MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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

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

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-30
DISASSEMBLY SERVICE POINTS
AA"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the output shaft.
AB"REVERSE GEAR BEARING SLEEVE REMOVAL
Install the special tool on the reverse gear, and remove the
reverse gear bearing sleeve from the output shaft.
AC"5TH-REVERSE SPEED SYNCHRONIZER HUB
REMOVAL
Install the special tool on the 4th speed gear, and remove
5th-reverse synchronizer hub.
AD"3RD SPEED GEAR REMOVAL
Install the special tool on the 2nd speed gear, and remove
the 3rd speed gear.
AE"2ND SPEED GEAR SLEEVE REMOVAL
Install the special tool on the 1st speed gear, and remove
the 2nd speed gear sleeve.
MD998801Taper roller
bearing
MD998801
Sleeve
MD998801Synchronizer hub
MD9988013rd speed gear
MD998801
Sleeve

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-31
AF"1ST SPEED GEAR SLEEVE REMOVAL
Using the special tool, remove the 1st speed gear sleeve
from the output shaft.
AG"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the output shaft.
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
Accurately tap in the oil seal to the dimensions shown in
the illustration.
"BATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the roller bearing onto the output
shaft.
"CA1ST SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 1st speed gear sleeve onto
the output shaft.
MD998801
Sleeve
MD998801Taper roller
bearing
Oil seal3.5 mm
MD998801MD998812
MD998819
Taper roller
bearing
MD998364SleeveMD998812
MD998814
MD998824

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-32
"DASYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring at the position shown in the
illustration.
"EA1ST-2ND SPEED SYNCHRONIZER HUB
Using the special tool, install the 1st-2nd speed synchronizer
hub onto the output shaft in the direction shown in the
illustration.
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 1st speed gear
rotates smoothly.
"FASYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve onto the output shaft at
the direction shown in the illustration.
(2) Align the synchronizer hub deep grooves with the sleeve
protrusions and install onto the output shaft.
Synchronizer
spring
2nd
speed
side 1st
speed
side
Installation
direction
MD998364 Synchronizer hubMD998812
MD998814
MD998824
Identification
groove2nd
speed
side 1st
speed
side
Installation
direction
Synchronizer sleeve protrusion section
Synchronizer hub deep groove section

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-33
"GA2ND SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 2nd speed gear sleeve onto
the output shaft.
"HA3RD SPEED GEAR INSTALALTION
Using the special tool, install the 3rd speed gear onto the
output shaft.
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 2nd speed gear
rotates smoothly.
"IASNAP RING INSTALLATION
Select and install the snap ring onto the output shaft so that
the output shaft 3rd speed gear clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
"JA4TH SPEED GEAR INSTALLATION
Using the special tool, install the 4th speed gear onto the
output shaft.
"KA5TH SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 5th speed gear sleeve onto
the output shaft.
MD998364SleeveMD998812
MD998814
MD998824
MD998364 3rd speed gearMD998812
MD998814
MD998824
Snap ring
MD998364 4th speed gearMD998812
MD998813
MD998821
MD998364SleeveMD998812
MD998813
MD998821

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-34
"LASYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring at the position shown in the
illustration.
"MA5TH-REVERSE SPEED SYNCHRONIZER HUB
INSTALLATION
Using the special tool, install the 5th-reverse synchronizer
hub onto the output shaft in the direction shown in the
illustration.
Caution
After assembling, confirm that the 5th speed gear rotates
smoothly.
Caution
Press in so that the synchronizer ring does not bite in.
"NAREVERSE GEAR/NEEDLE ROLLER
BEARING/REVERSE GEAR BEARING SLEEVE
INSTALLATION
Using the special tool, install the reverse gear/needle roller
bearing/reverse gear bearing sleeve onto the output shaft.
"OATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing onto
the output shaft.
Synchronizer
spring
Reverse
side 5th
speed
side
Installation
direction
MD998364 Synchronizer hubMD998812
MD998813
MD998821
MD998364 Reverse gearMD998812
MD998820
Sleeve
MD998364MD998812
MD998819