transmission MITSUBISHI LANCER EVOLUTION 2007 Service Owners Manual

MANUAL TRANSMISSION OVERHAUL -Snap Rings, Spacers and Thrust
Plates for Adjustment22B-9
SNAP RINGS, SPACERS AND THRUST PLATES FOR ADJUSTMENT
SPACERS (FOR ADJUSTMENT OF INPUT SHAFT END PLAY)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.34
1.43
1.5234
43
52MD723600
MD723603
MD7236061.61
1.70
1.7961
70
79MD723609
MD756760
MD756763
SNAP RINGS (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.43
1.51Green, two pieces
White, two piecesMD746708
MD7467091.59Yellow, two piecesMD746710
SNAP RINGS (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.44
1.51None
BlueMD746602
MD7466031.58BrownMD746604
THRUST PLATES (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
3.82
3.86
3.90
3.940
2
3
5MD748465
MD748466
MD748467
MD7484683.98
4.02
4.06
4.106
7
8
9MD748469
MD748470
MD748471
MD748472
SPACERS (FOR ADJUSTMENT OF OUTPUT SHAFT PRELOAD)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.86
0.89
0.92
0.95
0.98
1.01
1.04
1.07
1.10
1.13
1.1686
89
92
95
98
01
04
07
J
D
KMD720938
MD720939
MD720940
MD720941
MD720942
MD720943
MD720944
MD720945
MD710454
MD700270
MD7104551.19
1.22
1.25
1.28
1.31
1.34
1.37
1.40
1.43
1.46L
G
M
N
E
O
P
None
Q
RMD710456
MD700271
MD710457
MD710458
MD706574
MD710459
MD710460
MD706573
MD710461
MD710462

MANUAL TRANSMISSION OVERHAUL -Snap Rings, Spacers and Thrust
Plates for Adjustment22B-10
SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT BEARING CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.36
1.40
1.44
1.48
1.51Yellow
Green
None
Black
BlueMD748449
MD748450
MD746602
MD748451
MD7466031.55
1.58
1.63
1.68White
Brown
Orange
BlueMD748452
MD746604
MD748453
MD748454
SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
2.81
2.85
2.89
2.93None
Blue
Brown
YellowMD746594
MD746595
MD746596
MD7465972.97
3.01
3.05
3.09Green
Black
White
OrangeMD746598
MD746599
MD746600
MD746601
SPACERS (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.74
0.77
0.80
0.83
0.86
0.89
0.92
0.95
0.98
1.0174
77
80
83
86
89
92
95
98
01MD727660
MD754476
MD727661
MD720937
MD720938
MD720939
MD720940
MD720941
MD720942
MD7209431.04
1.07
1.10
1.13
1.16
1.19
1.22
1.25
1.28
1.3104
07
J
D
K
L
G
M
N
EMD720944
MD750945
MD710454
MD700270
MD710455
MD710456
MD700271
MD710457
MD710458
MD706547
SPACERS (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PINION
BACKLASH)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.6
0.7
0.8-
-
-MD748362
MD748363
MD7483640.9
1.0
1.1-
-
-MD748365
MD748366
MD748367

MANUAL TRANSMISSION OVERHAUL -Tightening Torque22B-11
TIGHTENING TORQUE
TRANSMISSION
ItemsTightening torque N•m
Under cover mounting bolt6.9±1
Interlock plate bolt30±3
Clutch housing and transmission case tightening bolt44±5
Clutch release bearing retainer mounting bolt9.8±2
Control housing mounting bolt18±3
Shift cable bracket mounting bolt18±3
Speedometer gear mounting bolt3.9±1
Stopper bracket mounting bolt18±3
Select lever mounting bolt18±3
Select lever mounting nut11±1
Center differential drive gear mounting bolt132±5
Backup light switch32±2
Poppet spring32±2
Reverse idler gear shaft mounting bolt48±5
Roll stopper bracket mounting bolt69±9
TRANSFER
ItemsTightening torque N•m
Transfer cover mounting bolt23±3
Transmission and transfer tightening bolt69±9

