2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

MANUAL TRANSMISSION - Transfer Assembly22A-49
TRANSFER ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DSide Under Cover Removal and Installation
DTransmission Oil Draining and Supplying (Refer to P.22A-40.)
DTransfer Oil Draining and Supplying (Refer to P.22A-40.)
DEngine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.)
DBattery and Battery Tray Removal and Installation
DAir Cleaner, Air Intake Hose Removal and Installation (Refer to GROUP 15 - Air Cleaner.)
DSecondary Air Hose Removal and Installation (Refer to GROUP 15 - Secondary Air Control System.)
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DAir Hose E, Air By-pass Hose and Air By-pass Valve, Air Pipe C, Air Hose D, Air Pipe B, Air Hose A Removal and
Installation (Refer to GROUP 15 - Intercooler.)
DRadiator Removal and Installation (Refer to GROUP 14.)
DBleeding and Hydraulic Pressure Check (Refer to P.22A-42, 43)
12 3
4
5 6 7
8
25±5 N·m
108±10 N·m
39±5 N·m
39±5 N·m
245±29 N·m
Removal steps
1. Stabilizer bar connection
2. Stabilizer link
3. Wheel speed sensor cable clamp
and brake hose clampAA"4. Tie rod end connection
5. Lower arm ball joint connection
AB"6. Drive shaft connection
AB"7. Drive shaft connection
AC"8. Output shaft

MANUAL TRANSMISSION - Transfer Assembly22A-50
11 12
9
1013
14
15 16
13
59±9 N·m
59±9 N·m
44±5 N·m
69±10 N·m
52±7 N·m*
52±7 N·m*
69±10 N·m
9. Rear roll stopper connection bolt
10. Centermember assembly
11. Front propeller shaft
(Refer to GROUP 25.)
12. Transfer oil pressure hose assem-
bly
13. Gasket
14. Dust seal guard
AD"15. Transfer assembly
16. O-ring
Caution
*: Indicates parts which should be initially tightened,
and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine
on the vehicle body.
REMOVAL SERVICE POINTS
AA"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.MB991113 or
MB990635
Cord Ball joint
Nut

MANUAL TRANSMISSION - Transfer Assembly22A-51
AB"DRIVE SHAFT /DRIVE SHAFT
DISCONNECTION
1. As shown in the figure, pull out the transfer shaft
from the transmission using the pry bar. As shown in
the illustration, press a hammer, etc. against the driveshaft
, and pull out the driveshaft from the transfer
assembly using the pry shaft.
Caution
As the TJ may damage when the driveshaft is pulled
out from the BJ side, be sure to use the lever.
2. Cover with a cloth to prevent foreign particles from entering
the transfer.
AC"OUTPUT SHAFT REMOVAL
1. Using the special tool (MB991721), remove the output
shaft.
2. Cover with a cloth to prevent foreign particles from entering
the transmission case.
AD"TRANSFER ASSEMBLY REMOVAL
With the engine mount and transmission mount installed,
roll the engine and transmission assembly towards the front
of the vehicle, and remove the transfer assembly from between
the engine block and crossmember.
Transmission
side
Pry bar
Pry barHammer
Protrusion


MB991721
Output shaft
Engine and
transmission
assembly
Transfer assembly
Front of the vehicle

MANUAL TRANSMISSION - Transmission Assembly22A-52
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DTransfer Assembly Removal and Installation (Refer to P.22A-49.)
DStarter Motor Removal and Installation (Refer to GROUP 16.)
DAir Cleaner Bracket Removal and Installation (Refer to GROUP 15 - Air Cleaner.)
DRear Roll Rod Assembly and Rear Roll Rod Bracket , Rear Roll Mount
Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper.)
1
2
3 45
5 6
7
18±3 N·m18±3 N·m
18±3 N·m
70±10 N·m
Removal steps
1. Transmission harness clamp
2. Back-up lamp switch connector
connection
3. Vehicle speed sensor connector
connection
4. Clutch release cylinder and clutch
oil pipe5. Snap pin
6. Shift cable and select cable as-
sembly connection
7. Rear roll mount bracket
AA"DEngine and transmission
assembly supporting

