2007 MITSUBISHI LANCER EVOLUTION rear

PROPELLER SHAFT - Propeller Shaft25-5
DISASSEMBLY AND REASSEMBLY
LJ kit LJ boot kit11 9
876 5
4
3
1
2
1716
15 14
1312
16
15
141312
111415
1412
11
187±29 N·m
34±5 N·m187±29 N·m
34±5 N·m
10
Disassembly steps
1. Bolt
2. Front propeller shaft assembly
"DA3. Self locking nut
AA""DA4. Companion flange
AB""DA5. Center bearing assembly
AC"6. Bolt
"DA7. Self locking nut
"DA8. Companion flange
"DA9. Center bearing assembly10. Center propeller shaft
11. Snap ring
"CA12. Boot band
AD""BA13. LJ assembly
14. Rubber packing
AE""AA15. LJ boot
16. Washer
17. Rear propeller shaft

PROPELLER SHAFT - Propeller Shaft25-7
DISASSEMBLY SERVICE POINTS
AA"COMPANION FLANGE REMOVAL
Make mating marks on the companion flange and center
propeller shaft. Then, remove the companion flange.
AB"CENTER BEARING ASSEMBLY REMOVAL
AC"BOLT REMOVAL
Make mating marks on the rear propeller shaft, LJ assembly
and companion flange. Then, remove the bolt.
AD"LJ ASSEMBLY REMOVAL
1. Remove the LJ boot from the LJ assembly.
2. Mark the mating marks in outer race, cage and inner
race, then remove the circlip, outer race and ball.
NOTE
Ensure the installation position of ball and keep the ball
in order to refer in installation.Mating marks
MD998801
Center
bearing
assembly
LJ assembly
LJ boot
Circlip Outer race
Inner race
Cage
Ball

PROPELLER SHAFT - Propeller Shaft25-10
"DACENTER BEARING ASSEMBLY/COMPANION
FLANGE/SELF LOCKING NUT INSTALLATION
1. Install the center bearing assembly to the rear propeller
shaft in the direction shown as the illustration.
2. After alining the mating marks of the companion flange
and rear propeller shaft, install them.
3. Tightening the self locking nut, press fit the center bearing
assembly using companion flange.Center propeller shaft rear side
Companion
flange
Self
locking
nut
Center bearing
assembly
Dust sealRubber
mount
Center propeller shaft front side
Companion
flange
Self
locking
nut

27B-1
REAR AXLE
CONTENTS
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
SEALANTS 4................................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING (AYC) 8.................
ON-VEHICLE SERVICE 16....................
Rear Axle Total Backlash Check 16...............
Gear Oil Level Check 16........................
Gear Oil Change 17............................
Fluid Level Check 19............................
Bleeding 19....................................
AYC Operation Check 20........................
Oil Pressure Check 21..........................Wheel Bearing Axial Play Check 22...............
Wheel Bearing Rotary-sliding Resistance Check 22.
Hub Bolt Replacement 23.......................
Differential Carrier Oil Seal Replacement 23........
Action When Battery Runs Out 24................
REAR HUB ASSEMBLY 25....................
KNUCKLE 28................................
DRIVE SHAFT 29.............................
DIFFERENTIAL CARRIER
35......
DIFFERENTIAL CARRIER
55...................
HYDRAULIC UNIT
61..............

REAR AXLE -General Information27B-2
GENERAL INFORMATION
The rear axle consists of rear hubs, wheel bearings,
drive shafts, and rear differential and, it has the
following features.
DThe wheel bearing is a unit bearing (double-row
angular contact ball bearing).
DThe drive shaft incorporates B.J.-T.J. type
constant velocity joints with high transmission
efficiency and low vibration and noise.DABS rotors for detecting the wheel speeds are
press-fitted to the B.J. outer wheels in vehicles
with ABS or ACD.
NOTE
1. B.J.: Birfield Joint
2. T.J.: Tripod Joint
SPECIFICATIONS
ItemVehicles without AYCVehicles with AYC
Wheel
bearingsWheel bearing typeUnit bearing (Double-row angular contact ball
bearing)
g
Bearing (outside diameter×inside diameter) mm78×40
Drive
shaft
Joint typeOutsideB.J.
shaftInsideT.J.
Shaft length*1×Shaft diameter
mm
Left483×25426×25
mmRight573×25446×25
NOTE
*1: The shaft length indicates the length between the center points of each joint.
STRUCTURAL DIAGRAM
Oil sealRear hub Differential carrier
B.J.
Drive shaftT. J .

