service MITSUBISHI LANCER EVOLUTION IV 1998 Repair Manual

MANUAL TRANSMISSION – On-vehicle Service22A-3
ON-VEHICLE SERVICE
1. TRANSMISSION OIL CHECK
(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 Nm {3.3 kgfm}
2. TRANSMISSION OIL REPLACEMENT
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transmission oil
Specified oil:
MITSUBISHI genuine “Dia-Queen” multi gear oil
<75W/85W>
Quantity: 2.8 dm
3 (2.8
)
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
3. TRANSFER OIL CHECK
(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 Nm {3.3 kgfm}
4. TRANSFER OIL REPLACEMENT
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transfer oil
Specified oil:
MITSUBISHI genuine “Dia-Queen Super” hypoid
gear oil (GL-5)
Quantity: 0.62 dm
3 (0.62
)
(4) Tighten the filler plug to the specified torque.
Tightening torque: 32 Nm {3.3 kgfm}
Transmission oilFiller plug hole
Filler plug
Drain plug
Filler plug
Drain plug
Transfer oil

MANUAL TRANSMISSION – Transmission Control22A-5
INSTALLATION SERVICE POINTS
ASHIFT CABLE AND SELECT CABLE ASSEMBLY
/ SHIFT CABLE CONNECTION / SELECT CABLE
CONNECTION
(1) Set the transmission side shift lever and the passenger
compartment side shift lever to the neutral position.
(2) For the transmission side, the white and yellow paint
marks on the shift and select cable ends should face
the snap pins.
(3) Move the shift lever to all positions and check that the
operation is smooth.
BNUT / SPRING WASHER / SHIFT KNOB
INSTALLATION
(1) Screw in the nut all the way by hand, turn back half
a turn, and then insert the spring washer.
(2) Screw in the shift knob until it touches the spring washer,
and make one more turn. Then turn more to adjust the
shift pattern on the shift knob.
(3) If the above steps are impossible, you can turn back
the shift knob by one turn at most after screwing in all
the way to adjust the shift pattern.Shift lever
Neutral position

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

MANUAL TRANSMISSION – Transfer Assembly22A-10
TRANSFER ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Transmission Oil Draining and Supplying
(Refer to P.22A-3.)

Transfer Oil Draining and Supplying
(Refer to P.22A-3.)
Front Exhaust Pipe Removal and Installation
(Refer to GROUP 15.)
Gear oil:
MITSUBISHI genuine “Dia-Queen
Super” hypoid gear oil (GL-5)
Unit: Nm {kgfm}
2
69 {7.0}
1
Removal steps

Drive shaft (Refer to P.22A-9.)

Output shaft (Refer to P.22A-9.)
1. Front propeller shaft
(Refer to GROUP 25)
A2. Transfer assembly
REMOVAL SERVICE POINT
ATRANSFER ASSEMBLY REMOVAL
Caution
(1) Use care not to damage the lip of the oil seal in the
transfer case.
(2) Use the special tool to cover the opening in the transfer
case to prevent oil from flowing out or foreign materi-
als from entering the case.
Oil seal lip MB991193

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 –
Specifications /
Service Specifications22B-4
SPECIFICATIONS
TRANSMISSION MODEL TABLE
Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-1-X6AA29/364.529Not available
W5M51-1-X6A1A29/364.529Available
W5M51-1-X7AA30/364.529Not available
W5M51-1-X7A1A30/364.529Available
W5M51-1-Z6AB29/364.875Not available
W5M51-1-Z6A1B29/364.875Available
W5M51-1-Z7AB30/364.875Not available
W5M51-1-Z7A1B30/364.875Available
GEAR RATIO TABLE
AB
1st2.785←
2nd1.950←
3rd1.4071.444
4th1.0311.096
5th0.7610.825
Reverse3.416←
Transfer gear ratio0.3018←
SERVICE SPECIFICATIONS
ItemsAllowable rangeLimit
Input shaft end play mm0.05 – 0.17–
Input shaft front bearing clearance mm0 – 0.12–
Input shaft rear bearing clearance mm0 – 0.12–
Input shaft 5th speed gear clearance mm0 – 0.09–
Output shaft preload mm0.13 – 0.18–
Output shaft bearing clearance mm0 – 0.09–
Output shaft 3rd speed gear clearance mm0 – 0.09–
Center differential case preload mm0.05 – 0.11–
Center differential case pinion backlash mm0.025 – 0.150–
Synchronizer ring back surface to gear clearance mm–0.5

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-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