2007 MITSUBISHI LANCER EVOLUTION boot

CLUTCH -General Information/Service Specifications/Lubricants/On-vehicle Service21A-3
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm202.1 - 206.1
173.5 - 177.5
Clutch pedal clevis pin play mm1-3
Clutch pedal free play mm4-13
Distance between the clutch pedal and the toeboard
when the clutch is disengaged mm114.3 or more
100 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidBrake fluid DOT3 or DOT4As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMITSUBISHI genuine grease Part No.
0101011
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height and the clutch pedal
clevis pin play.
Standard value (A):
202.1 - 206.1 mm
173.5 - 177.5 mm
Standard value (B): 1 - 3 mm
Clutch pedal height

A
A
Clutch pedal
stopper
Clutch pedal clevis pin play
B

CLUTCH -Clutch Control21A-9
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
1
4 5
27
223
4
Grease: Rubber grease
Clutch fluid:
Brake fluid DOT3 or DOT4
Piston repair kit
13±2 N·m
12
3
6
8

4 5
8
Disassembly steps
1. Piston stopper ring
2. Piston assembly
"AA3. Push rod assembly
4. Boot5. Spring pin
6. Reservoir tank
7. Seal
8. Master cylinder body
INSTALLATION SERVICE POINT
"AAPUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of clutch pedal easier.
104.3±0.5 mm

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 -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

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-40
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
16107
11
8
9
6
5
3 41
2
17 1213
15 14
18
18±3N•m
Disassembly steps
AA""FA1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate
"EA7. Spring pin
"DA8. Spring pin
9. Stopper body10. Neutral return spring
11. Control shaft
"CA12. Air breather
13. Control shaft boot
"BA14. Oil seal
"AA15. Needle bearing
16. Spring washer
17. Stopper bracket
18. Control housing

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

PROPELLER SHAFT - Propeller Shaft25-5
DISASSEMBLY AND REASSEMBLY
LJ kit LJ boot kit11 9
876 5
4
3
1
2
1716
15 14
1312
16
15
141312
111415
1412
11
187±29 N·m
34±5 N·m187±29 N·m
34±5 N·m
10
Disassembly steps
1. Bolt
2. Front propeller shaft assembly
"DA3. Self locking nut
AA""DA4. Companion flange
AB""DA5. Center bearing assembly
AC"6. Bolt
"DA7. Self locking nut
"DA8. Companion flange
"DA9. Center bearing assembly10. Center propeller shaft
11. Snap ring
"CA12. Boot band
AD""BA13. LJ assembly
14. Rubber packing
AE""AA15. LJ boot
16. Washer
17. Rear propeller shaft