Mitsubishi Lancer Evolution IX. Manual — part 617

ON-VEHICLE SERVICE

MANUAL TRANSMISSION (FF)

22A-151

STEP 7. Retest the system.

Q: Is the shifting of the gears still hard?

YES :

Return to Step 1.

NO :

The procedure is complete.

INSPECTION PROCEDURE 4: Jumps out of gear

DIAGNOSIS

STEP 1. Check the transmission control

Q: Are the shift cable and the select cable in good

condition?
YES :

Go to Step 2.

NO :

Repair or replace the shift cable and the
select cable. Refer to

P.22A-157

. Then go

to Step 6.

STEP 2. Remove and disassemble the
transmission. Check the poppet spring for
breakage.

Q: Is the poppet spring broken?

YES :

Replace the poppet spring. Refer to

GROUP 22B

− Transmission

P.22B-11

.

Then go to Step 6.

NO :

Go to Step 3.

STEP 3. Check the control housing.

Q: Is the control housing in good condition?

YES :

Go to Step 4.

NO :

Repair or replace the control housing. Refer
to GROUP 22B

− Transmission

P.22B-11

.

Then go to Step 6.

STEP 4. Check the gear shift forks for wear.

Q: Is the gear shift forks worn?

YES :

Replace the gear shift fork. Refer to

GROUP 22B

− Transmission

P.22B-11

.

Then go to Step 6.

NO :

Go to Step 5.

STEP 5. Check the clearance.

Q: Is the clearance between the synchronizer hub and

sleeve excessive?
YES :

Replace the synchronizer hub or sleeve.

Refer to GROUP 22B

− Input Shaft

P.22B-24

. Then go to Step 6.

NO :

Go to Step 6.

STEP 6. Retest the system.

Q: Does the transmission still jump out of gear?

YES :

Return to Step 1.

NO :

The procedure is complete.

ON-VEHICLE SERVICE

TRANSMISSION OIL CHECK

M1221000900491

1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler

plug hole.

3. Check that the transmission oil is not noticeably

dirty, and that it has a suitable viscosity.

4. Tighten the filler plug to the specified torque.

Tightening torque: 32

± 2 N⋅m

AC210553 AB

Filler plug hole

Filler plug

Transmission oil

ON-VEHICLE SERVICE

MANUAL TRANSMISSION (FF)

22A-152

TRANSMISSION OIL REPLACEMENT

M1221001000565

1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.

Tightening torque: 35

± 4 N⋅m

4. Fill with specified oil till the level comes to the

lower portion of oil filler plug hole.
Specified transmission oil: DIA QUEEN

SUPER MULTI GEAR 75W

−85W (GL−4) or

exact equivalent

Quantity: 2.2 L

5. Tighten the oil filler plug to the specified torque.

Tightening torque: 35

± 4 N⋅m

TRANSFER OIL CHECK

M1221001100120

1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler

plug hole.

3. Check that the transfer oil is not noticeably dirty,

and that it has a suitable viscosity.

4. Tighten the filler plug to the specified torque.

Tightening torque: 32

± 2 N⋅m

TRANSFER OIL REPLACEMENT

M1221001200138

1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.

Tightening torque: 32

± 2 N⋅m

4. Fill with specified oil till the level comes to the

lower portion of oil filler plug hole.
Specified transfer oil: Dia Quieen LSD gear oil
Quantity: 0.6 L

5. Tighten the oil filler plug to the specified torque.

Tightening torque: 32

± 2 N⋅m

FLUID CHECK

M1221011500033

1. Remove the maintenance lid located in the

luggage compartment.

2. <Not using M.U.T.-II/III>

• If the vehicle has been run, leave it for 90 min. or

more in an ordinary temperature (10

°C − 30°C) to

allow the accumulator internal pressure to drop.

NOTE: If the ambient temperature is 10

°

C or less,

allow more time to leave the vehicle to stand idle.

3. <Using M.U.T.-II/III>

CAUTION

Turn the ignition switch to the LOCK (OFF) posi-
tion before connecting or disconnecting the
M.U.T.-II/III.

• Set the M.U.T.-II/III to the 16-pin diagnosis con-

nector.

• Turn ON the ignition switch, perform M.U.T.-II/III

actuator test (Item No.03), forcibly drive the
hydraulic unit and remove the pressure in the
accumulator.

AC504941

AB

Filler plug

Drain plug

AC210553AC

Filler plug hole

Filler plug

Transfer oil

AC310836AF

Filler plug

Oil pan

Drain plug

ON-VEHICLE SERVICE

MANUAL TRANSMISSION (FF)

22A-153

NOTE:

.

•

In the actuator test (Item No.03: Oil Level
Check Mode), the directional valve of the
hydraulic unit is moved to the left and right for
20 times, and then the differential is cleared
automatically. Drive can also be cleared forci-
bly using the clear key of the M.U.T.-II/III.

•

If the function has been stopped by fail-safe,
the hydraulic unit cannot be cleared forcibly.

4. Check that the fluid level in the oil reservoir is in

the range between MAX and MIN.

5. If the fluid level is lower than MIN, add the

specified fluid.

