Installation/User Manual Important Safety Notice
Contents
1. CAUTION To ensure safety during installation turn the ignition key to the OFF position and set the parking brake firmly Jack up the car body and firmly support it with a set of jack stands using only the jacking and support points specified in the Car Owner s Manual Failure to use the designated jacking support points could result in deformation of the body or other parts AA NOTICE This Installation User Manual explains only the essential points of the installation procedure for this product For further details regarding installation procedure refer to the Mitsubishi Motors Corporation MMC Workshop Manual for your car model All attachment bolts and nuts should be securely tightened at the specified torque Install this product using the specified set of parts only Do not combine parts of other products into the assembly of this product Special Tools Required Bearing puller Bearing inner race installer CT9 202 0302 Kit Contents Ensure that the following parts are contained in the kit Rear LSD The following parts must be purchased separately for Other Parts Required installation of this product Two MB393957 side bearings 1 set of MB241903 spacers CT9 202 0302 Installation Procedure 1 Removal of Rear Differential Carrier Assembly Before removing the rear differential carrier assembly from the car drain all differential oil from the differential carrier and then2. RAL ART Lancer Evolution VIII VII Super Traction Rear LSD Kit RA534828K1 Installation User Manual Thank you for purchasing our Ralliart product This installation user manual explains the procedure for installing this product as well as information on how to use it effectively Please read this manual carefully to ensure thorough understanding of the details of this product before installation Give this manual to the customer to save for future reference Important Safety Notice Please follow the instructions in this manual carefully to ensure proper installation of this product This manual contains the following warning symbols CAUTION This indicates important safety information that must be carefully observed JN CAUTION All safety messages that follow this symbol must be carefully observed in order to reduce the risk of personal injury or accidents x NOTICE This indicates information that should be observed when installing parts Install the parts to the car as instructed in this manual Failure to follow the instructions may hamper the function of this product or cause car trouble e Be aware that Ralliart takes no responsibility for any product malfunction or car trouble that occurs during or after installation of this product After installing this product please give the customer this installation user manual to save for future reference To the Owner E Precautions for Use
3. Friction plate RA282104K1 2200 piece Outer lug T 1 6 mm RA138432K1 2200 piece Outer lug T 1 7 mm RA163449K1 2200 piece Outer lug T 1 8 mm Friction disc RA138433K1 2200 piece Inner lug T 1 7 mm Cam ring set Right and left per set RA192402S1 23000 set 55 55 55 35 Corn spring RA792400K1 RA783801K1 2900 piece 2900 piece T 1 7 mm Ti 190 N m T 2 0 mm Ti 255 N m
4. where there is a fitting projection in the cam ring Projection E Groove 55 Groove 35 NCAUTION 2 Align the pinion shaft and the mating surfaces of the cam rings snugly as shown in the figure below Improper alignment could damage the LSD assembly In the case where the 35 groove 1 8 way is In the case where the 55 groove 2 way is assembled in the coast side assembled in the coast side Identification groove Identification groove Pinion shaft Pinion shaft Z ASSIN h LYASE Cam ring Cam ring To Case A To Case B To Case A T Case B 3 After completion of the assembly the assembly looks like either of the following figures View from the case A View from the case A Pinion shaft assembled in the 55 35 groove Pinion shaft assembled in the 55 55 groove Instructions 3 Assembly of the inner plates Measure the depth of the case A and the assembly height of the inner plates D as shown below and assemble the inner plates the case A and the case B so that the clearance S in the assembled case is within the standard values See the last Note in this page Corn spring attachment part 1 Measurement of the depth A Measure the depth of the case A and B and calculate the depth A by adding the two measured values a and b A a b i ik Measure the depth excluding the depth of the hollow part for setting the cor
5. Do not use or install this product on non applicable car models Such installation could result in car damage or accidents Do not modify or disassemble this product in any manner Because this product is a mechanical multi plate type LSD assembly it may cause a dragging noise from the drive wheels or a rattling noise chatter from the differential gears during cornering maneuvers If you experience any problems when driving your car after this product is installed stop your car immediately and have it checked at a repair shop Failure to do so could result in car damage or accidents Install this product using only the specified parts supplied in the kit Do not combine parts of other products into the assembly of this product Have your car inspected when necessary to maintain normal installation and operating conditions of this product If the original function of this product cannot be maintained due to damage or deterioration replace it immediately W Applicable Models Car Model Name Series Transmission Type Lancer Evolution VIII SJDFZ 6FM T SNDFZ 5FM T Lancer Evolution VII SNDFZ 5FM T Lancer Evolution VI including TM edition 5FM T Lancer Evolution V 5FM T Lancer Evolution IV 5FM T Lancer Evolution III 5FM T Lancer Evolution II SFM T Lancer Evolution SFM T This product cannot be installed on cars equipped with AYC Active Yaw Control Precautions for Installation
