transmission MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION OVERHAUL -Transmission22B-19
(3) Set solder (10 mm long, 1.6 mm diameter) on the
transmission case at the position shown in the illustration.
(4) Install the outer race onto the transmission case.
(5) Install the transmission case, and tighten the bolt with
the specified torque.
(6) If the solder has not been crushed, carry out steps (2) to (5) with
solder having a larger diameter.
(7) Using a micrometer, measure the thickness of the crushed solder,
and select a spacer so that the end play and preload are at the
standard values.
Standard value:
Input shaft end play
0.05mm loose to 0.17mm loose
Output shaft preload
0.13mm tight to 0.18mm tight
Center differential preload
0.05mm tight to 0.11mm tight
REASSEMBLY SERVICE POINTS
"AAINPUT SHAFT/OUTPUT SHAFT/CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and center differential onto
the clutch housing at the same time.
"BA5TH-REVERSE SPEED SHIFT
FORK/5TH-REVERSE SPEED SHIFT
RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH
SPEED SHIFT RAIL INSTALLATION
(1) Assemble the 3rd-4th speed shift rail, fork and the
5th-reverse speed shift rail and fork.
Solder
Solder
Output shaft
Center differentialInput
shaft
3rd-4th speed
shift rail
5th-reverse
speed shift rail 5th-reverse
speed shift
fork
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL -Transmission22B-20
(2) Slide each shift rail in the direction shown in the illustration,
and then install onto the shift rail hole on the clutch
housing.
"CASPRING PIN INSTALLATION
Install the spring pin onto the shift rail so that the slit faces
the direction shown in the illustration.
"DASPACER INSTALLATION
Install the spacer selected in the section “Adjustment before
reassembly”.
"EATRANSMISSION CASE INSTALLATION
Apply sealant at the positions of the transmission case shown
in the illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
"FAUNDER COVER INSTALLATION
Apply sealant at the positions of the transmission case shown in the
illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
3rd-4th speed
shift rail
5th-reverse
speed shift rail
Spring pin
Shift rail

MANUAL TRANSMISSION OVERHAUL -Transmission22B-21
"GACONTROL HOUSING INSTALLATION
Apply sealant at the positions of the transmission case shown
in the illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
"HASPEEDOMETER GEAR INSTALLATION
Apply transmission oil on the O-ring for the speedometer
gear.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"IASELECT LEVER INSTALLATION
Apply grease on the sliding section of the select lever shoe’s
control shaft.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011 or
equivalent
"JAO-RING INSTALLATION
Apply transmission oil on the O-ring.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
INSPECTION
BACKUP LIGHT SWITCH
Check the continuity between the terminals.
ItemsContinuity
Switch pressedContinuity not established
Switch releasedContinuity established
Control shaft
Select
lever
shoe

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-22
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
2
81
Apply gear oil on
all sliding sections
before installing.
13
1911 12
18
10 1514
21
22 201716
4
3
5 6
7
9
18
Disassembly steps
"MA1. Snap ring
AA""LA2. Ball bearing
AB""KA3. Thrust plate stopper
"JA4. Thrust plate
AC""IA5. 5th speed gear
6. 4th speed gear
7. Needle roller bearing
AD""HA8. 4th speed gear sleeve
9. Synchronizer ring
"GA10. Synchronizer spring
"FA11. Synchronizer sleeve"EA12. 3rd-4th speed synchronizer hub
13. Outer synchronizer ring
"DA14. Synchronizer spring
15. Synchronizer cone
16. Inner synchronizer ring
17. 3rd speed gear
18. Needle roller bearing
"CA19. Snap ring
AE""BA20. Ball bearing
"AA21. Oil seal
22. Input shaft

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-23
DISASSEMBLY SERVICE POINTS
AA"BALL BEARING REMOVAL
Using the special tool, remove the ball bearing from the input
shaft.
AB"THRUST PLATE STOPPER REMOVAL
Using a screwdriver, lift the stopper at the position shown
in the illustration, and remove the thrust plate stopper.
AC"5TH SPEED GEAR REMOVAL
Using the special tool, remove the 5th speed gear from the
input shaft.
AD"4TH SPEED GEAR SLEEVE REMOVAL
Install the special tool on the 3rd speed gear, and remove
the 4th speed gear sleeve from the input shaft.
AE"BALL BEARING REMOVAL
Using the special tool, remove the ball bearing from the input
shaft.
MD998801
MD998801
MD998801
MD998801