MANUAL TRANSMISSION - Transmission Assembly22A-53
10
10 11
9
1412 88
13
48±5 N·m
48±5 N·m
48±5 N·m
48±5 N·m
9.0±1.0 N·m
26±5 N·m
82±7 N·m*
47±7 N·m*
8. Transmission assembly upper part
coupling bolts
AA"9. Transmission mount assembly
"AA10. Transmission mount stopper
11. Transmission mount bracket
AB"DEngine assembly supporting
AC"DClutch release bearing connection
12. Bell housing cover13. Transmission assembly lower part
coupling bolts
14. Transmission assembly
Caution
*: Indicates parts which should be initially tightened,
and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine
on the vehicle body.
REMOVAL SERVICE POINTS
AA"ENGINE AND TRANSMISSION ASSEMBLY
SUPPORTING/TRANSMISSION MOUNT
ASSEMBLY REMOVAL
While supporting the engine and transmission assembly with
a garage jack, remove the transmission mount assembly.Engine and transmission
assembly
Garage jack

MANUAL TRANSMISSION - Transmission Assembly22A-54
AB"ENGINE ASSEMBLY SUPPORTING
Set the special tool to the vehicle to support the engine
assembly.
AC"CLUTCH RELEASE BEARING SEPARATION
1. Remove the cover from the service hole in the clutch
housing.
2. While pushing the release fork by hand in the direction
A, insert a flap-tip screwdriver between the release bearing
and the wedge collar.
Caution
Be sure to push the release fork in the direction A
before inserting a screwdriver.
3. Separate the release bearing from the wedge collar by
prying with the screwdriver (turning the screwdriver grip
90˚).
NOTE
The release fork is forced to move fully in the direction
B by the return spring as soon as it is separated from
the wedge collar.
Caution
If it is hard to turn the screwdriver (to pry off the
release bearing), remove the screwdriver once and
repeat the above procedure after pushing the release
fork fully in the direction a two to three times. Forcibly
prying can cause the release bearing to be damaged.
INSTALLATION SERVICE POINT
"AATRANSMISSION MOUNT STOPPER
INSTALLATION
Install so that the arrow on the transmission mounting stopper
faces the top of the vehicle.
MZ203827
MB991453
BA
Service hole
Release fork
Wedge collar
Release bearing
Transmission
mount bracket
Transmission
mount stopper Engine side

MANUAL TRANSMISSION -4WD-ECU with ACD and AYC>22A-55
4WD-ECU AYC>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DCowl Side Trim Removal and Installation. (Refer to GROUP 52A - Trims.)
DFront floor Console Removal and Installation. (Refer to GROUP 52A - Floor Console.)
4.9¶0.9 Nm
4WD-ECU
4.9¶0.9 Nm
4WD-ECU

MANUAL TRANSMISSION -Sensor, Switch and Relay or vehicles with ACD and AYC>22A-56
SENSOR, SWITCH AND RELAY VEHICLES WITH ACD AND AYC>
REMOVAL AND INSTALLATION
Caution
Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP
52B Precautions in Servicing and Airbag Module Clock Spring.
1
3
2
4
5
Parking brake lever
Steering wheel sensor removal
steps
DSteering wheel and column cover
(Refer to GROUP 37A.)
1. Steering wheel sensor
G sensor removal steps
DFloor console (Refer to GROUP 52A.)
2. Longitudinal G sensor
3. Lateral G sensorElectric pump relay removal
4. Electric pump relay
ACD mode switch removal steps
DInstrument panel ornament (Refer to
GROUP 52A – Instrument Panel.)
5. ACD mode switch
NOTE
For details on the wheel speed sensor, refer to GROUP
35B.
REMOVAL SERVICE POINT
AA"STEERING WHEEL SENSOR REMOVAL
Remove the steering wheel sensor from the column switch.
Caution
Make sure no oil adheres to the steering wheel sensor
because a photocoupler is used.Steering wheel sensor