transmission MITSUBISHI LANCER EVOLUTION IV 1998 Repair Manual

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-41
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
4
2
1
3
8 6 7
5*
9.8 {1.0}
Unit: Nm {kgf
m}
Disassembly steps
1. Clutch release bearing retainer

E2. Oil seal
A

D3. Outer race
B

C4. Outer race
B5. Bushing*

A6. Cover-A

A7. Cover-B
8. Clutch housing
NOTE:
*: Never remove the bushings from the clutch housing.
Only the case when installing new bushings into a new clutch housing, refer to
B.

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 – Clutch Housing22B-43

COUTER RACE INSTALLATION

DOUTER RACE INSTALLATION

EOIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W
MB990935
MB990938
MB991445MB990938
MB990928
MB990938

MANUAL TRANSMISSION OVERHAUL – Transmission Case22B-44
TRANSMISSION CASE
DISASSEMBLY AND REASSEMBLY
4 3*2*1
Disassembly steps

C1. Oil seal

B2. Needle bearing*

A3. Bushing*
4. Transmission case
NOTE:
*: Never remove the bearing and bushing from the transmission case.
Only the case when installing new bearing and bushing into a new transmission case, refer to
A
and
B.

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 – Center Differential22B-48
(5) Install the front output shaft to the side gear and fit the
snap ring.
(6) Attach the spacer on the other side gear, then install
the side gear in the center differential case.
NOTE
If a new side gear is to be installed, select a spacer
with medium thickness (0.8 – 0.9 mm).
(7) Install the center differential flange on the case while
aligning the mating marks, then secure it temporarily with
machine screw.
(8) Measure the backlash between the side gear and the
pinion.
Standard value: 0.025 – 0.150 mm
(9) If the measurement deviates from the standard value,
correct the backlash using a spacer of different thickness
and check it again.
NOTE
The backlash must be the same on both sides.

DCENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
(1) Apply sealant to the entire threaded portion of the bolt.
Specified sealant:
THREEBOND 1303 or LOKTITE 648
(2) Tighten the bolts to the specified torque in the illustrated
sequence.
1
8
7
6
5
4
3
2
10
9

MANUAL TRANSMISSION OVERHAUL – Transfer22B-49
TRANSFER
DISASSEMBLY AND REASSEMBLY
10 2
114
8
7
9
5
3
1
6
Apply gear oil to all
moving parts before
installation.
23 {2.4}
Unit: Nm {kgf
m}
Disassembly steps

F1. Air breather
2. Dust seal guard

E3. Oil seal

D4. Oil seal

A5. O-ring

A6. O-ring

C7. Oil seal

B8. Oil seal

A9. O-ring
10. Transfer cover
11. Transfer

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