2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

REAR AXLE -On-vehicle Service27B-23
3. If the limit value is exceeded, loosen the flange nut and
then tighten it to the specified torque 225±25 N·m and
check the rear hub rotary sliding resistance again.
4. Replace the rear hub assembly if an adjustment cannot
be made to within the limit.
HUB BOLT REPLACEMENT
1. Remove the brake caliper and brake disc.
2. Use the special tools to remove the hub bolts.
NOTE
To retain a space for removing the hub bolts, remove
near the retainer spring mounting position.
3. Install the plain washer to the new hub bolt, and install
the bolt with a nut.
DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
Differential part
1. Remove the drive shaft. (Refer to P. 27B-29.)
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.
27B-29.)
6. Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)
MB991618MB990767
Plain
washerMB990767
MB990938
MB991115

REAR AXLE -On-vehicle Service27B-24
Torque transfer mechanism part
1. Remove the drive shaft. (Refer to P. 27B-29.)
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.
27B-29.)
6. Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)
ACTION WHEN BATTERY RUNS OUT
When the engine is started using a booster cable where the
battery has completely run down and you attempt to start
the vehicle without waiting for the battery to recover a certain
charge, the engine can misfire and you just cannot start to
move it. In such cases, charge the battery sufficiently; or,
remove the AYC battery cable from the battery fuse assembly
to make AYC inactive before attempting to start the vehicles.
When the battery cable is removed, the ACD mode indicator
lamp lights up. After the battery has been recharged, fit the
battery cable back again and start the engine to ensure that
the ACD mode indicator lamp is off.
MD998829
MD998813 MD998812
Battery fuse assembly
Battery cable
for AYC

REAR AXLE -Rear Hub Assembly27B-25
REAR HUB ASSEMBLY
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched. And if there is
brake fluid on the caliper, wipe out quickly.
Pre-removal Operation
Gear Oil Draining (Refer to P. 27B-17.)Post-installation Operation
DGear Oil Filling (Refer to P. 27B-17.)
DParking Brake Lever Stroke Adjustment (Refer to
GROUP 36 – On-vehicle Service.)
2
118±19 N·m
4
1
3
225±25 N·m
8
7
6
5
10
9
54±5 N·m
81±6 N·m
Removal steps
AA"1. Rear brake caliper
2. Rear brake disc
3. Parking brake shoe & lining assembly
(Refer to GROUP 36 - Parking Brake
Drum.)
4. Clip5. Parking brake cable connection
6. Split pin
AB""AA7. Drive shaft nut
8. Rear drive shaft assembly
AC"9. Rear hub assembly
10. Backing plate

REAR AXLE -Rear Hub Assembly27B-26
REMOVAL SERVICE POINTS
AA"REAR BRAKE CALIPER REMOVAL
Suspend the rear brake caliper from the body with wire, etc.
to prevent it from falling.
Caution
If the vehicle is equipped with the Brembo disc brake,
during maintenance, take care not to contact the parts or
tools to the caliper because the paint of caliper will be
scratched. And if there is brake fluid on the caliper, wipe
out quickly.
AB"DRIVE SHAFT NUT REMOVAL
Caution
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
AC"REAR HUB ASSEMBLY REMOVAL
1. Using the special tool, remove the drive shaft from the
rear hub assembly.
2. Remove the mounting bolts and remove the rear hub
assembly from the knuckle.
INSTALLATION SERVICE POINT
"AADRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.
2. Tighten the drive shaft nut fully with special tools.
Caution
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing
before tightening drive shaft nut fully.
3. If the pin hole does not align with another, tighten the
drive shaft nut (less than 250 N
·m) and find the nearest
hole then bend the split pin to fit in.
MB990767
MB990767
MB990242MB991354
MB990244
(3)
MB990767
225±25 N·m
Washer

REAR AXLE -Rear Hub Assembly27B-27
INSPECTION
WHEEL BEARING ROTATION STARTING TORQUE
CHECK
1. Tighten special tools in rear hub assembly to the specified
torque.
2. Hold rear hub assembly in a vice by way of wooden
block.
3. Measure the wheel bearing rotation torque with special
tools.
Limit: 1.0 N
·m
4. Hub rotation starting torque must be under the limit value
and there should be no stickiness or roughness when
rotating the hub.
WHEEL BEARING AXIAL PLAY CHECK
1. Check the wheel bearing axial play.
Limit: 0.05 mm
2. If the wheel bearing axial play exceeds the limit value
at the specified torque of (225±25 N
·m), replace the
rear hub assembly.
Wooden
block
MB991000
(MB990998)MB991017
225±25 N·m
MB990326
Wooden
block
Wooden
block

