clutch MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

MANUAL TRANSMISSION – Transmission Assembly22A-8
16 18
Unit: Nm {kgfm}
52 {5.3}*
19
17
9
10
12
1315
1214
69 {7.0} 69 {7.0} 15 – 33
{1.5 – 3.4} 39 {4.0}59 – 71
{6.0 – 7.2} 26 – 33
{2.7 – 3.4}48 {4.9}
52 {5.3}*
Lifting up of the vehicle
9. Stabilizer bar connection
10. Wheel speed sensor cable connec-
tion <Vehicles with ABS>
11. Brake hose clamp
12. Tie rod end connection
13. Lower arm ball joint connection
A
Clutch release bearing connection
14. Centermember assembly
B15. Drive shaft <LH> connection
B16. Drive shaft <RH> connection

Strut assembly <LH>
(Refer to GROUP 33A.)C17. Output shaft

Air hose A
(Refer to GROUP 15 – Intercooler.)
18. Transmission assembly lower part
coupling bolts
19. Transmission assembly
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.

MANUAL TRANSMISSION – Transmission Assembly22A-9
REMOVAL SERVICE POINTS
ACLUTCH RELEASE BEARING SEPARATION
(1) Remove the cover from the service hole in the clutch
housing.
(2) While pushing the release fork by hand in the direction
A, insert a flap-tip screwdriver between the release bearing
and the wedge collar.
Caution
Be sure to push the release fork in the direction A
before inserting a screwdriver.
(3) Separate the release bearing from the wedge collar by
prying with the screwdriver (turning the screwdriver grip
90).
NOTE
The release fork is forced to move fully in the direction
B by the return spring as soon as it is separated from
the wedge collar.
Caution
If it is hard to turn the screwdriver (to pry off the
release bearing), remove the screwdriver once and
repeat the above procedure after pushing the release
fork fully in the direction A two to three times. Forcibly
prying can cause the release bearing to be damaged.
BDRIVE SHAFT <LH> / DRIVE SHAFT <RH>
DISCONNECTION
(1) To disconnect the left-hand drive shaft, insert a lever
as shown and pry out the shaft from the transmission.
To disconnect the right-hand drive shaft, apply a lever
and a hammer as shown and lever out the shaft from
the transfer assembly using the hammer as a fulcrum.
NOTE
Remove the drive shafts with the hub and knuckle
attached.
Caution
Do not attempt to pull out the drive shaft from the
BJ in this stage since it can cause the TJ to be
damaged. Be sure to remove the drive shaft first from
the transmission side using a lever.
(2) Suspend the removed drive shaft with a wire so that
there are no sharp bends in any of the joints.
COUTPUT SHAFT REMOVAL
(1) Use the special tools (MB991612, MB990211) to remove
the output shaft.
(2) Use a shop towel to cover the transmission case not
to let foreign material get into it.
Service hole
Release fork
Wedge collar
Release bearing
Trans-
mission
side
Lever
Projection
Hammer
Lever
Output shaft
Transmission caseMB990211
MB991612

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION 2. . . . . . . . . . . . . . . .
SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 4. . . . . . . . . . . . . .
SEALANTS AND ADHESIVES 5. . . . . . . . . . . .
LUBRICANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
SNAP RINGS, SPACERS AND THRUST
PLATES FOR ADJUSTMENT 6. . . . . . . . . . . . .
TORQUE SPECIFICATIONS 9. . . . . . . . . . . . . .
SPECIAL TOOLS 10. . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION 13. . . . . . . . . . . . . . . . . . . . . . .
INPUT SHAFT 20. . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SHAFT 27. . . . . . . . . . . . . . . . . . . . . . .
REVERSE IDLER GEAR 35. . . . . . . . . . . . . . .
SPEEDOMETER GEAR 36. . . . . . . . . . . . . . . .
SELECT LEVER 37. . . . . . . . . . . . . . . . . . . . . . .
CONTROL HOUSING 38. . . . . . . . . . . . . . . . . .
CLUTCH HOUSING 41. . . . . . . . . . . . . . . . . . . .
TRANSMISSION CASE 44. . . . . . . . . . . . . . . . .
CENTER DIFFERENTIAL 46. . . . . . . . . . . . . . .
TRANSFER 49. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL TRANSMISSION OVERHAUL – Sealants and Adhesives22B-5
SEALANTS AND ADHESIVES
TRANSMISSION
ItemsSpecified sealants and adhesives
Clutch housing-transmission case mating surfaceTHREEBOND 1216
Control housing-transmission case mating surface
Under cover-transmission case mating surface
Air breatherTHREEBOND 1501
Center differential drive gear boltTHREEBOND 1303 or LOKTITE 648
TRANSFER
ItemsSpecified sealants and adhesives
Air breatherTHREEBOND 1501
FORM-IN-PLACE GASKET
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that
the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
SURFACE PREPARATION
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 10 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

