2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

REAR AXLE -Drive Shaft27B-31
(4) To prevent entry of foreign matter into the
differential carrier, use the special tool as a cover.

INSTALLATION SERVICE POINTS
"AADRIVE SHAFT INSTALLATION
Caution
When installing the drive shaft to the differential carrier,
be careful that the spline part of the drive shaft does not
damage the oil seal.
"BADRIVE 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.
MB991460
MB990767
225±25 N·m
Washer

REAR AXLE -Drive Shaft27B-32
DISASSEMBLY AND REASSEMBLY
Caution
(1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be
careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race
to prevent the rotor from damage.
(2) Never disassemble the B.J. assembly except when replacing the B.J. boot.
2
6
4
3
5
7
1
4
2
43
61
2
4
51
2
9
10
1
8
8
97
6
T.J. repair kitT.J. boot repair kit B.J. boot repair kit
Disassembly steps
"BA1. T.J. boot band (large)
"BA2. T.J. boot band (small)
AA""AA3. T.J. case
4. Snap ring
AA""AA5. Spider assemblyAB""AA6. T.J. boot
7. B.J. boot band (large)
8. B.J. boot band (small)
9. B.J. boot
10. B.J. assembly

REAR AXLE -Drive Shaft27B-33
DISASSEMBLY SERVICE POINTS
AA"T.J. CASE/SPIDER ASSEMBLY REMOVAL
1. Wipe off grease from the spider assembly and the inside
of the T.J. case.
2. Always clean the spider assembly when the grease
contains water or foreign material.
Caution
Do not disassemble the spider assembly.
AB"T.J. BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the T.J. boot, wrap plastic tape around
the shaft spline to avoid damaging the boot.
REASSEMBLY SERVICE POINTS
"AAT.J. BOOT/SPIDER ASSEMBLY/T.J. CASE
INSTALLATION
1. Apply the specified grease furnished in the repair kit to
the spider assembly between the spider axle and the
roller.
Specified grease: Repair kit grease
Caution
(1) The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
(2) If the spider assembly has been cleaned, take
special care to apply the specified grease.
2. Install the spider assembly to the shaft from the direction
of the spline bevelled section.
3. After applying the specified grease to the T.J. case, insert
the drive shaft and apply grease one more time.
Specified grease: Repair kit grease
Amount to use: 105±10 g
NOTE
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint uses special grease. Do not mix
old and new or different types of grease.Bevelled
section

REAR AXLE -Drive Shaft27B-34
"BAT.J. BOOT BAND (SMALL)/T.J. BOOT BAND
(LARGE) INSTALLATION
Set the T.J. boot bands at the specified distance in order
to adjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot bands securely.
Standard value (A): 90±3mm
INSPECTION
DCheck the drive shaft for damage, bending or corrosion.
DCheck the drive shaft spline part for wear or damage.
DCheck the spider assembly for roller rotation, wear or
corrosion.
DCheck the groove inside T.J. case for wear or corrosion.
DCheck the boots for deterioration, damage or cracking.
DCheck the dust cover for damage or deterioration.
B.J. BOOT (RESIN BOOT) REPLACEMENT
Refer to GROUP26 Front Axle-Drive shaft.
A

REAR AXLE -Differential Carrier 27B-35
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation
DDifferential Gear Oil Draining (Refer to P.27B-17.)
DLower Arm Assembly Removal (Refer to GROUP
34.)
DRear Stabilizer Removal (Refer to GROUP 34.)
DDrive Shaft Removal (Refer to P. 27B-29.)Post-installation Operation
DDrive Shaft Installation (Refer to P. 27B-29.)
DRear Stabilizer Installation (Refer to GROUP 34.)
DLower Arm Assembly Installation (Refer to GROUP
34.)
DDifferential Gear Oil Filling (Refer to P.27B-17.)
12
765
4 8 910
32¶2Nm
2
3
3 3
3
76
9
120±10 N·m
88±10 N·m
69±9 N·m
88±10 N·m
88±10 N·m
88±10 N·m
120±10 N·m
120±10 N·m
120±10 N·m
69±9 N·m
88±10 N·m
Removal steps
AA"1. Propeller shaft connection (Refer to
GROUP 25.)
2. Toe control bar
3. Differential support member mount-
ing boots and nuts
AB""AA4. Rear crossmember and differential
carrier assembly5. Differential support member
6. Upper stopper
7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential carrier assembly

REAR AXLE -Differential Carrier 27B-36
REMOVAL SERVICE POINTS
AA"PROPELLER SHAFT DISCONNECTION
Suspend the removed propeller shaft from the body with a
wire to prevent bending.
AB"REAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY REMOVAL
1. Using a jack, support the differential carrier from its
underside.
2. Remove the rear crossmember mounting bolts and
remove the differential carrier, where it is attached to
the rear crossmember, from the vehicle.
INSTALLATION SERVICE POINTS
"AAREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY INSTALLATION
Tighten the rear crossmember mounting bolts in the numerical
order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the rear crossmember mounting holes have
different diameters between front and rear. This is the reason
for specifying the tightening sequence of the mounting bolts.
No.Bolt typeBolt size(thread
dia.×length)mm
1, 2, 3Flange bolt(with washer)12×105
4Bolt(with spring washer and
washer)12×152
5Flange bolt(with washer)12×70
5
Front of vehicle
1
3
442
3

REAR AXLE -Differential Carrier 27B-37
BUSHING REPLACEMENT
1. Remove and press fit the bush with special tool. (About
removal and press fitting the bush of the differential
support arm, refer to P. 27B-57.)
2. Press fit the bush so that the hollow of the bush is on
the position shown as the illustration.
3. Press fill the bush until the surface of the outer sleeve
of the bush, differential mounting bracket.
MB990641 Bush
Differential
mount
bracket
Steel block
Hollow

REAR AXLE -Differential Carrier 27B-38
DISASSEMBLY
19
2
6
8
20
22
26
5
113
4
9
12
15
16
1314
10
21
1
23
24
25
18
17
7
897
Disassembly steps
AA"DInspection before disassembly
1. Filler plug
2. Drain plug
3. Differential cover assembly
4. Vent plug
5. Bearing cap
AB"6. Differential case assembly
AB"7. Side bearing spacer
AB"8. Side bearing outer race
AC"9. Side bearing inner race
AD"10. Drive gear
11. Limited slip differential case assembly*
AE"12. Self-locking nut
13. Washer
AF"14. Drive pinion assemblyAF"15. Companion flange
16. Drive pinion front shim (For adjusting
preload of drive pinion)
17. Drive pinion spacer
AG"18. Drive pinion rear bearing inner race
19. Drive pinion rear shim (For adjusting
drive pinion height)
20. Drive pinion
AH"21. Oil seal
AH"22. Drive pinion front bearing inner race
AH"23. Drive pinion front bearing outer race
AI"24. Drive pinion rear bearing outer race
25. Oil seal
26. Differential carrier