2007 MITSUBISHI LANCER EVOLUTION ABS

MANUAL TRANSMISSION - Troubleshooting 22A-39
Termi-
nal no.Normal state Check condition Check item
24*2Longitudinal G sensor
earth, lateral G sensor
earthAny time1 V or less
26ECU earthAny time1 V or less
31ECU backup power
supplyAny timeSystem voltage
32Pressure sensorIgnition switch: ON0.5 - 1.5 V
33Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowly1-2V↔2.5 -
4.5 V flushing
34Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowly1-2V↔2.5 -
4.5 V flushing
35Diagnosis data input/
output--
36Idle switchIgnition switch: ONAccelerator pedal: Full closed1 V or lessg
Accelerator pedal: Depress4.5 - 5.0 V
37Parking brake switchIgnition switch: ONParking brake lever: Pull1 V or lessgg
Parking brake lever: ReleaseSystem voltage
38Stop lamp switchIgnition switch: ONBrake pedal: DepressSystem voltageppg
Brake pedal: Release1 V or less
39TPSIgnition switch: ONAccelerator pedal: Full closed0.5 - 0.7 Vg
Accelerator pedal: Full throttle4.5 - 5.5 V
40ACD mode indicator
lamp Ignition switch: ONACD mode indicator lamp position:
TARMAC0V
p
ACD mode indicator lamp position:
Except for aboveApprox. 10.5 V
42ECU earthAny time1 V or less
43Pressure sensor earthAny time1 V or less
44Steering wheel sensor
STN
Ignition switch: ONSteering wheel: Neutral1-2Vg

g
Steering wheel: Turn from the
neutral position2.5 - 4.5 V
46Diagnosis control--
47ACD mode switchIgnition switch: ONSwitch: PressSystem voltageg
Switch: Release0V
49*1ABS monitorWith ABS not activeSystem voltage
With ABS active1.5 V or less
50*2EarthAny time1 V or less
51ACD mode indicator
lamp Ignition switch: ONACD mode indicator lamp position:
SNOW0V
p
ACD mode indicator lamp position:
Except for aboveApprox. 10.5 V
52ACD mode indicator
lamp Ignition switch: ONACD mode indicator lamp position:
GRAVEL0V
p
ACD mode indicator lamp position:
Except for aboveApprox. 10.5 V

MANUAL TRANSMISSION - On-vehicle Service22A-45
Output voltage:
Above 70 mV when measured with the circuit
tester
Above 200 mVP-P when measured with the
oscilloscope
4. If the output voltage is lower than the above values, the
following reasons may be suspected. Check or replace
the wheel speed sensor.
DExcessive clearance between the ball piece of the
wheel speed sensor and ABS rotor
DWheel speed sensor faul
INSPECTION PROCEDURE USING OSCILLOSCOPE
After checking the connected state of the harness of the
wheel speed sensor and connector, and measure the output
voltage waveform of each wheel speed sensor on the
oscilloscope as follows.
Start the engine, shift the transmission to the 1st gear to
rotate the driving wheel, and rotate the non-driving wheel
at constant velocity with the hand.
NOTE
1. It is also possible to actually drive the vehicle and observe
the waveform.
2. The output voltage is low if the wheel speed is low and
gradually increases as the speed increases.

PhenomenonProbable causeSolution
Waveform amplitude is too small or
not output at allWheel seed sensor faultReplace the sensor
Excessive waveform amplitude
(However allowed if above the
iilit df100V)
Excessive vibration or concentricity of
the axle hubReplace the hub
(
minimum amplitude of 100 mV)4WD-ECU earth faultCorrect
Noise in the waveform or waveform
ibl
Open circuit of the sensorReplace the sensor
is abnormalOpen circuit of the harnessReplace the harness
Wheel speed sensor installation faultCorrect the installation of the sensor
Chipping or flattening of the ABS rotorReplace the ABS rotor
Caution
As the wheel speed sensor cable follows the movement of the front or rear suspension, it will
change considerably on poor condition roads. Therefore, also observe the output voltage waveform
of the wheel speed sensor with the sensor harness vibrated to simulate special conditions such
as driving in poor road conditions.
When rotated with the hand
When idling (5 – 6 km/h)
1st gear
10.0 ms/DIV
IV/DIV

MANUAL TRANSMISSION OVERHAUL -Sealants22B-7
SEALANTS
TRANSMISSION
ItemsSpecified sealants
Clutch housing and transmission case contact surfaceMITSUBISHI genuine sealant Part
No MD997740orequivalent
Control housing and transmission case contact surface
No.MD997740or equivalent
Under cover and transmission case contact surface
Air breather3M SUPER WEATHERSTRIP No.8001 or
equivalent
Center differential drive gear bolt3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)
FIPG is used for several members of this transmission. With this gasket, caution is required to the application
amount, application procedure and state of the application surface so that the performance is sufficiently
attained.
If sufficient gasket is not applied, leaks could occur, and if too much is applied, the gasket could protrude
and plug or restrict the oil flow passage. Thus, to prevent leaks from the joined sections, it is absolutely
necessary to evenly apply the correct amount.
DISASSEMBLY
The parts assembled with FIPG can be easily disassembled without special means. However, in some
cases, the sealant on the contact surfaces must be broken by lightly tapping with a wood hammer or
similar tool.
Washing the gasket surface
Completely remove all matters adhered on the contact surfaces with a gasket scraper. Confirm that the
FIPG application surface is smooth. There must be no grease or foreign matter on the contact surfaces.
Always remove the old FIPG that has entered the mounting holes and screw holes.
APPLICATION PROCEDURES
Apply an even coat of FIPG within the predetermined radius (1.5±0.3 mm). Completely cover the areas
around the mounting holds. The FIPG can be wiped off if it has not hardened. Install at the set position
while the FIPG is still wet (within 10 minutes). When installing, make sure that the FIPG does not get
on areas other than the required areas. After installing, do not subject the application areas to oil or
water or start operation until the FIPG has sufficiently hardened (approx. one hour).
The FIPG application procedures differ according to the member, so follow the procedures given in this
manual and apply the FIPG.

