2007 MITSUBISHI LANCER EVOLUTION torque

MANUAL TRANSMISSION OVERHAUL -Transmission22B-19
(3) Set solder (10 mm long, 1.6 mm diameter) on the
transmission case at the position shown in the illustration.
(4) Install the outer race onto the transmission case.
(5) Install the transmission case, and tighten the bolt with
the specified torque.
(6) If the solder has not been crushed, carry out steps (2) to (5) with
solder having a larger diameter.
(7) Using a micrometer, measure the thickness of the crushed solder,
and select a spacer so that the end play and preload are at the
standard values.
Standard value:
Input shaft end play
0.05mm loose to 0.17mm loose
Output shaft preload
0.13mm tight to 0.18mm tight
Center differential preload
0.05mm tight to 0.11mm tight
REASSEMBLY SERVICE POINTS
"AAINPUT SHAFT/OUTPUT SHAFT/CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and center differential onto
the clutch housing at the same time.
"BA5TH-REVERSE SPEED SHIFT
FORK/5TH-REVERSE SPEED SHIFT
RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH
SPEED SHIFT RAIL INSTALLATION
(1) Assemble the 3rd-4th speed shift rail, fork and the
5th-reverse speed shift rail and fork.
Solder
Solder
Output shaft
Center differentialInput
shaft
3rd-4th speed
shift rail
5th-reverse
speed shift rail 5th-reverse
speed shift
fork
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL -Center Differential22B-50
(5) Install the front output shaft onto the side gear, and install
the snap ring.
(6) After assembling the side gear into the center differential
case, install the spacer onto the side gear.
(7) Match the alignment marks, install the center differential
flange, and temporarily fix the machine screw.
(8) Measure the backlash between the side gear and pinion.
Standard value: 0.025 - 0.150 mm
(9) If the backlash is not within the standard value, select
a spacer, and measure the backlash again.
NOTE
Adjust so that the backlash on both sides is even.
"DACENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Confirm that rust-proofing oil is applied, and then apply
sealant on all of the bolt threads.
Sealant
Specified sealant:
3M STUD Locking No.4170 or equivalent
(2) Tighten with the specified torque following the order shown
in the illustration.

FRONT AXLE -Service Specifications/Lubricants/Special Tools26-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Wheel bearing axial play mm-0.06
WheelbearingrotationstartingtorqueN·m-103orlessWheelbearing rotation startingtorqueN·m-1.03orless
Setting of T.J. boot length mm85±3-
Opening dimension of the
special tool (MB991561) mmWhen the B.J.boot band
(small) is crimped.2.9-
When the B.J.boot band
(big) is crimped.3.2-
Crimped width of the B.J.boot band mm2.4 - 2.8-
LUBRICANTS
ItemsSpecified lubricantsQuantity g
T.J. boot greaseRepair kit grease120±10
B.J.boot greaseRepair kit grease11 0±10
SPECIAL TOOLS
ToolNumberNameUse
MB990767End yoke holderFixing of the hub
MB991618Hub bolt removerRemoval of the hub bolt
MB991113 or
MB990635Steering linkage
pullerDisconnection of ball joint
A
B
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller barDRemoval of the drive shaft
DRemoval of the hub
MB991354Puller bodyDRemoval of the drive shaft
DRemoval of the hub

FRONT AXLE -Special Tools26-4
Tool UseName Number
MB990685Torque wrenchMeasurement of wheel bearing rotation
starting torque
MB990326Preload socketMeasurement of wheel bearing rotation
starting torque
A
B
C
A: MB991017
B: MB990998
C: MB991000A,B: Front hub
remover and
installer
C: SpacerDProvisional holding of the wheel bearing
DMeasurement of wheel bearing rotation
starting torque
DMeasurement of wheel bearing axial play
MB991000, which belongs to MB990998,
should be used as a spacer.
MB991721Sliding hammerOutput shaft removal
MB991561Boot band clipping
toolResin boot band installation
MB990925
Brass bar
Installer adapterTool box
Bar (snap-in type) ACB
TypeTool numberO.D. mmTypeTool numberO.D. mm
MB99092639MB99093363.5
MB99092745MB99093467.5
MB99092849.5AMB99093571.5
AMB99092951MB99093675.5
MB99093054MB99093779
MB99093157BMB990938-
MB99093261CMB990939-

FRONT AXLE -Hub and Knuckle Assembly26-8
INSTALLATION SERVICE POINT
"AACASTLE NUT INSTALLATION
1. Be sure to install the castle nut washer in the specified
direction.
2. Using the special tool, tighten the castle nut.
Caution
Before securely tightening the castle nuts, make sure
there is no load on the wheel bearings. Otherwise
wheel bearing will be damaged.
INSPECTION
INSPECTION OF WHELL BEARING ROTATION STARTING
TORQUE
1. Tighten special tools in hub and knuckle assembly to
the specified torque.
2. Measure the wheel bearing rotation starting torque with
special tools.
Limit: 1.03 N·m or less
3. Wheel bearing rotation starting torque must be under
the limit value and there should be no roughness when
rotating the hub.
WHEEL BEARING AXLE PLAY CHECK
1. Secure knuckle in a vice to measure axle play in wheel
bearing.
Limit: 0.06 mm
2. If the limit value of wheel bearing axle plya cannot be
obtained when tightened to the specified torque (245
±29 N·m), check mounting bolt for hub and knuckle
assembly. If no defects are found, replace hub assembly.
MB990767
245±29 N·m
Washer
MB991000
(MB990998)
Bolt
245±29 N·m
Secure bolt and
tighten nut.
MB991017
MB990326
MB990685
MB991000
(MB990998)
245±29 N·m
Secure bolt and
tighten nut.
MB991017

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.