REAR AXLE -Service Specifications/Lubricants27B-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Rear axle total backlash mm-6
Wheel bearing rotation starting torque N·m-1.0
Wheel bearing axial play mm-0.05 or less
Wheel bearing rotary-sliding resistance N-22 or less
TJ boot assembly dimension mm90±3-
Drive gear backlash mm0.11 – 0.16-
Drive gear runout mm-0.05
Drive pinion turning
torqueN·m
Without oil seal0.88 – 1.17-
torqueN·m
With oil sealCompanion flange (oil seal contact-
ing area) with anti-rust agent0.98 – 1.27-
Companion flange (oil seal contact-
ing area) with gear oil applied0.49 – 0.58-
Vehicles with mechani-
cal LSDRight-to-left difference in combined thickness of friction
plate and friction disc
mm
0 – 0.05-
Clearance between spring plate and differential case
mm
0.06 – 0.25-
LSDdifferential
torqueN·m
When new clutch plate is installed5–19-
torqueN·m
When existing clutch plate is
installed2–19-
Distortion of friction plate and friction discmm-0.08
Difference in thickness between friction plate, friction
disc, and spring plate
mm
-0.1
Vehicles with ACD and
AY CPressure generated by hydraulic unit (pressure sensor
value
)MPa
0.9 – 1.1-
LUBRICANTS
ItemSpecified lubricantsQuantity
Vehicles with
mechanical
S
Gear oilHypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 81496300.55L
LSDMITSUBISHIGenuineGearOilPartNo.8149630
EX, CASTROL HYPOY LS (GL-5, SAE 90),
SHELL-LSD (GL-5, SAE 80W - 90) or equivalent
Vehicles with
ACD and
AY CGear oilDifferentialHypoid gear oil
API classification GL-5 or higher SAE viscosity
No.90, 80W0.55±0.02L
Torque transfer
mechanismATF-SP™0.65 - 0.7L

REAR AXLE -Lubricants/Sealants/Special tools27B-4
ItemQuantity Specified lubricants
Vehicles with
ACDand
Hydraulic piping fluidATF-SP™1L
ACDand
AY CTorque transfer mechanism oil
seal lipsVaselineAs required
B.J. jointRepair kit grease85±10 g
T.J. jointRepair kit grease105±10 g
SEALANTS
ItemsSpecified sealantsRemarks
Vehicles with me-
chanicalLSD
Vent plug3M ATD Part No. 8661, 8663 or
equivalent
Semi-drying sealant
chanicalLSD
Differential cover assembly
equivalent
Vehicles with ACD
andAYC
Vent plug
andAYC
Differential carrier cover
mounting part
Vehicles with me-
chanical LSDDrive gear and differential
case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IIsub as-
semblyInspection of AYC (diagnosis display by
MUT-II)
MB991529Diagnosis code
check harnessInspection of AYC
(diagnosis display by ACD mode indicator
lamp)
MD998330
(MD998331)Oil pressure gaugeHydraulic pressure measurement with AYC>
MB991705Hose adapter
MB990925Bearing and oil
seal installer setRemoval of wheel bearing

REAR AXLE -Special Tools27B-5
Tool UseName Number
MB991115Oil seal installerPress-fitting of oil seal
(AYC differential: used in combination with
MB990938)
MD998812Installer capPress-fitting of oil seal
(torque transfer mechanism of vehicles with
AYC)
MD998813Installer100
MD998829Installer adapter
(60)
MB990767Front hub and
flange yoke holderRemoval, installation of the drive shaft nut
A
B
MB990241
A: MB990242
B: MB990244Rear axle shaft
puller
A:Puller shaft
B:Puller barDRemoval of drive shaft
DRemoval of rear hub assembly
MB991354Puller body
A
CB
00005697
A: MB991017
B: MB990998
C: MB991000A,B: Front hub re-
mover and in-
staller
C: SpacerDTemporary fixing of wheel bearing
DMeasurement of wheel bearing rotation
starting torque
DMeasurement of wheel bearing axial play
Use MB991000 (component of MB990998)
for the spacer.