MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-35
"PASNAP RING INSTALLATION
Select and install the snap ring onto the output shaft so that
the output shaft rear bearing clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
INSPECTION
OUTPUT SHAFT
Check the spline for damage and wear.
NEEDLE BEARING
(1) When the needle bearing is assembled with the bearing
sleeve and gear 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
Snap ring
Gear“A”
Synchronizer
ring

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-36
OUTER SYNCHRONIZER RING, INNER
SYNCHRONIZER RING AND SYNCHRONIZER CONE
(1) The gear teeth and cone surface must not be damaged
or broken.
(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.
Gear
“A”
Inner ringOuter ring
Cone

MANUAL TRANSMISSION OVERHAUL -Reverse Idler Gear22B-37
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil on
all sliding sections
before installing.
7653
41
2
Disassembly steps
1. Snap ring
2. Cone spring
3. Thrust washer
4. Steel ball5. Reverse idler gear
6. Needle roller bearing
7. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) When the needle bearing is assembled with the shaft
and gear and rotated, the needle bearing must rotate
smoothly without play or abnormal noise.
(2) The holder must not be deformed.

MANUAL TRANSMISSION OVERHAUL -Speedometer Gear22B-38
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil on
all sliding sections
before installing.
34
2
1
Disassembly steps
1. e-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve

MANUAL TRANSMISSION OVERHAUL -Select Lever22B-39
SELECT LEVER
DISASSEMBLY AND REASSEMBLY
3
4 6
1 5
2 7
8
9
10
11±1N•m
Disassembly steps
"AA1. Dust cover
2. Nut
3. Spring washer
4. Plane washer
5. Select lever bush6. Select lever shoe
7. Select lever
8. Select lever bush
"AA9. Dust cover
10. Select lever shaft
REASSEMBLY SERVICE POINT
"AADUST COVER INSTALLATION
Install the dust cover onto the select lever.
Dust
cover

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-40
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
16107
11
8
9
6
5
3 41
2
17 1213
15 14
18
18±3N•m
Disassembly steps
AA""FA1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate
"EA7. Spring pin
"DA8. Spring pin
9. Stopper body10. Neutral return spring
11. Control shaft
"CA12. Air breather
13. Control shaft boot
"BA14. Oil seal
"AA15. Needle bearing
16. Spring washer
17. Stopper bracket
18. Control housing

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-41
DISASSEMBLY SERVICE POINT
AA"LOCK PIN REMOVAL
Tap out the lock pin from the direction shown in the illustration.
REASSEMBLY SERVICE POINTS
"AANEEDLE BEARING INSTALLATION
Press the needle bearing into the dimensions shown in the
illustration so that the type stamp side faces the indicated
direction.
"BAOIL SEAL INSTALLATION
Apply transmission oil on the oil seal lip section.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"CAAIR BREATHER INSTALLATION
(1) Apply sealant on the periphery of the insertion section.
Sealant
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or
equivalent
(2) Install so that the protrusion faces the direction shown
in the illustration.
Lock pin
Control
finger
Control
housing
Needle
bearing
2mm Type
stamp
side

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-42
"DASPRING PIN INSTALLATION
Install the spring pin onto the stopper body from the direction
shown in the illustration.
"EASPRING PIN INSTALLATION
Install the spring pin onto the stopper body.
"FALOCK PIN INSTALLATION
Tap the lock pin into the control finger from the direction
shown in the illustration.Control shaftStopper body
Installation
direction
Slit
Spring
pin
Spring pin
45_
Lock pin
Control finger

MANUAL TRANSMISSION OVERHAUL -Clutch Housing22B-43
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
7
5*3
6
4
2
18
9.8±2N•m
Disassembly steps
1. Clutch release bearing retainer
"EA2. Oil seal
AA""DA3. Outer race
AB""CA4. Outer race"BA5. Bush*
"AA6. Cover A
"AA7. Cover B
8. Clutch housing
NOTE
*: Refer to the installation procedures only when replacing the clutch housing.
DISASSEMBLY SERVICE POINTS
AA"OUTER RACE REMOVAL
Using the special tool, remove the outer race from the clutch
housing.MD999566

MANUAL TRANSMISSION OVERHAUL -Clutch Housing22B-44
AB"OUTER RACE REMOVAL
Using the special tool, remove the outer race from the clutch
housing.
REASSEMBLY SERVICE POINTS
"AACOVER A/COVER B INSTALLATION
Install each cover onto the clutch housing in the direction
shown in the illustration.
"BABUSH INSTALLATION
Press the bush into the clutch housing to the position shown
in the illustration. Make sure that the split face of the bush
does not cover the air bleeding groove on the housing.
"CAOUTER RACE INSTALLATION
Using the special tool, install the outer race onto the clutch
housing.
MD999566
Cover A
Cover B
Air bleeding groove
Bush
Bush
1mm
MB990938
MB990935