not turn.
MB990607
Socket
Rack stopper
Rack
Circlip

STEERING – Power Steering Gear Box37A-11
FRACK STOPPER / RACK BUSHING / RACK
REMOVAL
Pull out the rack assembly gently, and remove the rack stopper
and rack bushing together.
GOIL SEAL REMOVAL
Partially bend the oil seal to remove from the rack bushing.
Caution
Do not damage the oil seal press fitting surface of the
rack bushing.
HBALL BEARING REMOVAL
Use a brass bar or the special tool to remove the ball bearing
from the gear housing.
INEEDLE ROLLER BEARING REMOVAL
Use the special tool to remove the needle roller bearing from
the rack housing.
Caution
Do not open the special tool excessively to prevent
damaging housing interior.
JOIL SEAL REMOVAL
Use a piece of pipe or similar tool to remove the oil seal
from the gear housing.
Caution
Be careful not to damage the inner surface of the rack
cylinder of the gear housing.
Rack bushing
Ball
bearing MB990939 or
brass bar
MB991120
Needle roller
bearing
Gear housing
Pipe or similar tool
Oil seal

STEERING – Power Steering Gear Box37A-12
REASSEMBLY SERVICE POINTS
AGEAR HOUSING MOUNTING RUBBER
INSTALLATION
1. Install the gear housing mounting rubber on the rack
housing so that the dimension shown is achieved.
NOTE
The gear housing mounting rubber can be installed
regardless of the installation direction of the slit.
2. Apply specified adhesive to the slit of the gear housing
mounting rubber.
Specified adhesive:
3M ATD Part No. 8155 or equivalent
BOIL SEAL INSTALLATION
CNEEDLE ROLLER BEARING / BALL BEARING
INSTALLATION
DRACK INSTALLATION
1. Apply a coating of repair kit grease to the rack tooth
face.
Caution
Do not close the vent hole in the rack with grease.
Slit Gear housing
mounting rubber3.1 mm
MB991452
Oil sealMB991197
(Bar)
Needle roller
bearing
MB990938
MB991202MB990938
MB991202
Ball bearing
Vent hole