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-12
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bush remover
and installer ringInstallation of transfer oil seal
MB990891Bush remover and
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller
bearing
MB990936Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing
MB990937Installer adapterInstallation of differential case taper roller
bearing and transfer extention housing oil
seal
MB990938HandleUse for installer adaptor
MB991445Bush remover and
installer baseInstallation of differential case taper roller
bearing outer race

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-13
Tool UseName Number
MD998364Camshaft oil seal
installerInstallation of each gear, bearing and sleeve
MD998800Oil seal installerInstallation of differential oil seal and transfer
cover oil seal
MD998801Bearing removerInstallation and removal of each gear, bearing
and sleeve
MD998812Installer capUse for installer and installer adaptor
MD998813Installer 100Use for installer cap and installer adaptor
MD998814Installer 200Use for installer cap and installer adaptor
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

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-14
Tool UseName Number
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 removerInstallation and removal of each gear, bearing
and sleeve
MD999566ClawRemoval of taper roller bearing outer race

MANUAL TRANSMISSION OVERHAUL -Transmission22B-15
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
3
69±9N•m18±3N•m
69±9N•m18±3N•m
69±9N•m 32±2N•m
32±2N•m
3.9±1N•m
6
2
37
8 59
110
4
Disassembly steps
1. Transfer
2. O-ring
3. Roll stopper bracket
4. Shift cable bracket
5. Select lever"JA6. Speedometer gear
7. Backup light switch
8. Gasket
"IA9. Poppet spring
"HA10. Gasket

MANUAL TRANSMISSION OVERHAUL -Transmission22B-16
18±3N•m
6.9±1N•m 48±5N•m 30±3N•m
44±5N•m
20
Apply gear oil on
all sliding sections
before installing.
2113
14
11
12
19
1716
18
15 25
23
22
2426
Disassembly steps
11. Interlock plate bolt
12. Gasket
"GA13. Control housing
14. Neutral return spring
"FA15. Under cover
16. Reverse idler shaft bolt
17. Gasket
18. Reverse idler gear"EA19. Transmission case
20. Outer race
21. Outer race
"DA22. Spacer
"DA23. Spacer
"DA24. Spacer
25. Oil guide
26. Oil guide

MANUAL TRANSMISSION OVERHAUL -Transmission22B-17
29
Apply gear oil on
all sliding sections
before installing.
36
3230
28
35
38 37 3927
34 33
31
Disassembly steps
"CA27. Spring pin
28. 1st-2nd speed shift rail
29. 1st-2nd speed shift fork
"CA30. Spring pin
AA""CA31. Spring pin
AB""BA32. 3rd-4th speed shift rail
AB""BA33. 3rd-4th speed shift forkAB""BA34. 5th-reverse speed shift rail
AB""BA35. 5th-reverse speed shift fork
AC""AA36. Center differential
AC""AA37. Output shaft
AC""AA38. Input shaft
39. Clutch housing

MANUAL TRANSMISSION OVERHAUL -Transmission22B-18
DISASSEMBLY SERVICE POINTS
AA"SPRING PIN REMOVAL
Shift the 5th-reverse speed shift fork in the direction shown
in the illustration, and remove the spring pin.
AB"3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/5TH-REVERSE SPEED SHIFT
RAIL/5TH-REVERSE SPEED SHIFT FORK
REMOVAL
(1) Move each shift rail in the direction shown in the illustration,
and remove from the shift rail hole on the clutch housing.
(2) Remove each shift rail and shift fork as a set.
AC"CENTER DIFFERENTIAL/OUTPUT SHAFT/INPUT
SHAFT REMOVAL
Remove the input shaft, output shaft and center differential
from the clutch housing at the same time.
ADJUSTMENT BEFORE REASSEMBLY
SELECTION OF INPUT SHAFT END PLAY/OUTPUT
SHAFT END PLAY/OUTPUT SHAFT PRELOAD AND
CENTER DIFFERENTIAL PRELOAD ADJUSTMENT
SPACER
(1) Install the input shaft, output shaft and center differential
onto the clutch housing at the same time.
(2) Set solder (approx. 10 mm long, 1.6 mm diameter) on
the input shaft rear bearing at the position shown in the
illustration.
5th-reverse
speed shift
fork
3rd-4th speed
shift rail
5th-reverse
speed shift rail
Output shaft
Center differentialInput
shaft
Output shaft
Center differentialInput
shaft
Solder