1999 MITSUBISHI LANCER EVOLUTION VI service

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-5
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
4
2
1
3
8 6 7
5*
9.8 Nm
Disassembly steps
1. Clutch release bearing retainer
E2. Oil seal
AD3. Outer race
BC4. Outer raceB5. Bushing*
A6. Cover-A
A7. Cover-B
8. Clutch housing
NOTE:
(1)*: Never remove the bushings from the clutch housing.
Only the case when installing new bushings into a new clutch housing, refer to B.
(2) For each service point, refer to Basic Manual. (Pub. No. S9806CNCP9)

FRONT AXLE – General / Axle Hub and Knuckle 26-1
GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE

The installation method of the ball joint between the knuckle and the lower arm has been changed,
and accordingly the removal and installation procedures of the axle hub and the knuckle have been
revised.
AXLE HUB AND KNUCKLE
REMOVAL AND INSTALLATION
Caution
(1) For vehicles with AYC, be careful when handling the pole piece at the tip of the speed sensor so as
not to damage it by striking against other parts.
(2) For vehicles with AYC, be careful not to damage the rotors installed to B.J. outer race during removal
and installation of the drive shaft.
Post-installation Operation

Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
1
23
4 5 6 7
8
12 1415
1388 Nm 108 – 127 Nm
90 – 110 Nm
15 – 33 Nm177 – 275 Nm 25 Nm
25 Nm
9 Nm
103 Nm
74 –87
Nm
11 910
1610
11
Ball joint kit
Removal steps
1. Front speed sensor AYC>
A2. Caliper assembly
3. Brake disc
4. Split pin
BA5. Drive shaft nut
6. Front hub assembly
7. Dust shield
8. Connection for lower arm ball joint
9. Connection bolt for lower arm joint10. Lower arm ball joint
11. Dust cover
12. Split pin
C13. Connection for tie rod end
D14. Front drive shaft
15. Front strut mounting bolt
16. Knuckle
NOTE
Follow the conventional procedures for removal
and installation service points.

FRONT AXLE – Axle Hub and Knuckle 26-2
INSPECTION
LOWER ARM BALL JOINT ROTATION STARTING
TORQUE CHECK
(1) After shaking the ball joint stud several times, install the
nut to the stud and use the special tool to measure the
rotation starting torque of the ball joint.
Standard value: 1.0 – 3.4 Nm
(2) When the measured value exceeds the standard value,
replace the ball joint assembly.
(3) When the measured value is lower than the standard
value, check that the ball joint turns smoothly without
excessive play. If so, it is possible to use that ball joint.
LOWER ARM BALL JOINT DUST COVER
REPLACEMENT
When the dust cover is damaged during service work or grease
leaks out from the dust cover, replace the dust cover in the
conventional procedure. After replacement, check the dust
cover for cracks or damage by pushing it with finger.
MB990326

27-1
REAR AXLE
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 4. . . . . . . . . . . . .
ON-VEHICLE SERVICE
31. . . . . . . . . . . . . . .
Rear Axle Total Backlash Check 31. . . . . . . . . . .
Gear Oil Level Check 31. . . . . . . . . . . . . . . . . . . .
Gear Oil Change 32. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Check 33. . . . . . . . . . . . . . . . . . . . . . . . Bleeding 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AYC Operation Check 34. . . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Check 35. . . . . . . . . . . . . . . . .
Differential Carrier Oil Seal
Replacement 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Measurement 37. . . . .
Action When Battery Runs Out 38. . . . . . . . . . . .
HYDRAULIC UNIT
39. . . . . . . . . . . . . . .
SENSOR RELAY
41. . . . . . . . . . . . . . .
AYC-ECU 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE – General / Service Specifications / Lubricant27-2
GENERAL
OUTLINE OF CHANGE

The descriptions of the service procedures for the AYC system including the troubleshooting using
an MUT-II tester has been incorporated.
SERVICE SPECIFICATIONS

ItemsStandard valueLimit
Rear axle total backlash mm–5
Pressure generated by hydraulic unit MPa0 – 1.6–
Wheel bearing axial play mm–0.05
Wheel bearing rotation starting torque Nm–1.0 or less
LUBRICANT

ItemsSpecified lubricantCapacity
Gear oilTorque
transfer
differential
DifferentialHypoid gear oil API classification GL-5 or higher
SAE viscosity No. 90, 80W0.41 ± 0.02

differentialTorque transfer
mechanismMITSUBISHI GENUINE DIA QUEEN AYC FLUID0.700
0.05

Hydraulic piping fluidDia Queen ATF SPII or equivalent1

Torque transfer mechanism oil seal lipsVaselineAs required

REAR AXLE – Special Tools / Troubleshooting 27-4
MB990925
Brass bar
Bar (one-touch type)Toolbox
Installer adapter
Tool number (MB990925)O.D. mmTool number (MB990925)O.D. mm
AMB99092639.0AMB99093363.5
MB99092745.0MB99093467.5
MB99092849.5MB99093571.5
MB99092951.0MB99093675.5
MB99093054.0MB99093779.0
MB99093157.0BMB990938–
MB99093261.0CMB990939–
TROUBLESHOOTING
BASIC TROUBLESHOOTING CONDITIONS
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.
NOTE
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.

The correct steering wheel has been properly installed in the neutral position of the steering column
shaft.

Tire and wheel sizes are correct with correct specifications. Inflation pressure, balance, and wear
conditions are okay.

Wheel alignment is correct.

The engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
DIAGNOSIS FUNCTION
READING THE DIAGNOSIS CODE
Read the diagnosis code using an MUT-II tester or the AYC warning lamp.
(Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.)
ERASING THE DIAGNOSIS CODE
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.

REAR AXLE – On-vehicle Service 27-31
ON-VEHICLE SERVICE

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.
GEAR OIL LEVEL CHECK
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:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W.
NOTE
10C or more: #90, less than 10C: #80
4. Fit the filler plug and tighten it to the specified torque.
Alignment marks
Filler plug
49 Nm
Gear oil
Upper
limit
Lower
limit

REAR AXLE – On-vehicle Service 27-32
TORQUE TRANSFER MECHANISM
1. Remove the filler plug.
2. Check that the gear oil level is up to the bottom end
of the filler plug hole.
3. If the gear oil level is lower than the bottom end of the
filler plug hole, 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
4. Fit the filler plug and tighten it to the specified torque.
GEAR OIL CHANGE
DIFFERENTIAL
1. Remove the drain plug to discharge the gear oil.
2. Fit the drain plug and tighten it to the specified torque.
Tightening torque: 49 Nm
3. Remove the filler plug and add the specified gear oil
up to the bottom end of the filler plug hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W.
Quantity used: 0.41 ± 0.02

NOTE
10C or more: #90, less than 10C: #80
4. Fit the filler plug and tighten it to the specified torque.
Filler plug
49 Nm
Gear oil
Filler plug
49 Nm
Gear oil
Drain plug