Snap Rings, Spacers and Thrust Plates
for Adjustment / Torque Specifications MANUAL TRANSMISSION
OVERHAUL –22B-9
Part namePart No. Identification symbol Thickness mm
Spacer
(For adj stment of center differential case
1.19LMD710456
(For adjustment of center differential case
preload)1.22GMD700271p
1.25MMD710457
1.28NMD710458
1.31EMD706574
Spacer
(For adj stment of center differential case pinion
0.6–MD748362
(For adjustment of center differential case pinion
backlash)0.7–MD748363
0.8–MD748364
0.9–MD748365
1.0–MD748366
1.1–MD748367
TORQUE SPECIFICATIONS
TRANSMISSION
ItemsNm {kgf
m}
Under cover mounting bolt6.9 {0.7}
Interlock plate bolt30 {3.1}
Clutch housing-transmission case mounting bolt44 {4.5}
Clutch release bearing retainer mounting bolt9.8 {1.0}
Control housing mounting bolt18 {1.9}
Shift cable bracket mounting bolt18 {1.9}
Speedometer gear mounting bolt3.9 {0.4}
Stopper bracket mounting bolt18 {1.9}
Select lever mounting bolt18 {1.9}
Select lever mounting nut11 {1.2}
Center differential drive gear mounting bolt132 {13.5}
Back-up lamp switch32 {3.3}
Poppet spring plug32 {3.3}
Reverse idler gear shaft mounting bolt48 {4.9}
Roll stopper bracket mounting bolt69 {7.0}

MANUAL TRANSMISSION OVERHAUL – Transmission22B-15
Apply gear oil to all
moving parts before
installation.
2829
3031
32
3334
3536 37
38
39 40
Disassembly steps

C28. Spring pin
29. 1st-2nd speed shift rail
30. 1st-2nd speed shift fork

C31. Spring pin
A

C32. Spring pin
B

B33. 3rd-4th speed shift rail
B

B34. 3rd-4th speed shift forkB

B35. 5th-reverse speed shift rail
B

B36. 5th-reverse speed shift fork
C

A37. Center differential
C

A38. Output shaft
C

A39. Input shaft
40. Clutch housing

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-18
(2) Slide the shift rails into the shift rail holes in the clutch
housing.

CSPRING PIN INSTALLATION
Install the spring pin with its slit directed as shown in the
illustration.

DSPACER INSTALLATION
Install the spacer selected in the section “ADJUSTMENT
BEFORE REASSEMBLY”.

ETRANSMISSION CASE INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.

FUNDER COVER INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.
3rd-4th speed
shift rail
5th-reverse
speed shift
rail
Spring pin
Shift rail

2 mm

2 mm

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 – Input Shaft22B-26
(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
than the limit, replace.
Limit: 0.5 mm
Caution
When any of the outer ring, inner ring or cone has
to be replaced, replace them as a set.
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
Caution
When replacement of either the synchronizer sleeve
or hub is necessary, make sure that the synchronizer
sleeve and hub are replaced as a set.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces
are not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Outer ring
Cone
Inner ring
Sleeve
Hub