2007 MITSUBISHI LANCER EVOLUTION clutch

CLUTCH OVERHAUL -Clutch21B-3
CLUTCH
REMOVAL AND INSTALLATION
18±3N•m
111
12
9
10
17
1519
18
16
18±3N•m9.8±2N•m
18±3N•m
15±2N•m
22±2N•m
16
14
1320 2
8
7
6
3 45
Removal steps
1. Clutch fluid line bracket
2. Clutch tube
3. Union bolt
4. Union
5. Gasket
"EA6. Valve plate
"EA7. Valve plate spring
"DA8. Clutch release cylinder
9. Clutch cover
10. Clutch disc"CA11. Sealing cap
12. Release fork shaft
13. Support spring (L)
14. Packing
"BA15. Release fork
"AA16. Bush
17. Clutch release bearing
18. Packing
19. Support spring (R)
20. Release fork boot

CLUTCH OVERHAUL -Clutch21B-4
REASSEMBLY SERVICE POINTS
"AABUSH INSTALLATION
Press the bush into the position of the release valve shown
in the illustration.
"BARELEASE FORK INSTALLATION
Apply grease on the release fork at the position shown in
the illustration.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011
or equivalent
"CASEALING CAP INSTALLATION
Press the sealing cap into the position shown in the illustration
while taking care so that it is not tilted.
"DACLUTCH RELEASE CYLINDER INSTALLATION
Fill grease in the release fork to the position shown in the
illustration.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011
or equivalent
"EAVALVE PLATE SPRING/VALVE PLATE
INSTALLATION
Set the spring’s large diameter side to the valve plate side,
and install the valve plate spring and valve plate.
Bush
2mm
Release fork
Valve plate spring
Release cylinder
Valve plate

CLUTCH OVERHAUL -Clutch21B-5
INSPECTION
CLUTCH COVER
(1) Check the pressure plate surface for wear, cracks or
discoloration.
(2) Check the strap plate rivet for looseness. If loose, replace
the clutch cover.
CLUTCH DISC
Caution
Do not wash the clutch disc with cleaning oil.
(1) Check the facing for decomposition caused by rivet
looseness, single-side contact or seizure, and check for
the presence of grease. If any fault is found, replace
the clutch disc.
(2) Measure the rivet sinking level, and replace the clutch
disc if the limit is exceeded.
Limit value: 0.3 mm
(3) Check the torsion spring for play and breakage. If faulty,
replace the clutch disc.
(4) Set the clutch disc onto the input shaft, and check the
sliding state and for play in the rotation direction. If the
sliding state is poor, wash the disc, reassemble and then
check the state again. If there is extreme play, replace
the clutch disc or input shaft or both parts.
CLUTCH RELEASE BEARING
Caution
Grease is filled in the release bearing, so do not wash with
washing oil.
(1) Check the bearing for seizure, damage, abnormal noise
or improper rotation.
(2) Check that the pull ring of the release bearing is not
worn.
(3) If the surface where the bearing contacts the release
fork is abnormally worn, replace the bearing.
RELEASE FORK AND RELEASE FORK SHAFT
(1) If the surface where the release fork contacts the bearing
is abnormally worn, replace the release fork.
(2) Check the release fork shaft for bending and wear. If
any abnormality is found, replace the release fork shaft.

CLUTCH OVERHAUL -Clutch Release Cylinder21B-6
CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
5 341
2
678
11±1N•m
Disassembly step
1. Cap
2. Air breather
3. Push rod
4. Boot"AA5. Piston cup
"AA6. Piston
7. Conical spring
8. Release cylinder

CLUTCH OVERHAUL -Clutch Release Cylinder21B-7
REASSEMBLY SERVICE POINT
"AAPISTON/PISTON CUP INSTALLATION
After applying brake fluid on the inner surface of the release
cylinder and circumference of the piston and piston cup, insert
the piston and piston cup into the release cylinder.
Brake fluid
Specified fluid:
MITSUBISHI genuine brake fluid “DIA-QUEEN
BRAKE FLUID SUPER 4” or equivalent
INSEPCTION
RELEASE CYLINDER
(1) Check the inner surface of the release cylinder for rust
and damage.
(2) Using a cylinder gauge, measure the inner diameter of
the release cylinder at approx. three positions (deepest
section, middle, opening). If the clearance with the outer
diameter of the piston exceeds the limit value, replace
the release cylinder assembly.
Limit value: 0.15 mm
Piston cup Piston