6. Install the parts to the vehicle as instructed in this manual Failure to follow the instructions may hamper the function of the product or cause vehicle trouble e Be aware that RALLIART takes no responsibility for any product malfunction or vehicle trouble that has occurred during or after the installation On completion of installation of the garnish please give the customer this installation user manual Instructions Components of Rear LSD Assembly Corn spring Case A Friction plate Cam ring Side gear Pinion shaft Side gear Product Name QTY Available as spare part Case A Case B Side gear Pinion gear Pinion shaft Friction plate Outer lug Friction disc Inner lug Cam ring set 55 35 55 55 elelolololeloleloE N Co Co gt BY PO Corn spring T 1 7mm Ti 190Nem Assembly of Rear LSD 1 Assembly procedure and direction of each plate Friction plate Coast side A Cam ring Corn spring Friction discs Friction discs Corn spring AA NOTICE Please refer to the above figure for the assembly procedure and direction of the plates in the instructions to be explained hereafter Instructions 2 Assembly of the pinion shaft and the cam rings 1 The cam ring has grooves of angles of 35 1 8 way and 55 2 way in the coast side MA NOTICE The 35 groove in the coast side is located
7. remove the rear lower arm rear stabilizer and rear driveshaft 1 Remove nuts and their corresponding bolts to disconnect the differential carrier from the propeller shaft 2 Remove bolts and to disconnect the components attached to the differential carrier assembly Differential carrier 2 Bolt 3 Remove bolts to disconnect the differential mount brackets from each side of the assembly Differential mount bracket Bolt Bolt 1 Remove bolt to disconnect the differential Differential cover a cover from the carrier case 2 Remove bolts to detach the bearing caps 3 Remove the existing LSD assembly from the differential case Bearing cap Spacer CT9 202 0302 Installation Procedure 4 Remove the attachment bolts that secure the drive gear to the existing LSD assembly Hit the drive gear with a plastic hammer to make it easier to remove it from the LSD assembly AA NOTICE The removed drive gear will be re used when installing the new LSD assembly 1 Apply an anaerobic adhesive to the drive gear as shown at left Attach the drive gear to the new LSD assembly using attaching bolts e Specified torque Bolts 84 4 Nem 8 5 kgfm e Anaerobic adhesive ThreeBond 1303 or equivalent 2 Fit a side bearing onto the LSD assembly using the special tools listed in this manual Backing metal CT9 202 0302 Installation Procedure 4 Assembly of Rear Differential Ca
8. SD Gear Oil GL 5 Specified torque Filler plug 49 9 Nem 5 0 kgfm Reference Information i Scheduled Interval for Fluid Change After Installation Periodic Replacement interval Capacity dm Product Name replacement item Mitsubishi Genuine Dia Queen LSD Gear Oil GL 5 Differential oil 20 000 km 0 55 AA NOTICE The above fluid change interval is a guideline only The differential oil may deteriorate more quickly depending on its conditions of use In such cases it is recommended to replace the oil sooner than the above recommended interval NOTES CT9 202 0302 RALLINNART Thank you for purchasing our product This overhaul manual explains the procedure for overhauling the super traction rear L S D assembly installed on Lancer Evolution VIII VIl Please read this manual carefully to ensure thorough understanding of the details of this product before overhaul Give this manual to the customer to save for future reference Important Safety Notice Please follow the instructions in this manual carefully to ensure proper installation of this product This manual contains the following warning symbols NCAUTION This indicates important safety information AN CAUTION All safety messages that follow this symbol must be carefully observed in order to reduce the risk of personal injury or accidents a NOTICE This indicates information that must be observed when installing parts
9. n spring 2 Measurement of the assembled height D of the inner plates Assemble the plates cam rings pinion shaft pinion gears and side gears and measure the height D with a micrometer e Measure while pressing from both sides so that each plate contacts with each other e Clean every part sufficiently prior to measurement Ensure that the pinion shaft is properly placed between two cam rings so that each corresponding groove faces each other 3 Measurement of the clearance Calculate the clearance S from the depth A and the height of the inner plates D S A D Instructions 4 Adjustment of clearance Where the clearance is out of the standard values replace the friction plates with those of proper thickness so that the assembly height of the inner plates is within the range of the standard values AA NOTICE Thickness of the alternative friction plates RA282104K1 1 6 mm RA138432K1 1 7 mm RA163449K1 1 8 mm 5 Cam angle and initial torque at delivery Cam angle Initial torque 55 55 Drive side coast side approx 190N m The initial torque is a value set at the installation in the vehicle A half of the initial torque is to be measured in the procedure shown in the figure at left Instructions Spare parts Part Name Part Number Price yen Remarks
10. rrier Assembly 1 Attach a side bearing outer race to the LSD assembly and also attach spacers that have been selected according to the backlash adjustment procedure specified in the MMC Workshop Manual Install the LSD assembly on the carrier case 2 Align the alignment marks of the carrier case with those of each bearing cap and secure the bearing caps to the carrier case by means of bolts 3 Apply a semi drying sealing agent over the mating surface of the differential cover and Bearing attach it to the carrier case using bolts cap AA NOTICE e Specified torque Bolts 37 2 Nem 3 8 kgfm Bolts 36 5 Nem 3 7 kgfm e Semi drying sealing agent ThreeBond 1216 or equivalent 2 to 3mm bead dia Installation of Rear Differential Carrier Assembly 1 Install the rear differential carrier assembly on the car in the reverse order of the removal procedure RA NOTICE a Specified torque Propeller 2 Bolts 88 10 Nem 9 0 kgfm shaft a NG 3 Bolts 120 10 Nem 12 2 kgfm Bolts 88 10 Nem 9 0 kgfm Differential carrier Nuts 32 2 Nem 3 2 kgfm assembly CT9 202 0302 Installation Procedure 2 Fill the specified differential oil into the differential case so that the fluid level reaches Gear oil the bottom of the opening for the filler plug then attach and tighten the filler plug at the specified torque AA NOTICE Specified differential oil Mitsubishi Genuine Dia Queen L
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