bearing MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

MANUAL TRANSMISSION OVERHAUL – Transmission22B-16
DISASSEMBLY SERVICE POINTS
A
SPRING PIN REMOVAL
Shift the 5th-reverse shift fork in the direction shown in the
illustration.
B
3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED
SHIFT FORK / 5TH-REVERSE SPEED SHIFT
RAIL / 5TH-REVERSE SPEED SHIFT FORK
REMOVAL
Pull out the shift rails from the shift rail holes in the clutch
housing.
C
CENTER DIFFERENTIAL / OUTPUT SHAFT /
INPUT SHAFT REMOVAL
Remove the input shaft, output shaft and center differential
together.
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR ADJUSTING INPUT SHAFT
END PLAY / OUTPUT SHAFT PRELOAD /
DIFFERENTIAL PRELOAD
(1) Install the input shaft, output shaft and center differential
as a set to the clutch housing.
(2) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the input shaft rear bearing at the
positions shown in the illustration.
5th-reverse
shift fork
5th-reverse
shift rail3rd-4th
speed
shift rail
Output shaft
Center
differentialInput
shaft
Output shaft
Center
differentialInput
shaft
Solders

MANUAL TRANSMISSION OVERHAUL – Transmission22B-17
(3) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the transmission case at the positions
shown in the illustration.
(4) Install the bearing outer race.
(5) Install the transmission case and tighten the bolts to the
specified torque.
(6) Remove the transmission case. If the solder is not crushed,
repeat the steps (2) through (5) using the solder with
larger diameter.
(7) Measure the thickness of the crushed solder with a
micrometer and select spacers that will provide the
standard end play/preload value.
Standard value:
Input shaft end play 0 – 0.17 mm . . . . . . . . . .
Output shaft end play 0.13 – 0.18 mm . . . . . . . .
Center differential preload 0.05 – 0.11 mm . . . .
REASSEMBLY SERVICE POINTS

AINPUT SHAFT / OUTPUT SHAFT / CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and differential as a unit.

B5TH-REVERSE SPEED SHIFT FORK /
5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
RAIL INSTALLATION
(1) Install the 3rd-4th speed shift rails and fork, and
5th-reverse speed shift rail and fork.
Solders
Solders
Output shaft
Center
differentialInput
shaft
3rd-4th speed
shift fork
5th-reverse
speed shift fork5th-reverse
speed shift rail
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-20
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
1 2
3 4
5 6
79
810
Apply gear oil to all
moving parts before
installation.
21
19
11 12
14
13
15
16
17
18
20
1822
Disassembly steps

M1. Snap ring
A

L2. Ball bearing
B

K3. Thrust plate stopper

J4. Thust plate
C

I5. 5th speed gear
6. 4th speed gear
7. Needle roller bearing
D

H8. 4th speed gear sleeve
9. Synchronizer ring

G10. Synchronizer spring

F11. Synchronizer sleeve
E12. 3rd-4th speed synchronizer hub
13. Outer synchronizer ring

D14. Synchronizer spring
15. Synchronizer cone
16. Inner synchronizer ring
17. 3rd speed gear
18. Needle roller bearing

C19. Snap ring
E

B20. Ball bearing

A21. Oil seal
22. Input shaft

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-21
DISASSEMBLY SERVICE POINTS
A
BALL BEARING REMOVAL
B
THRUST PLATE STOPPER REMOVAL
Using a screwdriver, pry up the position shown in the illustration
and remove the thrust plate stopper.
C
5TH SPEED GEAR REMOVAL
D
4TH SPEED GEAR SLEEVE REMOVAL
Install the special tool to the 3rd speed gear and remove
the 4th speed gear sleeve.
E
BALL BEARING REMOVAL
MD998801
MD998801
MD998801
MD998801

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-22
REASSEMBLY SERVICE POINTS

AOIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.

BBALL BEARING INSTALLATION

CSNAP RING INSTALLATION
Select and install a snap ring so that the input shaft front
bearing end play will have the standard value.
Standard value: 0 – 0.12 mm

DSYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely to the illustrated
position of the outer synchronizer ring.