Specified fluid: DIA QUEEN ATF SP III

6. Reinstall the maintenance lid.

BLEEDING

M1221011600018

CAUTION

If bleeding is not performed completely, noise
may be produced from the hydraulic unit, or the
durability of the pump, etc. may drop.
1. Lift up the vehicle.

CAUTION

Turn the ignition switch to the "LOCK"(OFF)
position before connecting or disconnecting the
M.U.T.-II/III.
2. Set the M.U.T.-II/III to the 16-pin diagnosis

connector.

3. Turn the ignition switch to the ON position.
4. Set the steering wheel in the straight-ahead

position.

5. Perform the M.U.T.-II/III actuator test (Item

No.01), and forcibly drive the hydraulic unit.

NOTE:

.

•

The actuator test (Item No.01: Bleeding Mode)
will be performed for 5 minutes, after which it
will be cleared automatically. Drive can also be
cleared during forced driving using the clear
key of the M.U.T.-II/III.

•

If the hydraulic unit function has been stopped
by fail-safe, the hydraulic unit cannot be forci-
bly driven.

6. Remove the cap of the bleeder screw on the

transfer, and connect the vinyl hose.

CAUTION

During bleeding, replenish the fluid so that some
always remains in the oil reservoir.
7. Slowly turn the steering wheel to the left or right

from the neutral state. Loosen the bleeder screw,
and check that air is discharged together with the
fluid.

8. After the air is discharged, tighten the bleeder

screw, and return the steering wheel to the neutral
state.

9. Repeat steps 6 and 7 several 2 to 3 times, and

after checking that no more air mixes in, tighten
the bleeder screw at the specified torque.

Tightening torque: 5

± 1 N⋅m

10.After bleeding, check the fluid level. (Refer to

P.22A-152

).

11.If the hydraulic pressure unit is removed, bleed

the AYC (Refer to GROUP 27

− On-vehicle

Service

P.27-28

).

ACD OPERATION CHECK

M1221011700037

CAUTION

Turn the ignition switch to the "LOCK" (OFF)
position before connecting or disconnecting the
M.U.T.-II/III.
1. Set the M.U.T.-II/III to the 16-pin diagnosis

connector.

2. Start the engine.

AC310841AB

AC310843AB

Front exhaust pipe

Bleeder screw

ON-VEHICLE SERVICE

MANUAL TRANSMISSION (FF)

22A-154

3. Set the steering wheel to the neutral position, and

carry out the actuator test (Item No.05) using
M.U.T.-II/III. Then, activate the transfer forcibly.
NOTE:

.

•

The actuator test (Item No.05: ACD Operation
Check Mode) is performed for 1 minute, after
which it will be cleared automatically. Drive
can also be cleared during forced driving using
the clear key of the M.U.T.-II/III.

•

If the hydraulic unit function has been stopped
by fail-safe, the transfer cannot be forcibly
driven.

4. Turn the steering wheel 180

° or more to the right

or left, and drive the vehicle at 20 km/h or less to
check that tight corner braking phenomenon.
NOTE:

.

•

The occurrence level of the body vibration and
noise depends on the condition of tyres and
roads.

•

If tight corner braking does not occur, check
the hydraulic pressure because the system
may be defective.

HYDRAULIC PRESSURE CHECK

M1221011800034

1. Lift up the vehicle.

CAUTION

Turn the ignition switch to the LOCK (OFF) posi-
tion before connecting or disconnecting the
M.U.T.-II/III.
2. Set the M.U.T.-II/III to the 16-pin diagnosis

connector.

3. Disconnect the hydraulic unit and transfer

connector assembly, and connect the special tool
to the hydraulic unit.

4. Turn the ignition switch to ON.
5. Perform the M.U.T.-II/III actuator test (Item

No.05), and forcibly drive the hydraulic unit.

NOTE:

.

•

The actuator test (Item No.05 ACD Operation
Check Mode) is performed for 1 minute, after
which it will be cleared automatically. Drive
can also be cleared during forced driving using
the clear key of the M.U.T.-II/III.

•

If the hydraulic unit function has been stopped
by fail-safe, the hydraulic unit cannot be forci-
bly driven.

CAUTION

While the oil pressure is checked, add fluid as
necessary to ensure that it is left in the oil reser-
voir during the entire procedure.
6. Check that the generated oil pressure of the

hydraulic unit satisfies the standard value.

Standard value: 1.0

− 1.6 MPa

7. If the measured value exceeds the standard

value, replace the hydraulic unit.

8. Connect the hydraulic unit and transfer connector

assembly, and tighten the flare nut at the specified
torque.

Tightening torque:

34

± 5 N⋅m (when screw is dry)

26

± 4 N⋅m (when screw is applied with oil)

9. Supply the specified fluid up to the MAX level of

the oil reservoir, and bleed the oil pressure pipes.

• Specified fluid: DIA QUEEN ATF SP III

• Quantity: 1.0 L

WHEEL SPEED SENSOR OUTPUT
VOLTAGE MEASUREMENT

M1221011900019

Lift the vehicle, and release the parking brake.

CAUTION

Insert the probe from the harness of the connec-
tor. Inserting in the terminal side may cause con-
tact fault.
1. Disconnect the 4WD-ECU connector, and

measure at the connector of the harness.

AC310844AC

MB991705

MD998330

AC310852AB