differential MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

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 – General Information22B-2
GENERAL INFORMATION
SECTIONAL VIEW – Without Front Limited Slip Differential (Front LSD)

MANUAL TRANSMISSION OVERHAUL – General Information22B-3
SECTIONAL VIEW – With Front Limited Slip Differential (Front LSD)

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 – 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.

Lubricants / Snap Rings, Spacers
and Thrust Plates for Adjustment MANUAL TRANSMISSION
OVERHAUL –22B-6
LUBRICANTS
TRANSMISSION
ItemsSpecified lubricants
Drive shaft oil seal lip areaDIA QUEEN MULTI-GEAR OIL 75W/85W
(Transmission oil)
Input shaft oil seal lip area
(Transmission oil)
Control shaft oil seal lip area
Select lever shoeMOLYWHITE TA No.1 or No.2
TRANSFER
ItemsSpecified lubricants
Drive shaft oil seal lip areaDIA QUEEN MULTI-GEAR OIL 75W/85W
(Transmission oil)
Front differential oil seal lip area
(Transmission oil)
O-rings
SNAP RINGS, SPACERS AND THRUST PLATES FOR
ADJUSTMENT
Part nameThickness mmIdentification symbolPart No.
Spacer
(For adj stment of inp t shaft end pla )
1.3434MD723600
(For adjustment of input shaft end play)1.4343MD723603
1.5252MD723606
1.6161MD723609
1.7070MD756760
1.7979MD756763
Snap ring
(For adj stment of inp t shaft front bearing
1.43Green (2)MD746708
(For adjustment of input shaft front bearing
clearance)1.51White (2)MD746709
1.59Yellow (2)MD746710
Snap ring
(For adj stment of inp t shaft rear bearing
1.44NoneMD746602
(For adjustment of input shaft rear bearing
clearance)1.51BlueMD746603
1.58BrownMD746604

Snap Rings, Spacers and Thrust Plates
for Adjustment MANUAL TRANSMISSION
OVERHAUL –22B-8
Part namePart No. Identification symbol Thickness mm
Snap ring
(For adj stment of o tp t shaft bearing clear
1.36YellowMD748449
(For adjustment of output shaft bearing clear-
ance)1.40GreenMD748450
1.44NoneMD746602
1.48BlackMD748451
1.51BlueMD746603
1.55WhiteMD748452
1.58BrownMD746604
1.63OrangeMD748453
1.68BlueMD748454
Snap ring
(For adj stment of o tp t shaft 3rd speed gear
2.81NoneMD746594
(For adjustment of output shaft 3rd speed gear
clearance)2.85BlueMD746595
2.89BrownMD746596
2.93YellowMD746597
2.97GreenMD746598
3.01BlackMD746599
3.05WhiteMD746600
3.09OrangeMD746601
Spacer
(For adj stment of center differential case
0.7474MD727660
(For adjustment of center differential case
preload)0.7777MD754476p
0.8080MD727661
0.8383MD720937
0.8686MD720938
0.8989MD720939
0.9292MD720940
0.9595MD720941
0.9898MD720942
1.0101MD720943
1.0404MD720944
1.0707MD720945
1.10JMD710454
1.13DMD700270
1.16KMD710455

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