E3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the synchronizer hub in such a way that it will be oriented
in the direction shown.Oil seal
3.5 mm
MD998801MD998812
MD998813
MD998818
Snap ring
Synchronizer spring
Installation
direction
Identification mark

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-24

I5TH SPEED GEAR INSTALLATION

JTHRUST PLATE INSTALLATION
Select and install a thrust plate so that the input shaft 5th
speed gear clearance will have the standard value.
Standard value: 0 – 0.09 mm
Caution
Install the plate with its identification stamped surface
faced against the thrust plate stopper.

KTHRUST PLATE STOPPER INSTALLATION
Install the thrust plate stopper by pressing the special tools
with hand. Make sure that the stopper is not installed aslant.

LBALL BEARING INSTALLATION

MSNAP RING INSTALLATION
Select and install a snap ring so that the input shaft rear
bearing clearance will have the standard value.
Standard value: 0 – 0.12 mm
MD998801MD998812
MD998813
MD998825
Stamped
surface
Thrust plate
MD998812
MD998813
MD998825
MD998812
MD998819
MD998801
Snap ring

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-25
INSPECTION
INPUT SHAFT
(1) Check the outside diameter of the needle bearing
mounting portion for damage, abnormal wear and seizure.
(2) Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the input shaft and gear are
combined and made to rotate, they rotate smoothly without
looseness and noise.
(2) Check to ensure that the cage is not deformed.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside surface is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance “A”. If “A” is less than the limit, replace.
Limit: 0.5 mm
OUTER SYNCHRONIZER RING / INNER
SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surface and
cone surface are not damaged and broken.
Gear
Synchronizer
ring
Damage, Break
Damage, Break
Damage,
Break

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-27
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
18
19
20 21
22
23
35
1124
10 1213
987654
3
2 1
26
2725
13 14
15
16 172928
3231
36
3433
4 30
Disassembly steps

P1. Snap ring
A

O2. Taper roller bearing
B

N3. Reverse gear bearing sleeve

N4. Needle roller bearing

N5. Reverse gear
6. Synchronizer ring

L7. Synchronizer spring

F8. Synchronizer sleeve
C

M9. 5th-reverse speed synchronizer hub
10. Synchronizer ring

L11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing

K14. 5th speed gear sleeve

J15. 4th speed gear

I16. Snap ring
D

H17. 3rd speed gear
18. 2nd speed gear19. Needle roller bearing
E

G20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring

D24. Synchronizer spring

F25. Synchronizer sleeve

E26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring

D28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing
F

C33. 1st speed gear sleeve
G

B34. Taper roller bearing

A35. Oil seal
36. Output shaft

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-28
DISASSEMBLY SERVICE POINTS
A
TAPER ROLLER BEARING REMOVAL
B
REVERSE GEAR BEARING SLEEVE REMOVAL
Mount a special tool on the reverse gear and remove the
reverse gear bearing sleeve.
C
5TH-REVERSE SPEED SYNCHRONIZER HUB
REMOVAL
Mount a special tool on the 4th speed gear and remove
the 5th-reverse speed synchronizer hub.
D
3RD SPEED GEAR REMOVAL
Mount a special tool on the 2nd speed gear and remove
the 3rd speed gear.
E
2ND SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the 1st speed gear and remove the
2nd speed gear sleeve.Taper roller bearing MD998801
Reverse gear
bearing sleeve MD998801
5th-reverse
speed
synchronizer
hub MD998801
3rd speed gear
MD998917
2nd speed
gear sleeve
MD998917

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-29
F
1ST SPEED GEAR SLEEVE REMOVAL
G
TAPER ROLLER BEARING REMOVAL
REASSEMBLY SERVICE POINTS

AOIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.

BTAPER ROLLER BEARING INSTALLATION

C1ST SPEED GEAR SLEEVE INSTALLATION
1st speed
gear sleeve MD998801
Taper roller bearing
MD998801
Oil seal3.5 mm
Taper roller
bearing MD998801MD998812
MD998819
1st speed
gear sleeve
MD998364
MD998812
MD998814
MD998824