2007 MITSUBISHI LANCER EVOLUTION service

MANUAL TRANSMISSION OVERHAUL -Transmission Case22B-46
TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY
2*
3*
41
Disassembly steps
"CA1. Oil seal
"BA2. Needle bearing*"AA3. Bush*
4. Transmission case
NOTE
*: Refer to the installation procedures only when replacing the transmission case.
REASSEMBLY SERVICE POINTS
"AABUSH INSTALLATION
Press in the bush to the position shown in the illustration
so that the split face of the bush does not cover the air bleeding
groove on the case.
Bush Air
bleeding
hole

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-48
CENTER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
Apply gear oil on
all sliding sections
before installing.
161310 7
11
8 9653
41
2
17
12
1514
912 121112
132±5N•m
Disassembly steps
"DA1. Center differential drive gear
"CA2. Center differential flange
AA""BA3. Taper roller bearing
"CA4. Snap ring
"CA5. Front output shaft
"CA6. Spacer
"CA7. Side gear
"CA8. Lock pin
"CA9. Pinion shaft"CA10. Pinion shaft holder
"CA11. Pinion
"CA12. Washer
"CA13. Side gear
"CA14. Spacer
AB""AA15. Taper roller bearing
16. Speedometer drive gear
17. Differential case
DISASSEMBLY SERVICE POINTS
AA"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the center differential flange.MD998917

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-49
AB"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the center differential case.
REASSEMBLY SERVICE POINTS
"AATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing onto
the center differential case.
"BATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing onto
the center differential flange.
"CASPACER/SIDE GEAR/WASHER/PINION/PINION
SHAFT HOLDER/PINION SHAFT/LOCK
PIN/FRONT OUTPUT SHAFT/SNAP RING/CENTER
DIFFERENTIAL FLANGE INSTALLATION
(1) After assembling the spacer onto the side gear, install
the side gear into the center differential case.
NOTE
When installing a new side gear, assemble a medium
thickness (0.8 or 0.9 mm) spacer.
(2) Align the washer on the back of the pinion. Engage the
four pieces onto the side gear simultaneously, and rotate
to install at the specified position. Then, install the pinion
shaft holder.
(3) Insert the pinion shaft into the differential case.
(4) Install the lock pin in the direction shown in the illustration.
MD998917 MB990932
MB990937
MD998823MD998812
Differential case
Lock pin
Pinion shaft

MANUAL TRANSMISSION OVERHAUL -Transfer22B-52
REASSEMBLY SERVICE POINTS
"AAO-RING INSTALLATION
Apply hypoid gear oil on the O-ring.
Hypoid gear oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN SUPER” hypo-
id gear oil (GL-5) or equivalent
"BAOIL SEAL INSTALLATION
Apply hypoid gear oil on the lip section of the oil seal, and
install using the special tool.
Hypoid gear oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN SUPER” hypo-
id gear oil (GL-5) or equivalent
"CAOIL SEAL INSTALLATION
Apply hypoid gear oil on the lip section of the oil seal, and
install using the special tool.
Hypoid gear oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN SUPER” hypo-
id gear oil (GL-5) or equivalent
"DAOIL SEAL INSTALLATION
Apply hypoid gear oil on the lip section of the oil seal, and
install using the special tool.
Hypoid gear oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN SUPER” hypo-
id gear oil (GL-5) or equivalent
"EAOIL SEAL INSTALLATION
Apply hypoid gear oil on the lip section of the oil seal, and
install using the special tool.
Hypoid gear oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN SUPER” hypo-
id gear oil (GL-5) or equivalent
MD998800
MB990937MB990938
MB990887MB990891
MB990936

25-1
PROPELLER
SHAFT
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANT 2...............................SEALANT 2..................................
SPECIAL TOOL 2............................
PROPELLER SHAFT 3.......................

PROPELLER SHAFT -General Information/Service Specification/
Lubricant/Sealant/Special Tool25-2
GENERAL INFORMATION
3 way split 4-joint type propeller shaft with center bearing is adopted.
SERVICE SPECIFICATION
ItemsStandard valueLimit
Propeller shaft runout mm-0.5
LUBRICANT
ItemsSpecified lubricantQuantity
Front propeller shaft sleeve
yokeHypoid gear oil SAE 75W-90 or 75W-85W or 80W
conforming to API GL-4As required
LJ assemblyRepair kit grease75±5g
SEALANT
ItemsSpecified sealantsRemarks
LJ assembly rubber packing3M Stud Locking 4170 or equivalentAnaerobic sealant
SPECIAL TOOL
ToolNumberNameUse
MB998801Bearing removerRemoval of the center bearing assembly

PROPELLER SHAFT - Propeller Shaft25-3
PROPELLER SHAFT
REMOVAL AND INSTALLATION
Gear Oil: Hypoid gear oil SAE 75W-90 or
75W-85W or 80W conforming to API GL-41
3 22
1
1 1
30±4 N·m
32±2 N·m 30±4 N·m
Removal steps
1. Insulator
2. Spacer
AA""AA3. Propeller shaft assembly
REMOVAL SERVICE POINT
AA"PROPELLER SHAFT ASSEMBLY REMOVAL
1. Make mating marks on the differential companion flange
and flange yoke, and then remove the front propeller
shaft assembly.
2. By filling rag in the boot and align the propeller shaft,
remove the propeller shaft assembly
Caution
If the joint part is bent, the joint boot is danger of
damage by folding joint boot.
A10C0017
Joint assembly
Center propeller
shaft
Joint bootRag

PROPELLER SHAFT - Propeller Shaft25-4
INSTALLATION SERVICE POINT
"AAPROPELLER SHAFT ASSEMBLY INSTALLATION
When reusing the propeller shaft, align the mating marks
made during the removal and install the propeller shaft
assembly to the companion flange.
Caution
1. Do not damage the oil seal lips of the transmission
and transfer.
2. Wipe out oil and grease on the threads of the mounting
bolts and nuts before tightening, or they will loosen.
3. If the joint part is bent, the joint boot is in danger
of damage by folding joint boot.
INSPECTION
PROPELLER SHAFT RUNOUT
Limit: 0.5 mm
Oil seal
Transfer