Mitsubishi Lancer Evolution 7. Manual — part 288
REAR AXLE -
Differential Carrier <Vehicles with mechanical LSD>
27B-37
BUSHING REPLACEMENT
1. Remove and press fit the bush with special tool. (About
removal and press fitting the bush of the differential
support arm, refer to P. 27B-57.)
2. Press fit the bush so that the hollow of the bush is on
the position shown as the illustration.
3. Press fill the bush until the surface of the outer sleeve
of the bush, differential mounting bracket.
<Differential mount bracket>
MB990641
Bush
Differential
mount
bracket
Steel block
Hollow
REAR AXLE -
Differential Carrier <Vehicles with mechanical LSD>
27B-38
DISASSEMBLY
19
2
6
8
20
22
26
5
11
3
4
9
12
15
16
13
14
10
21
1
23
24
25
18
17
7
8 9
7
Disassembly steps
A
A"
D
Inspection before disassembly
1. Filler plug
2. Drain plug
3. Differential cover assembly
4. Vent plug
5. Bearing cap
A
B"
6. Differential case assembly
A
B"
7. Side bearing spacer
A
B"
8. Side bearing outer race
A
C"
9. Side bearing inner race
A
D"
10. Drive gear
11. Limited slip differential case assembly*
A
E"
12. Self-locking nut
13. Washer
A
F"
14. Drive pinion assembly
A
F"
15. Companion flange
16. Drive pinion front shim (For adjusting
preload of drive pinion)
17. Drive pinion spacer
A
G"
18. Drive pinion rear bearing inner race
19. Drive pinion rear shim (For adjusting
drive pinion height)
20. Drive pinion
A
H"
21. Oil seal
A
H"
22. Drive pinion front bearing inner race
A
H"
23. Drive pinion front bearing outer race
A
I"
24. Drive pinion rear bearing outer race
25. Oil seal
26. Differential carrier
REAR AXLE -
Differential Carrier <Vehicles with mechanical LSD>
27B-39
DISASSEMBLY SERVICE POINTS
A
A" INSPECTION BEFORE DISASSEMBLY
1. Remove the cover.
2. Hold the special tool in a vise, and install the differential
carrier assembly to the special tool.
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
2. If the backlash is not within the standard value, adjust
the final drive gear backlash. (Refer to P.27B-49.)
3. After the adjustment, inspect the drive gear tooth contact.
DRIVE GEAR RUNOUT
1. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
2. When runout exceeds the limit value, check for foreign
object between drive gear rear side and differential case,
or for loose drive gear installation bolts.
3. When check (2) gives normal results, reposition drive
gear and differential case and remeasure.
4. If adjustment is impossible, replace differential case, or
replace drive gear and pinion as a set.
DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the steps
below.
1. Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.
MB990909 and
MB991116
REAR AXLE -
Differential Carrier <Vehicles with mechanical LSD>
27B-40
2. Insert the brass 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 (approximate 2.5 -
3.0 N·m) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.
Standard tooth contact pattern
Problem
Solution
1
Narrow tooth side
2
Drive-side tooth surface (the
side applying power during
forward movement)
3
Wide tooth side
4
Coast-side tooth surface (the
side applying power during
reverse movement)
1
2
3
4
Tooth contact pattern resulting from
excessive pinion height
The drive pinion is positioned too far
from the centre of the drive gear.
1
2
3
4
Increase the thickness of the drive
pinion rear shim, and position the
drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.
1
2
3
4
Tooth contact pattern resulting from
insufficient pinion height
The drive pinion is positioned too
close to the centre of the drive gear.
1
2
3
4
Decrease the thickness of the drive
pinion rear shim, and position the
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.
1
2
3
4
NOTE
Checking the tooth contact pattern is the way 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.
MB990939
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