FRONT AXLE -General Information26-2
GENERAL INFORMATION
The front axle consists of front hubs, knuckles,
wheel bearings and drive shafts, and it has the
following features.
DThe wheel beearing is unit bearing integrated
with hub (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
ItemSpecifications
Wheel
bearingsWheel bearing typeHub unit bearing (Double-row angular
contact ball bearing)
g
Bearing (outside diameter) mm87*1
Drive
shaft
Joint typeOutsideB.J.
shaftInsideT.J.
Shaft length*2×Shaft diameter mmLeft350×26
Right427×26
NOTE
*1: The wheel beearing is integrated with hub, only the outer diameter is shown.
*2: The shaft length indicates the length between the center points of each joint.
STRUCTURAL DIAGRAM
B.J.T. J . KnuckleOutput shaft Strut assembly
Drive shaft
Wheel bearing Front hubT.J. (L.H.)
Output shaftT.J. (R.H.)

FRONT AXLE -Hub and Knuckle Assembly26-6
HUB AND KNUCKLE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe out quickly.
Pre-removal and Post-installation Operation
DTransmission Fluid Draining
DTransfer Oil Draining (Refer to GROUP 22 –
On-vehicle Service.)Pre-removal and Post-installation Operation
DCheck the dust cover for cracks or damage by
pushing it with finger.
DTransfer Oil Filling (Refer to GROUP 22 –
On-vehicle Service.)
DTransmission Fluid Filling
25¶5Nm
1
245¶29 Nm
58
3
4
2
108¶10 Nm
10
11
25¶6Nm
6
9
100¶10 Nm*1
108¶10 Nm*2
167¶9Nm
8.9¶1.9 Nm
*1: Vehicles without BREMBO disc brake
*2: Vehicles with BREMBO disc brake
7
Removal steps
1. Front speed sensor ACD or ABS>
AA"2. Caliper assembly
3. Brake disc
4. Split pin
AB""AA5. Castle nut
6. Dust shield7. Connection for lower arm ball joint
AC"8. Connection for tie rod end
AD"9. Drive shaft
10. Front strut to hub and knuckle
mounting bolt and nut
11. Hub and knuckle assembly

FRONT AXLE -Drive Shaft26-10
DRIVE SHAFT
REMOVAL AND INSTALLATION
Caution
1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And
if there is brake fluid on the caliper, wipe out quickly.
2. For vehicles with ABS or ACD, do not strike the rotor for wheel speed sensor installed to
the B.J. outer race of drive shaft against other parts when removing or installing the drive
shaft. Otherwise the rotor for wheel speed sensor will be damaged.
Pre-removal and Post-installation Operation
DTransmission Fluid Draining
DTransfer Oil Draining (Refer to GROUP 22 –
On-vehicle Service.)Pre-removal and Post-installation Operation
DCheck the Dust Cover for cracks or damage by
pushing it with finger.
DTransfer Oil Filling (Refer to GROUP 22 –
On-vehicle Service.)
DTransmission Fluid Filling
1
6 9
8 5
74
3
2 11
25¶4Nm 25¶5Nm
245¶29 Nm
108¶10 Nm
10
11
39¶5Nm
Removal steps
1. Split pin
"BA2. Castle nut
3. Front speed sensor ABS or ACD>
4. Front speed sensor harness brack-
et
5. Brake hose bracket6. Stabilizer bar link connection
7. Lower arm ball joint connection
AA"8. Tie rod end connection
AB""AA9. Drive shaft
AC""AA10. Output shaft
11. Circlip

FRONT AXLE -Drive Shaft26-13
DISASSEMBLY AND REASSEMBLY
Caution
(1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be
careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race
to prevent the rotor from damage.
(2) Never disassemble the B.J. assembly except when replacing the B.J. boot.
2
6
4
3
5
7
1
4
2
43
61
2
4
51
2
9
10
1
8
8
97
6
T.J. repair kitT.J. boot repair kit B.J. boot repair kit
Disassembly steps
"BA1. T.J. boot band (large)
"BA2. T.J. boot band (small)
AA""AA3. T.J. case
4. Snap ring
AA""AA5. Spider assemblyAB"6. T.J. boot
7. B.J. boot band (large)
8. B.J. boot band (small)
9. B.J. boot
10. B.J. assembly

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 .