oil MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION OVERHAUL -Sealants22B-7
SEALANTS
TRANSMISSION
ItemsSpecified sealants
Clutch housing and transmission case contact surfaceMITSUBISHI genuine sealant Part
No MD997740orequivalent
Control housing and transmission case contact surface
No.MD997740or equivalent
Under cover and transmission case contact surface
Air breather3M SUPER WEATHERSTRIP No.8001 or
equivalent
Center differential drive gear bolt3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)
FIPG is used for several members of this transmission. With this gasket, caution is required to the application
amount, application procedure and state of the application surface so that the performance is sufficiently
attained.
If sufficient gasket is not applied, leaks could occur, and if too much is applied, the gasket could protrude
and plug or restrict the oil flow passage. Thus, to prevent leaks from the joined sections, it is absolutely
necessary to evenly apply the correct amount.
DISASSEMBLY
The parts assembled with FIPG can be easily disassembled without special means. However, in some
cases, the sealant on the contact surfaces must be broken by lightly tapping with a wood hammer or
similar tool.
Washing the gasket surface
Completely remove all matters adhered on the contact surfaces with a gasket scraper. Confirm that the
FIPG application surface is smooth. There must be no grease or foreign matter on the contact surfaces.
Always remove the old FIPG that has entered the mounting holes and screw holes.
APPLICATION PROCEDURES
Apply an even coat of FIPG within the predetermined radius (1.5±0.3 mm). Completely cover the areas
around the mounting holds. The FIPG can be wiped off if it has not hardened. Install at the set position
while the FIPG is still wet (within 10 minutes). When installing, make sure that the FIPG does not get
on areas other than the required areas. After installing, do not subject the application areas to oil or
water or start operation until the FIPG has sufficiently hardened (approx. one hour).
The FIPG application procedures differ according to the member, so follow the procedures given in this
manual and apply the FIPG.

MANUAL TRANSMISSION OVERHAUL -Lubricants22B-8
LUBRICANTS
TRANSMISSION
ItemsSpecified lubricants
Drive shaft oil seal lip sectionMITSUBISHI genuine “DIA-QUEEN” multi
gearoil<75W/85W>orequivalent
Input shaft oil seal lip section
gear oil<75W/85W> or equivalent
Control shaft oil seal lip section
Select lever shoeMITSUBISHI genuine grease Part
No.0101011 or equivalent
TRANSFER
ItemsSpecified lubricants
Drive shaft oil seal lip sectionMITSUBISHI genuine “DIA-QUEEN
SUPER”hypoidgearoil(GL 5)or
Front differential oil seal lip section
SUPER”hypoidgear oil(GL-5)or
equivalent
Each O-ring

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 -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-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-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 -Output Shaft22B-29
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
32
Apply gear oil on
all sliding sections
before installing.
36
23
30
33
3526
29
34
282524
31
1613107
118
965
34
1
42 21
22
1727
1213
15 14201918
Disassembly steps
"PA1. Snap ring
AA""OA2. Taper roller bearing
AB""NA3. Reverse gear sleeve
"NA4. Needle roller bearing
"NA5. Reverse gear
6. Synchronizer ring
"LA7. Synchronizer spring
"FA8. Synchronizer sleeve
AC""MA9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"LA11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
"KA14. 5th speed gear sleeve
"JA15. 4th speed gear
"IA16. Snap ring
AD""HA17. 3rd speed gear
18. 2nd speed gear19. Needle roller bearing
AE""GA20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring
"DA24. Synchronizer spring
"FA25. Synchronizer sleeve
"EA26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring
"DA28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing
AF""CA33. 1st speed gear sleeve
AG""BA34. Taper roller bearing
"AA35. Oil seal
36. Output shaft