2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

REAR AXLE -Differential Carrier 27B-55
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
Pre-removal Operation
DHydraulic Piping Fluid Draining
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.)
DHydraulic Piping Fluid Filling and Bleeding (Refer
to P.27B-17 and P.27B-19.)
1
2
88¶10 Nm
7 6
5
48
9
10 3
11
44¶10 Nm
120¶10 Nm34¶5Nm*
1
32¶2Nm
12¶2Nm 26¶4Nm*
2
88¶10 Nm
88¶10 Nm 88¶10 Nm 88¶10 NmNOTE:
*1:Thread is not lubricated
*2:Thread is lubricated
Removal steps
1. Hydraulic unit hose assembly con-
nection
AA"2. Propeller shaft connection (Refer to
GROUP 25.)
3. Differential support member mount-
ing nuts
4. Rear crossmember and differential
carrier assembly
(Refer to P. 27B-35.)5. Differential support member
"AA6. Upper stopper
"AA7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential mount bracket
11. Differential carrier assembly

REAR AXLE -Differential Carrier 27B-56
REMOVAL SERVICE POINT
AA"PROPELLER SHAFT DISCONNECTION
Suspend the removed propeller shaft from the body with a
wire to prevent bending.
INSTALLATION SERVICE POINTS
"AALOWER STOPPER/UPPER STOPPER
INSTALLATION
Install the lower and upper stopper as shown in the illustration.Upper stopper
Lower stopper

REAR AXLE -Differential Carrier 27B-57
BUSHING REPLACEMENT
1. Remove and press fit the bush with special tool.
2. Press fit th 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 support member or differential
support arm contact.

Removal
Press-fitting Bush
Hollow Differential
support
member

Bush
Differential
support arm
HollowMB990641
MB991439 Steel block
Steel blockSteel block

REAR AXLE -Differential Carrier 27B-58
TORQUE TRANSFER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
Caution
1. The differential carrier assembly is non-maintainable.
2. No foreign matter should be allowed inside and at the joints of the differential carrier assembly.
14
2
6
4
35
7
1
9
10
8
3
4
11
13
12
186¶29 Nm
32¶2Nm 49¶10 Nm
5¶1Nm
9¶1Nm 49¶10 Nm
Disassembly steps
1. Drain plug
2. Packing
3. Filler plug
4. Gasket
5. Vent plug
6. Bleeder screw
7. CoverAA"8. Self-locking nut
9. Washer
10. Companion flange
11. Oil seal
"BA12. Oil seal
"AA13. Oil seal
14. Differential carrier assembly

REAR AXLE -Differential Carrier 27B-59
Lubrication and Adhesive Points
Grease: VaselineSealant: 3M ATD Part
No.8661, 8663 or equivalent
Sealant: 3M ATD Part
No.8661, 8663 or equivalent
DISASSEMBLY SERVICE POINT
AA"SELF-LOCKING NUT REMOVAL
MB990850

REAR AXLE -Differential Carrier 27B-60
ASSEMBLY SERVICE POINTS
"AAOIL SEAL PRESS-FITTING
1. Using the special tool, pressfit the oil seal as far as it
will go.
2. Apply the specified grease to the oil seal lip.
Specified grease: Vaseline
"BADRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
1. Using the special tool, pressfit the oil seal as far as the
oil seal will go.
2. Apply the multipurpose grease to the oil seal lip.
MD998829
MD998812
MD998813
MB990938
MB991115

REAR AXLE- Hydraulic Unit 27B-61
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
DTrunk Side Trim Removal (Refer to GROUP 52A.)
DHydraulic Piping Fluid DrainingPost-installation Operation
DHydraulic Piping Fluid Filling and Bleeding
(Refer to P.27B-17 and P.27B-19.)
DTrunk Side Trim Installation (Refer to GROUP 52A.)
12
7 6 4
8 9
10
311
34¶5Nm*1
24¶4Nm
12¶2Nm
26¶4Nm*
2
5
12¶2Nm
12¶2Nm
18¶2Nm 34¶5Nm*1
26¶4Nm*2
18¶2Nm12¶2Nm 34¶5Nm*
1
26¶4Nm*2
12¶2Nm
NOTE:
*1:Thread is not lubricated
*2:Thread is lubricated
Removal steps
1. Dust guard
2. Reservoir hose assembly and hy-
draulic unit connection
3. Hydraulic unit hose assembly and
hydraulic unit connection
4. Transfer connector assembly and
hydraulic unit connection
5. Hydraulic unit bracket assembly
mounting bolt
"BA6. Hydraulic unit assembly7. Hydraulic unit bracket
DStabilizer bar to differential support
arm connection (Refer to GROUP 34.)
DDifferential support arm (Refer to P.
27B-55.)
AA"8. Hydraulic unit hose assembly hicles with ACD+AYC>
9. Transfer connector assembly
"AA10. Reservoir hose assembly
11. Oil reserve

REAR AXLE- Hydraulic Unit REAR AXLE- Hydraulic Unit 27B-62
REMOVAL SERVICE POINTS
AA"HYDRAULIC UNIT HOSE ASSEMBLY REMOVAL
1. Disconnect the hydraulic unit side pipe and hose.
2. Put down the differential support arm, remove the
hydraulic unit hose assembly.
HYDRAULIC UNIT DISPOSAL
Should the hydraulic unit be discarded, drill a hole in the
accumulator at the illustrated position beforehand in order
to release the inside gas.
Caution
(1) The hydraulic unit has its accumulator filled with a high
pressure gas. Never throw it into a fire. Also, never
attempt to disassemble, press, weld or melt it.
(2) When drilling a hole in the accumulator, be sure to
wear safety goggles since drill chips may blow out
together with the gas.
INSTALLATION SERVICE POINTS
"AARESERVOIR HOSE ASSEMBLY INSTALLATION
Insert the reservoir hose assembly to the positioning spool.
"CAHYDRAULIC UNIT ASSEMBLY INSTALLATION
Hook the hydraulic unit assembly hook to the rear floor side
member and tighten the hydraulic unit assembly mounting
bolt.
Hose
Pipe
Hydraulic unit
hose assembly
Differential support arm
Positioning
spool Nipple
Reservoir hose
assembly
Hook
Rear floor side member