REAR AXLE -Knuckle27B-28
KNUCKLE
REMOVAL AND INSTALLATION
Caution
1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And
if there is brake fluid on the caliper, wipe out quickly.
2. With the part marked with *, first temporarily tighten it, then ground the vehicle and tighten
it to specification in unloaded condition.
Pre-removal Operation
Rear Hub Assembly Removal (Refer to P.27-25.)Post-installation Operation
DPress dust cover with a finger to check for crack
or damage in the dust cover.
DRear Hub Assembly Installation (Refer to P.27-25.)
1
2
3
4
5
6
25±6 N·m81±6 N·m
81±6 N·m*
88±10 N·m*
81±6 N·m
Removal steps
1. Vehicle speed sensor ABS or ACD>
AA"2. Knuckle and trailing arm connection
3. Knuckle and lower arm connectionAA"4. Knuckle and toe-control arm connec-
tion
AA"5. Knuckle and upper arm connection
6. Knuckle assembly
REMOVAL SERVICE POINT
AA"KNUCKLE AND TRAILING ARM/TOE-CONTROL
ARM/UPPER ARM DISCONNECTION
Caution
1. Use special tools to loosen the nut from the ball joint
instead of removing it.
2. Hang special tools with ropes to prevent them from
falling.
Nut
Cord
Ball joint
MB991113 or
MB990635

REAR AXLE -Drive Shaft27B-29
DRIVE SHAFT
REMOVAL AND INSTALLATION
Caution
1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And
if there is brake fluid on the caliper, wipe out quickly.
2. With the part marked with *, first temporarily tighten it, then ground the vehicle and tighten
it to specification in unloaded condition.
Pre-removal Operation
DGear Oil Draining (Refer to P.27-17.)
DCenter Exhaust Pipe Removal (Refer to GROUP
15.)Post-installation Operation
DPress dust cover with a finger to check for crack
or damage in the dust cover.
DCenter Exhaust Pipe Installation (Refer to GROUP
15.)
DGear Oil Filling (Refer to P.27-17.)
DParking Brake Lever Stroke Check and Adjustment
DWheel Alignment Check and Adjustment (Refer to
GROUP 34 – On-vehicle Service.)
4
1
3
7
6510
2
8
9
11
12
225±25 N·m
54±5 N·m
88±10 N·m*
81±6 N·m*
81±6 N·m
25±6 N·m
Removal steps
AA"1. Rear brake caliper
2. Rear brake disc
3. Parking brake shoe & lining assembly
(Refer to GROUP 36 - Parking Brake
Drum.)
4. Clip
5. Parking brake cable connection
6. Split pinAB""BA7. Drive shaft nut
8. Vehicle speed sensor ABS or ACD>
9. Knuckle and trailing arm connection
10. Knuckle and lower arm connection
11. Knuckle and toe-control arm connec-
tion
AC""AA12. Rear drive shaft assembly

REAR AXLE -Drive Shaft27B-30
REMOVAL SERVICE POINTS
AA"REAR BRAKE CALIPER REMOVAL
Suspend the rear brake caliper from the body with wire, etc.
to prevent it from falling.
Caution
If the vehicle is equipped with the Brembo disc brake, during
maintenance, take care not to contact the parts or tools to
the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe out quickly.
AB"DRIVE SHAFT NUT REMOVAL
Caution
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
AC"REAR DRIVE SHAFT ASSEMBLY REMOVAL
1. Use the special tools to push out the drive shaft from
the hub.
2. Remove the drive shaft from the transmission by the
following procedure.
Insert a pry bar between the differential carrier and the
drive shaft, and then pry the drive shaft from the differential
carrier.
Caution
(1) Do not pull on the drive shaft; doing so will damage
the T.J.; be sure to use the pry bar.
(2) When pulling the drive shaft out from the
differential carrier, be careful that the spline part
of the drive shaft does not damage the oil seal.
(3) Do not apply the vehicle weight to the wheel
bearing while loosening the drive shaft nut.
Otherwise wheel bearing will be damaged. If,
however, the vehicle weight must be applied to
the bearing (because of moving the vehicle),
temporarily secure the wheel bearing by using
the special tool.
MB990767
MB990767
MB990242MB991354
MB990244
(3)
Differential carrier
T.J. assembly
Lever
MB991017 MB991000
(MB990998)