Rear Axle - Evolution: Other Mitsubishi Lancer IX

GEAR OIL LEVEL CHECK

1. Remove the filler plug.
2. Check that gear oil level is not 8 mm (0.3 inch) below the bottom of filler plug hole. Specified gear oil: Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX or equivalent
3. Tighten the filler plug to the specified torque. Tightening torque: 49 +/- 9 N.m (37 +/- 6 ft-lb)

Scheme 96

WHEEL BEARING END PLAY CHECK

1. Remove the caliper assembly, and suspend the caliper assembly with a wire and remove the brake disc.
2. Fit the dial gauge as shown in the diagram and move the hub in the axial direction to measure the play. Limit: 0.05 mm (0.002 inch)
3. If the play exceeds the limit, the drive shaft nut should be tightened to the specified torque and check the axial play again. Tightening torque: 225 +/- 25 N.m (166 +/- 18 ft-lb)
4. Replace the rear hub assembly if adjustment cannot be made to within the limit.
5. Install the brake disc and caliper assembly, and tighten the caliper assembly mounting bolts to the specified torque. Tightening torque: 54 +/- 5 N.m (40 +/- 4 ft-lb)

Scheme 97

<< A >> PROPELLER SHAFT DISCONNECTION

1. Make mating marks on the differential companion flange and the propeller shaft assembly.
2. Suspend the removed propeller shaft from the body with a wire to prevent bending.

Scheme 98

< DIFFERENTIAL MOUNT BRACKET >

1. Use special tool MB990641 to remove or install the bushing.
2. Press-fit the bushing with its hollow portion facing in the direction shown.
3. Press-fit the bushing until the bushing outer case end face is flush with the differential mount bracket.

Scheme 99

Scheme 100

Scheme 101

1. Use special tool MB991439 to remove the bushing.
2. Press-fit the bushing with its marks facing in the direction shown.
3. Press-fit the bushing until the bushing outer case end face is flush with the differential support arm.

Scheme 102

Required Special Tools

1. MB990909: Working Base
2. MB991116: Working Base Adapter
3. MB990939: Brass Bar
4. MB990810: Side Bearing Puller
5. mb990811: Side Bearing Cup
6. MB990850: End Yoke Holder
7. MD998801: Remover

FINAL 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 (0.004 - 0.006 inch)
2. If the backlash is not within the standard value, adjust the final drive gear backlash (Refer to «ASSEMBLY»(ref-183221-S37234941192005081200000) ).
3. After the adjustment, inspect the final drive gear tooth contact.

Scheme 103

DRIVE GEAR RUNOUT

1. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm (0.002 inch)
2. When runout exceeds the limit value, check for foreign material between drive gear rear side and differential case, or for loose drive gear installation bolts.
3. When step (2) gives normal results, reposition the drive gear and differential case and re-measure.
4. If adjustment is impossible, replace the differential case, or replace the drive gear and pinion as a set.

Scheme 104

FINAL DRIVE GEAR TOOTH CONTACT

Check the tooth contact of drive gear by following the steps below.

Scheme 105

1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth. CAUTION: If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.
2. Insert special tool MB990939 between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear so that the revolution torque [approximately 2.5 - 3.0 N.m (22.1 - 26.6 in-lb)] is applied to the drive pinion.
3. Check the tooth contact condition of the drive gear and drive pinion.

Scheme 106

Scheme 107

Note. Check the tooth contact pattern to confirm that the adjustments of the pinion height and backlash have been done properly. Continue to adjust the pinion height and backlash until the tooth contact pattern resembles the standard pattern. If, even after adjustments have been made, the correct tooth contact pattern cannot be obtained, it means that the drive gear and the drive pinion have become worn beyond the allowable limit. Replace the gear set.

>> A << OIL SEAL PRESS-FITTING

Use special tools MB990938 and MB991380 to press-fit the oil seal.

Scheme 108

>> B << DRIVE PINION REAR BEARING OUTER RACE PRESS-FITTING

Use special tools MB990938 and MB990936 to press-fit the drive pinion rear bearing outer race.

Scheme 109

>> C << DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING

Use special tools MB990938 and MB990934 to press-fit the drive pinion front bearing outer race.

Scheme 110

FRICTION PLATE AND FRICTION DISC DISTORTION CHECK

Apply a dial indicator to the friction plate or disc on a surface plate and, turning the friction plate or disc, measure the distortion (flatness).

1. Limit: 0.08 mm (0.003 inch) [total runout]

Scheme 111

FRICTION PLATE, FRICTION DISC, AND SPRING PLATE WEAR CHECK

1. For the purpose of determining wear, measure thickness (A, B) of the friction surface and protrusion at several places and find the difference between the two. Limit: 0.1 mm (0.004 inch)
2. If the wear exceeds the limit, replace the part with a new one.

Scheme 112