manual transmission MITSUBISHI LANCER EVOLUTION IV 1998 Service Manual

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-29
F
1ST SPEED GEAR SLEEVE REMOVAL
G
TAPER ROLLER BEARING REMOVAL
REASSEMBLY SERVICE POINTS

AOIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown
in the illustration.

BTAPER ROLLER BEARING INSTALLATION

C1ST SPEED GEAR SLEEVE INSTALLATION
1st speed
gear sleeve MD998801
Taper roller bearing
MD998801
Oil seal3.5 mm
Taper roller
bearing MD998801MD998812
MD998819
1st speed
gear sleeve
MD998364
MD998812
MD998814
MD998824

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-30

DSYNCHRONIZER SPRING INSTALLATION

E1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 1st-2nd speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.

FSYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
(2) When the synchronizer sleeve is installed, make sure
that the deep groove portion of the synchronizer hub
is aligned with the projecting portion of the sleeve.
Synchronizer spring
Installation
direction
1st-2nd speed
synchronizer
hub
MD998364MD998824
MD998812
MD998814
Identification groove
Installation
direction
Synchronizer sleeve projections
Synchronizer hub deep grooves

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-31

G2ND SPEED GEAR SLEEVE INSTALLATION

H3RD SPEED GEAR INSTALLATION

ISNAP RING INSTALLATION
Select and install a snap ring so that the output shaft 3rd
speed gear clearance will have the standard value.
Standard value: 0 – 0.09 mm

J4TH SPEED GEAR INSTALLATION

K5TH SPEED GEAR SLEEVE INSTALLATION
2nd speed
gear sleeve
MD998364MD998824
MD998812
MD998814
3rd speed gear
MD998364MD998824
MD998812
MD998814
Snap ring
4th speed
gear
MD998364
MD998812
MD998813
MD998821
5th speed
gear sleeve
MD998364
MD998812
MD998813
MD998821

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-32

LSYNCHRONIZER SPRING INSTALLATION

M5TH-REVERSE SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 5th-reverse speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.

NREVERSE GEAR / NEEDLE ROLLER BEARING /
REVERSE GEAR BEARING SLEEVE
INSTALLATION

OTAPER ROLLER BEARING INSTALLATION
Synchronizer spring
Installation
direction
5th-reverse speed
synchronizer hub
MD998364
MD998812
MD998813
MD998821
Reverse gear
Reverse gear
bearing sleeve
MD998364
MD998812
MD998820
Taper roller
bearing
MD998364
MD998812
MD998819

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-33

PSNAP RING INSTALLATION
Select and install a snap ring so that the output shaft rear
bearing clearance will have the standard value.
Standard value: 0 – 0.09 mm
INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the bearing sleeve and gear
are combined and made to rotate, they rotate smoothly
without looseness and noise.
(2) Check the cage for deformation.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside diameter is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance “A”. If “A” is less than the limit, replace.
Limit: 0.5 mm
Snap ring
Gear
Synchronizer
ring

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-34
OUTER SYNCHRONIZER RING / INNER
SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surfaces and
cone surfaces are not damaged and broken.
(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
than the limit, replace.
Limit: 0.5 mm
Caution
When any of the outer ring, inner ring or cone has
to be replaced, replace them as a set.
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
Caution
When replacement of either the synchronizer sleeve
or hub is necessary, make sure that the synchronizer
sleeve and hub are replaced as a set.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces
are not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Damage, Break
Damage, Break
Damage,
Break
Gear
Outer ring
Cone
Inner ring
Sleeve
Hub

MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear22B-35
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
5
4321
TFM0807
Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the shaft and gear are combined
and made to rotate, they rotate smoothly without looseness
and noise.
(2) Check to ensure that the cage is not deformed.

MANUAL TRANSMISSION OVERHAUL – Speedometer Gear22B-36
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
4
3 2
1
TFM0593
Disassembly steps
1. e-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve

MANUAL TRANSMISSION OVERHAUL – Select Lever22B-37
SELECT LEVER
DISASSEMBLY AND REASSEMBLY
1098 7 6
5
4321
Unit: Nm {kgf
m}
11 {1.2}
Disassembly steps

A1. Dust cover
2. Nut
3. Spring washer
4. Washer
5. Select lever bushing6. Select lever shoe
7. Select lever
8. Select lever bushing

A9. Dust cover
10. Select lever shaft
REASSEMBLY SERVICE POINT

ADUST COVER INSTALLATION
Dust cover

MANUAL TRANSMISSION OVERHAUL – Control Housing22B-38
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
5
4
32 169 7
8
10 11 12
1314
15
16
17 19
18
Unit: Nm {kgf
m}
18 {1.9}
Disassembly steps
A

F1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate

E7. Spring pin

D8. Spring pin
9. Stopper body
10. Neutral return spring11. Spacer
12. Control shaft

C13. Air breather
14. Control shaft boot

B15. Oil seal

A16. Needle bearing
17. Spring washer
18. Stopper bracket
19. Control housing