2007 MITSUBISHI LANCER EVOLUTION lock

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

REAR AXLE -Differential Carrier 27B-39
DISASSEMBLY SERVICE POINTS
AA"INSPECTION BEFORE DISASSEMBLY
1. Remove the cover.
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.
DRIVE GEAR BACKLASH
1. With the drive pinion locked in place, use a dial gauge
to measure the drive gear backlash in four or more places
on the drive gear.
Standard value: 0.11 - 0.16 mm
2. If the backlash is not within the standard value, adjust
the final drive gear backlash. (Refer to P.27B-49.)
3. After the adjustment, inspect the drive gear tooth contact.
DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.
DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.MB990909 and
MB991116

REAR AXLE -Differential Carrier 27B-41
AB"DIFFERENTIAL CASE ASSEMBLY/ SIDE BEARING
SPACER/SIDE BEARING OUTER RACE REMOVAL
Use the handle of a hammer to remove the differential case
assembly, side bearing spacers and side bearings.
Caution
When taking out the differential case assembly, be careful
not to drop and damage the side bearing spacers or
the side bearing outer races.
NOTE
Keep the right and left side bearings and side bearing outer
race separate, so that they do not become mixed at the time
of assembly.
AC"SIDE BEARING INNER RACE REMOVAL
Use special tools to pull out the side bearing inner race.
NOTE
There are two notches provided (at the differential case side)
for the claw part of the special tool; use the special tool at
that position.
If notches of special tools touch the end of differential case
and fail to hook with inner race, file the notches to be able
to hook with inner race.
AD"DRIVE GEAR REMOVAL
1. Make the mating marks to the differential case and the
drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
AE"SELF-LOCKING NUT REMOVAL
Use special tool to hold the companion flange, and then
remove the companion flange self-locking nut.
MB990810
Socket
wrench
Mating marks
MB990850

REAR AXLE -Differential Carrier 27B-43
REASSEMBLY
11
14
26
25
1310
6
124
7
24
21
18
17
15
2019
9
3
8
5
2
1
22
23
16
191820
5
17
15
84±4 N·m
186±29 N·m64±4 N·m
49±9 N·m
37±2 N·m
36±5 N·m
Final drive gear set
Reassembly steps
1. Differential carrier
"AA2. Oil seal
"BA3. Drive pinion rear bearing outer race
"CA4. Drive pinion front bearing outer race
"DADDrive pinion height adjustment
5. Drive pinion
6. Drive pinion rear shim (For adjusting
drive pinion height)
7. Drive pinion rear bearing inner race
8. Drive pinion spacer
"EADDrive pinion turning torque adjustment
9. Drive pinion front shim (For adjusting
drive pinion preload)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
"EA12. Oil seal13. Companion flange
14. Washer
15. Self-locking nut
16. Limited slip differential case assembly
"FA17. Drive gear
"GA18. Side bearing inner race
19. Side bearing outer race
20. Side bearing spacer
21. Differential case assembly
"HA22. Bearing cap
23. Vent plug
24. Differential cover assembly
25. Drain plug
26. Filler plug
"HADFinal drive gear backlash adjustment

REAR AXLE -Differential Carrier 27B-44
Lubrication and Adhesive Points
Vent plug
2 - 3mm
(bead diameter)
Adhesive: 3M Stud Locking
4170 or equivalentSealant: 3M ATD Part No.8661, 8663
or equivalent
REASSEMBLY SERVICE POINTS
"AAOIL SEAL PRESS-FITTING
MB990938
MB991115

REAR AXLE -Differential Carrier 27B-47
3. Measure the drive pinion turning torque (without the oil
seal).
Standard value:
Bearing divisionTurning torque
New0.88 - 1.17 N·m
Caution
Take care not to fit gear oil on the bearing.
4. If the drive pinion turning torque is not within the standard
value, adjust the turning torque by replacing the drive
pinion front shim(s) or the drive pinion spacer.
NOTE
When selecting the drive pinion front shims, if the number
of shims is large, reduce the number of shims to a minimum
by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following
two types.
Height of drive pinion spacer mmIdentification colour
57.72-
57.08Red
5. Remove the companion flange and drive pinion again.
Then insert the drive pinion front bearing inner race into
the gear carrier. Use special tool to press-fit the oil seal.
6. Install the drive pinion assembly and companion flange
with mating marks properly aligned. Tighten the
companion flange self-locking nut to the specified torque
using special tool.
MB990326
MB990685
Identification
colour
MB990727
MB990850
186±29 N·m

REAR AXLE -Differential Carrier 27B-48
7. Measure the drive pinion turning torque (with oil seal)
to verify that the drive pinion turning torque complies
with the standard value.
Standard value:
Bearing
divisionCompanion flange lubricationTurning torque
NewNone (With anti-rust agent)0.98 - 1.27 N·m
Gear oil applied0.49 - 0.58 N·m
8. If the turning torque is not within the standard value,
check the tightening torque of the companion flange
self-locking nut, and the installation of the oil seal.
"FADRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes
of the drive gear by turning the special tool (tap M8 x
1.0), and then clean the threaded holes by applying
compressed air.
3. Apply the specified adhesive to the threaded holes of
the drive gear.
Specified adhesive:
3M Stud Locking 4170 or equivalent
4. Install the drive gear onto the LSD case with the mating
marks properly aligned. Tighten the bolts to the specified
torque in a diagonal sequence.
Tightening torque: 84±4N
·m
"GASIDE BEARING INNER RACE INSTALLATION
Use special tool to press-fit the side bearing inner races into
the differential case.
MB990326
MB990685
MB990813
Contact plate
MB990728
Contact
plate

REAR AXLE -Differential Carrier 27B-53
INSPECTION
DIFFERENTIAL CASE INTERNAL PARTS CONTACT/
SLIDING SURFACE CHECK
1. Clean the disassembled parts with cleaning oil and dry
them with compressed air.
2. Check each plate, disc, and pressure ring for the following:
A. Friction and sliding surfaces of friction discs, friction
plates, and spring plates.
Replace a defective part with heat discoloration and
excessive wear with a new one, as it degrades locking
performance.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
B. Inner periphery and outer periphery protrusions of
friction discs, friction plates, and spring plates.
Replace a cracked or damaged part with a new one.
C. Friction and sliding surfaces between pressure rings
and friction discs.
Grind a dented or scratched part with oil stone and
then lap and correct with a compound on a surface
plate.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
3. Check the following parts for contact and siding surfaces
(D to M) and correct burrs and dents with oil stone.
D: Sliding surfaces of side gear and case
E: Contacting surfaces of differential case and spring
plate
F: Contacting surfaces of pressure ring and differential
case inner face
G: Sliding surfaces of pressure ring hole and side gear
H: Protrusions on outer periphery of pressure ring
I: Pressure ring inner surface and differential pinion
gear spherical surface
J: Pressure ring V-groove and pinion shaft V
K: Sliding surfaces of pinion shaft and differential pinion
gear hole
L: Side gear grooves on outer periphery
M: Slits in inner periphery of differential
Friction disc
A
AB
C B Friction plateFriction plate
Pressure ring
E
D M
F
J
I
H D
G
F
D
K
K
I GLJ E