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-24
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
Accurately tap in the oil seal to the dimensions shown in
the illustration.
"BABALL BEARING INSTALLATION
Using the special tool, install the ball bearing onto the input
shaft.
"CASNAP RING INSTALLATION
Select and install the snap ring so that the input shaft front
bearing clearance is at the standard value.
Standard value: 0.01 mm tight to 0.12 mm loose
"DASYNCHRONIZER SPRING INSTALLATION
Accurately install the synchronizer spring onto the position
of the synchronizer ring shown in the illustration.
"EA3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 3rd-4th speed synchronizer hub onto the input
shaft at the direction shown in the illustration.Oil seal3.5 mm
MD998812
MD998813
MD998818 MD998801
Snap ring
Synchronizer spring
Identification mark3rd
speed
side
4th speed
side Installation
direction

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-25
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 3rd speed gear
rotates smoothly.
"FASYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve onto the input shaft at
the direction shown in the illustration.
(2) Align the synchronizer hub deep grooves with the sleeve
protrusions and install.
"GASYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring onto the input shaft.
"HA4TH SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 4th speed gear sleeve onto
the input shaft.
MD998812
MD998813
MD998825 MD998801
3rd
speed
side4th
speed
side
Installation
directionIdentification
groove
Synchronizer sleeve protrusion section
Synchronizer
hub deep
groove section
Synchronizer spring
MD998812
MD998813
MD998825 MD998801

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-26
"IA5TH SPEED GEAR INSTALLATION
Using the special tool, install the 5th speed gear onto the
input shaft.
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 4th speed gear
rotates smoothly.
"JATHRUST PLATE INSTALLATION
Select and install the thrust plate onto the input shaft so
that the input shaft 5th speed gear clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
Caution
Assemble the side with the identification stamp facing the
thrust plate stopper side.
"KATHRUST PLATE STOPPER INSTALLATION
Press the special tool by hand, and accurately fit the thrust
plate stopper onto the input shaft so that it is not inclined.
"LABALL BEARING INSTALLATION
Using the special tool, install the ball bearing onto the input
shaft.
"MASNAP RING INSTALLATION
Select and install the snap ring onto the input shaft so that
the input shaft rear bearing clearance is at the standard value.
Standard value: 0.01 mm tight to 0.12 mm looseMD998812
MD998813
MD998825 MD998801
Thrust
plateStamped
surface
MD998812
MD998813
MD998825
MD998801MD998812
MD998819
Snap
ring

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-27
INSPECTION
INPUT SHAFT
(1) There must be no damage, abnormal wear or seizure
on the outer diameter of the needle bearing installation
section.
(2) Check the spline for damage and wear.
NEEDLE BEARING
(1) When the needle bearing is assembled with the input
shaft and gears and rotated, the needle bearing must
rotate smoothly without play or abnormal noise.
(2) The holder must not be deformed.
SYNCHRONIZER RING
(1) The clutch gear teeth must not be damaged or broken.
(2) The inner diameter of the cone must not be damaged
or worn, and the screw threads must not be crushed.
(3) Press the synchronizer ring against the gears, and check
the clearance “A”. Replace if “A” is less than the limit
value.
Limit value: 0.5 mm
OUTER SYNCHRONIZER RING, INNER
SYNCHRONIZER RING AND SYNCHRONIZER CONE
(1) The gear teeth and cone surface must not be damaged
or broken.
Gear“A”
Synchronizer
ring

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-28
(2) Assemble the outer ring, inner ring and cone. Press
against the gears and check the clearance “A”. Replace
if “A” is less than the limit value.
Limit value: 0.5 mm
Caution
When replacing, replace the outer ring, inner ring and
cone as a set.
SYNCHRONIZER SLEEVE AND HUB
(1) When the synchronizer sleeve and hub are assembled
and slid, the parts should slide without catching.
(2) There must be no damage on the front and back ends
of the sleeve’s inner surface.
SYNCHRONIZER SPRING
The spring must not be weak, deformed or broken.
EACH SPEED GEAR
(1) None of the helical gears or clutch gear teeth must be
damaged or worn.
(2) The synchronizer cone surface must not be rough,
damaged or worn.
(3) The inner diameter and front/back surfaces of the gear
must not be damaged or worn.“A”
Outer ring
Cone
Inner ring