MANUAL TRANSMISSION -General/General Information/
Service Specification/Lubricants22A-3
GENERAL
OUTLINE OF CHANGE
With the addition of the EVOLUTION-VII, the W5M51 transmission service adjustment procedure has
been set as follows.
GENERAL INFORMATION
ItemsSpecifications
GradeRS, RS IIRS, RS II (With super cross gear)
Transmission modelW5M51
Engine model4G63-DOHC-T/C
Type5-speed, floor-shift
Gear ratio1st2.7852.785
2nd1.9501.950
3rd1.4071.444
4th1.0311.096
5th0.7200.825
Reverse3.4163.416
Final reduction ratio
(Differential gear ratio)4.5294.529
Front limited-slip differential
(Helical-gear type)Not providedProvided
TransferReduction ratio3.3073.307
Limited-slipdifferentialVCU or hydraulic multi plate
clutch (ACD)VCU or hydraulic multi plate
clutch (ACD)
SERVICE SPECIFICATION
ItemStandard value
Hydraulic unit generation oil pressureMPa1.0 - 1.6
LUBRICANTS
ItemSpecified lubricantQuantity L
Transmission oilGear oil SAE 75W-90 or 75W-85W conforming to API GL-42.8
Transfer
oilVehicles without ACD or ve-
hicles without ACD and AYCMITSUBISHI Genuine Gear Oil Part No.8149630 EX,
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL 5SAE80W90)orequivalent
0.55
Vehicles with ACD or vehicles
with ACD and AYC(GL-5, SAE 80W - 90) or equivalent0.6
FluidPiping between ACD and
hydraulic unitDIA QUEEN ATF SP III0.9
Pipes between ACD and hy-
draulic unit and between AYC
and hydraulic unit1.0

MANUAL TRANSMISSION - Troubleshooting 22A-36
Item
no.Normal conditions Check condition Check item
19Pressure sensor power
supplyIgnition switch: ONApprox.5 V
20Valve power supplyIgnition switch: ONSystem voltage
21Steering wheel sensor
voltage Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
22Steering wheel sensor
voltage Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
23Steering wheel sensor
ltSTN
Ignition switch: ONSteering wheel: Neutral1-2Vg
voltage
g
Steering wheel: Turn2.5 - 4.5 V
51Idle switchIgnition switch: ONAccelerator pedal: Full
closedON
Accelerator pedal: PressOFF
52Steering wheel sensor
STN
Ignition switch: ONsteering wheel: NeutralONg

g
Steering wheel: Turn from
the neutral positionOFF
53Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternaltely.
54Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternately
55Steering wheel sensor
learning Perform actual drivingSteering wheel sensor neu-
tral position learning exe-
cutedON
Steering wheel sensor neu-
tral position learning unex-
ecutedOFF
56Stop lamp switchIgnition switch: ONBrake pedal: DepressONppg
Engine: StoppedBrake pedal: ReleaseOFF
57Motor monitorElectric pump motor is currently operatingON
Electric pump motor is currently not operatingOFF
58Oil pressure stateElectric pump motor is currently operatingLOWp
Electric pump motor is currently not operatingHIGH
59Directional valve
Ri ht
AYC clutch right side is currently operatingON
AYC clutch right side is currently not operatingOFF
60Directional valve
Lft
AYC clutch left side is currently operatingON
AYC clutch left side is currently not operatingOFF
61ABS monitorABS is currently operatingON
ABS is currently not operatingOFF
62Parking brake switchIgnition switch: ONParking brake lever: PullONgg
Engine:StoppedParking brake lever: Re-
leaseOFF
63ACD mode switchIgnition switch: ONACD mode switch: PressONg
Engine:StoppedACD mode switch: ReleaseOFF

MANUAL TRANSMISSION - Troubleshooting 22A-37
ACTUATOR TEST JUDGEMENT VALUE
Item
no.Check itemTest descriptionNormal state
01Bleeding Input current to the Proportional valve
according to the steering angle, and operate
the Proportional valve for five minutes.Make sure no air leaks from the bleeder
screw on the transfer.
02Bleeding Input current to the Proportional valve
according to the steering angle, and operate
the directional valve for five minutes.Make sure no air leaks from the bleeder
screw on the torque transfer differential.
03Check the oil vol-
umeOperate the directional valve to the left and
right for 20 seconds.Check that the oil volume of the reservoir
tank is appropriate.
04Electric pump
driveOperate the electric pump for 5 seconds.Operation sounds of the electric pump
can be heard.
05Check the opera-
tions of the ACDOperate the Proportional valve and
supply the maximum oil pressure to the multi
plate clutch.9Generate the tight corner braking
phenomenon.
06Check clutch op-
erations Operate the direction valve and supply the
maximum oil pressure to the left clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
07Check clutch op-
erations Operate the direction valve and supply the
maximum oil pressure to the right clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
08Control OFFTurn OFF the electric pump relay, and turn
OFF the control of the ACD and AYC.In actual driving, there is difference
between control ON and OFF.
(1) The actuator test can be executed only when all the following conditions are satisfied.
DAll wheel speed sensor inputs below 20 km/h
DNo system malfunction detected
DSteering angle is within±30 degrees from the neutral position
(2) When the actuator test corresponds to one of the following conditions, forced driving will be cleared.
DWhen any one of the wheel speed sensor input is detected to be above 20 km/h (excluding
Item No.08 “Control OFF”.)
DWhen system malfunction is detected (excluding diagnostic code No.82, 84, and 85)
DWhen the forced drive time is exceeded
DWhen the MUT-IIis removed
DWhen the Clear key of the MUT-IIis operated