manual transmission MITSUBISHI LANCER EVOLUTION IV 1998 Owner's Manual

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}

Torque Specifications /
Special toolsMANUAL TRANSMISSION OVERHAUL – 22B-10
TRANSFER
ItemsNm {kgf
m}
Transfer cover mounting bolt23 {2.4}
Transmission-transfer mounting bolt69 {7.0}
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bushing
remover & installer
ringInstallation of transfer oil seal
MB990891Bushing remover &
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller bearing
MB990933Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing outer race
MB990937Installer adapterInstallation of differential case taper roller
bearing

MANUAL TRANSMISSION OVERHAUL – Special Tools22B-11
Tool UseName Number
MB990938HandleUse with Installer adapter
MB991445Bushing remover
and installer baseInstallation of differential case taper roller
bearing outer race
MD998304Oil seal installerInstallation of transfer extension housing oil
seal
MD998364Camshaft oil seal
installerInstallation of gear, bearing and sleeve
MD998800Oil seal installerInstallation of differential oil seal and transfer
cover oil seal
MD998801Bearing removerInstallation and removal of gear, bearing and
sleeve
MD998812Installer capUse with Installer and installer adapter
MD998813Installer-100Use with Installer cap and installer adapter
MD998814Installer-200Use with Installer cap and installer adapter

MANUAL TRANSMISSION OVERHAUL – Special Tools22B-12
Tool UseName Number
MD998818Installer adapter
(38)Installation of input shaft front bearing
MD998819Installer adapter
(40)Installation of input shaft rear bearing and
output shaft taper roller bearing
MD998820Installer adapter
(42)Installation of reverse gear bearing sleeve
MD998821Installer adapter
(44)Installation of 4th speed gear, 5th speed gear
sleeve and 5th-reverse speed synchronizer
hub
MD998824Installer adapter
(50)Installation of 1st-2nd speed synchronizer hub,
2nd speed gear sleeve and 3rd speed gear
MD998825Installer adapter
(52)Installation of 1st speed gear sleeve, 3rd-4th
speed synchronizer hub, 4th speed gear
sleeve, 5th speed gear and thrust plate stopper
MD998917Bearing removerRemoval and installation of gear, bearing and
sleeve
MD999566ClawRemoval of taper roller bearing outer race

MANUAL TRANSMISSION OVERHAUL – Transmission22B-13
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
1 2 34 5
6
78
910
11
Unit: Nm {kgf
m}
18 {1.9}
69 {7.0}69 {7.0} 18 {1.9}
69 {7.0}
3.9 {0.4}32 {3.3}32 {3.3}
3
Disassembly steps
1. Transfer

J2. O-ring
3. Roll stopper bracket
4. Insulator washer
5. Shift cable bracket

I6. Select lever
H7. Speedometer gear
8. Back-up lamp switch
9. Gasket
10. Plug
11. Gasket

MANUAL TRANSMISSION OVERHAUL – Transmission22B-14
Apply gear oil to all
moving parts before
installation.
12
13 14
15
1617 18
1920
21
22 23
24
25 26
27
Unit: Nm {kgf
m}
18 {1.9}
30 {3.1}
48 {4.9}
3.9 {0.7} 44 {4.5}
Disassembly steps
12. Interlock plate bolt
13. Gasket

G14. Control housing
15. Neutral return spring

F16. Under cover
17. Reverse idler gear shaft bolt
18. Gasket
19. Reverse idler gear
E20. Transmission case
21. Outer race
22. Outer race

D23. Spacer

D24. Spacer

D25. Spacer
26. Oil guide
27. Oil guide

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-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 – 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