service MITSUBISHI LANCER EVOLUTION IV 1998 Repair Manual

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-28
DISASSEMBLY SERVICE POINTS
A
TAPER ROLLER BEARING REMOVAL
B
REVERSE GEAR BEARING SLEEVE REMOVAL
Mount a special tool on the reverse gear and remove the
reverse gear bearing sleeve.
C
5TH-REVERSE SPEED SYNCHRONIZER HUB
REMOVAL
Mount a special tool on the 4th speed gear and remove
the 5th-reverse speed synchronizer hub.
D
3RD SPEED GEAR REMOVAL
Mount a special tool on the 2nd speed gear and remove
the 3rd speed gear.
E
2ND SPEED GEAR SLEEVE REMOVAL
Mount a special tool on the 1st speed gear and remove the
2nd speed gear sleeve.Taper roller bearing MD998801
Reverse gear
bearing sleeve MD998801
5th-reverse
speed
synchronizer
hub MD998801
3rd speed gear
MD998917
2nd speed
gear sleeve
MD998917

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 – 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-39
DISASSEMBLY SERVICE POINT
A
LOCK PIN REMOVAL
Drive the lock pin out of position from the direction shown.
REASSEMBLY SERVICE POINTS

ANEEDLE BEARING INSTALLATION
Press fit the needle bearing to the position shown in the
illustration, while making sure that the model number stamped
side is oriented in the direction shown.

BOIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

CAIR BREATHER INSTALLATION
(1) Apply a sealant to the outside circumference of the
inserting portion.
Specified sealant: THREEBOND 1501
(2) Make sure that the projecting portion is oriented in the
direction shown.
Lock pin
Control
finger
Control
housing
Needle
bearing Model
number
stamped
side
2 mm

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-42
DISASSEMBLY SERVICE POINTS
A
OUTER RACE REMOVAL
B
OUTER RACE REMOVAL
REASSEMBLY SERVICE POINTS

ACOVER-A / COVER-B INSTALLATION
Install the covers directed as shown in the illustration

BBUSHING INSTALLATION
Press fit the bushing to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
the air purge groove.
Outer race
MD999566
MD999566
Cover-B
Cover-A
Bushing
Air purge groove
Bushing
1 mm

MANUAL TRANSMISSION OVERHAUL – Transmission Case22B-45
REASSEMBLY SERVICE POINTS

ABUSHING INSTALLATION
Press fit the bushing to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
the air purge groove.

BNEEDLE BEARING INSTALLATION
Press fit the needle bearing until it is flush with the case,
while making sure that the model number stamped side is
oriented in the direction shown.

COIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85WAir purge groove
Bushing
Bushing
3 mm
Needle bearing Model No.
stamped surface
MD998800

MANUAL TRANSMISSION OVERHAUL – Center Differential22B-46
CENTER DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
5
43
21
6
1516177
8
910
11
12 13 14 121112
9
12
Apply gear oil to all
moving parts before
installation.
132 {13.5}
Unit: Nm {kgf
m}
Disassembly steps

D1. Center differential drive gear

C2. Center differential flange
A

B3. Taper roller bearing

C4. Snap ring

C5. Front output shaft

C6. Spacer

C7. Side gear

C8. Lock pin

C9. Pinion shaft
C10. Pinion shaft holder

C11. Pinion

C12. Washer

C13. Side gear

C14. Spacer
B

A15. Taper roller bearing
16. Speedometer drive gear
17. Differential case
DISASSEMBLY SERVICE POINTS
A
TAPER ROLLER BEARING REMOVAL
Use the special tool to remove the taper roller bearing.MD998917

MANUAL TRANSMISSION OVERHAUL – Center Differential22B-47
B
TAPER ROLLER BEARING REMOVAL
Use the special tools to remove the taper roller bearing.
REASSEMBLY SERVICE POINTS

ATAPER ROLLER BEARING INSTALLATION
Use the special tool to install the taper roller bearing.

BTAPER ROLLER BEARING INSTALLATION
Use the special tools to install the taper roller bearing.

CSPACER / SIDE GEAR / WASHER /
PINION/PINION HOLDER / PINION SHAFT /
LOCK PIN / FRONT OUTPUT SHAFT / SNAP
RING / CENTER DIFFERENTIAL FLANGE
INSTALLATION
(1) Install the side gear in the center differential case with
the spacer attached.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).
(2) Fit the washer on the back of each pinion. Engage the
4 pinions simultaneously in the side gear.
Rotate the gears to place them in position, then install
the pinion shaft holder.
(3) Insert the pinion shafts.
(4) Install the lock pins in the illustrated direction.
MD998917
MB990932
MB990937
MD998812
MD998823
Lock pin Differential case
Pinion shaft

MANUAL TRANSMISSION OVERHAUL – Transfer22B-50
REASSEMBLY SERVICE POINTS

AO-RING INSTALLATION
Apply transmission oil to the O-ring.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

BOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

COIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

DOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.

EOIL SEAL INSTALLATION
(1) Apply transmission oil to the oil seal lip area.
Transmission oil:
DIA QUEEN MULTI-GEAR OIL 75W/85W
(2) By using the special tool, install the oil seal.
MD998800
MB990938
MB990933
MB990891
MB990887
MD998304

26-1
FRONT AXLE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . AXLE HUB AND KNUCKLE 3. . . . . . . . . . . . . .