2007 MITSUBISHI LANCER EVOLUTION service

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-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-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-51
REMOVAL SERVICE POINT
AA"SCREWS REMOVAL
1. Check out the alignment marks.
2. Loosen a uniform amount little by little the screws securing
differential case A to B.
3. Separate differential case B from differential case A and
remove their components.
Keep the removed spring plates, friction plates, and friction
discs organized in the order of removal and for right and
left use.
INSTALLATION SERVICE POINTS
"AADIFFERENTIAL CASE B INSTALLATION
Before starting the assembly procedure, perform the following
steps to adjust dimensional differences (clutch plate friction
force) in the axial direction of the components inside the
differential case and axial clearance of the differential side
gear.
1. Place friction discs (two each) and friction plates (three
each) one on top of another as illustrated and, using
a micrometer, measure the thickness of each of the right
and left assemblies. Select different discs and plates so
that the difference between the right and left assemblies
falls within the specified range.
Standard value: 0 – 0.05 mm
NOTE
If a new part is used, note that the friction disc comes
in two thicknesses: 1.6 mm and 1.7 mm.
2. Measure the thickness of each of the right and left spring
plates.
3. Assemble the pressure ring internal parts (pinion shaft
and pressure ring), friction plates, and friction discs and,
using a micrometer, measure the overall width.
NOTE
When taking measurements, press the assembly from
both sides so that the pinion shaft makes a positive contact
with the groove in the pressure ring.
4. Find value (A) which is the thickness measured in step
(3) added to the thickness of two spring plates.
A
Groove

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-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 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