1998 MITSUBISHI LANCER EVOLUTION IV Workshop Manual

Snap Rings, Spacers and Thrust Plates
for Adjustment MANUAL TRANSMISSION
OVERHAUL –22B-7
Part namePart No. Identification symbol Thickness mm
Thrust plate
(For adj stment of inp t shaft 5th speed gear
3.820MD748465
(For adjustment of input shaft 5th speed gear
clearance)3.862MD748466
3.903MD748467
3.945MD748468
3.986MD748469
4.027MD748470
4.068MD748471
4.109MD748472
Spacer
(For adj stment of o tp t shaft preload)
0.8686MD720938
(For adjustment of output shaft preload)0.8989MD720939
0.9292MD720940
0.9595MD720941
0.9898MD720942
1.0101MD720943
1.0404MD720944
1.0707MD720945
1.10JMD710454
1.13DMD700270
1.16KMD710455
1.19LMD710456
1.22GMD700271
1.25MMD710457
1.28NMD710458
1.31EMD706574
1.34OMD710459
1.37PMD710460
1.40NoneMD706573
1.43QMD710461
1.46RMD710462

Snap Rings, Spacers and Thrust Plates
for Adjustment MANUAL TRANSMISSION
OVERHAUL –22B-8
Part namePart No. Identification symbol Thickness mm
Snap ring
(For adj stment of o tp t shaft bearing clear
1.36YellowMD748449
(For adjustment of output shaft bearing clear-
ance)1.40GreenMD748450
1.44NoneMD746602
1.48BlackMD748451
1.51BlueMD746603
1.55WhiteMD748452
1.58BrownMD746604
1.63OrangeMD748453
1.68BlueMD748454
Snap ring
(For adj stment of o tp t shaft 3rd speed gear
2.81NoneMD746594
(For adjustment of output shaft 3rd speed gear
clearance)2.85BlueMD746595
2.89BrownMD746596
2.93YellowMD746597
2.97GreenMD746598
3.01BlackMD746599
3.05WhiteMD746600
3.09OrangeMD746601
Spacer
(For adj stment of center differential case
0.7474MD727660
(For adjustment of center differential case
preload)0.7777MD754476p
0.8080MD727661
0.8383MD720937
0.8686MD720938
0.8989MD720939
0.9292MD720940
0.9595MD720941
0.9898MD720942
1.0101MD720943
1.0404MD720944
1.0707MD720945
1.10JMD710454
1.13DMD700270
1.16KMD710455

Snap Rings, Spacers and Thrust Plates
for Adjustment / Torque Specifications MANUAL TRANSMISSION
OVERHAUL –22B-9
Part namePart No. Identification symbol Thickness mm
Spacer
(For adj stment of center differential case
1.19LMD710456
(For adjustment of center differential case
preload)1.22GMD700271p
1.25MMD710457
1.28NMD710458
1.31EMD706574
Spacer
(For adj stment of center differential case pinion
0.6–MD748362
(For adjustment of center differential case pinion
backlash)0.7–MD748363
0.8–MD748364
0.9–MD748365
1.0–MD748366
1.1–MD748367
TORQUE SPECIFICATIONS
TRANSMISSION
ItemsNm {kgf
m}
Under cover mounting bolt6.9 {0.7}
Interlock plate bolt30 {3.1}
Clutch housing-transmission case mounting bolt44 {4.5}
Clutch release bearing retainer mounting bolt9.8 {1.0}
Control housing mounting bolt18 {1.9}
Shift cable bracket mounting bolt18 {1.9}
Speedometer gear mounting bolt3.9 {0.4}
Stopper bracket mounting bolt18 {1.9}
Select lever mounting bolt18 {1.9}
Select lever mounting nut11 {1.2}
Center differential drive gear mounting bolt132 {13.5}
Back-up lamp switch32 {3.3}
Poppet spring plug32 {3.3}
Reverse idler gear shaft mounting bolt48 {4.9}
Roll stopper bracket mounting bolt69 {7.0}

Torque Specifications /
Special toolsMANUAL TRANSMISSION OVERHAUL – 22B-10
TRANSFER
ItemsNm {kgf
m}
Transfer cover mounting bolt23 {2.4}
Transmission-transfer mounting bolt69 {7.0}
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bushing
remover & installer
ringInstallation of transfer oil seal
MB990891Bushing remover &
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller bearing
MB990933Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing outer race
MB990937Installer adapterInstallation of differential case taper roller
bearing

MANUAL TRANSMISSION OVERHAUL – Special Tools22B-11
Tool UseName Number
MB990938HandleUse with Installer adapter
MB991445Bushing remover
and installer baseInstallation of differential case taper roller
bearing outer race
MD998304Oil seal installerInstallation of transfer extension housing oil
seal
MD998364Camshaft oil seal
installerInstallation of gear, bearing and sleeve
MD998800Oil seal installerInstallation of differential oil seal and transfer
cover oil seal
MD998801Bearing removerInstallation and removal of gear, bearing and
sleeve
MD998812Installer capUse with Installer and installer adapter
MD998813Installer-100Use with Installer cap and installer adapter
MD998814Installer-200Use with Installer cap and installer adapter

MANUAL TRANSMISSION OVERHAUL – Special Tools22B-12
Tool UseName Number
MD998818Installer adapter
(38)Installation of input shaft front bearing
MD998819Installer adapter
(40)Installation of input shaft rear bearing and
output shaft taper roller bearing
MD998820Installer adapter
(42)Installation of reverse gear bearing sleeve
MD998821Installer adapter
(44)Installation of 4th speed gear, 5th speed gear
sleeve and 5th-reverse speed synchronizer
hub
MD998824Installer adapter
(50)Installation of 1st-2nd speed synchronizer hub,
2nd speed gear sleeve and 3rd speed gear
MD998825Installer adapter
(52)Installation of 1st speed gear sleeve, 3rd-4th
speed synchronizer hub, 4th speed gear
sleeve, 5th speed gear and thrust plate stopper
MD998917Bearing removerRemoval and installation of gear, bearing and
sleeve
MD999566ClawRemoval of taper roller bearing outer race

MANUAL TRANSMISSION OVERHAUL – Transmission22B-13
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
1 2 34 5
6
78
910
11
Unit: Nm {kgf
m}
18 {1.9}
69 {7.0}69 {7.0} 18 {1.9}
69 {7.0}
3.9 {0.4}32 {3.3}32 {3.3}
3
Disassembly steps
1. Transfer

J2. O-ring
3. Roll stopper bracket
4. Insulator washer
5. Shift cable bracket

I6. Select lever
H7. Speedometer gear
8. Back-up lamp switch
9. Gasket
10. Plug
11. Gasket

MANUAL TRANSMISSION OVERHAUL – Transmission22B-14
Apply gear oil to all
moving parts before
installation.
12
13 14
15
1617 18
1920
21
22 23
24
25 26
27
Unit: Nm {kgf
m}
18 {1.9}
30 {3.1}
48 {4.9}
3.9 {0.7} 44 {4.5}
Disassembly steps
12. Interlock plate bolt
13. Gasket

G14. Control housing
15. Neutral return spring

F16. Under cover
17. Reverse idler gear shaft bolt
18. Gasket
19. Reverse idler gear
E20. Transmission case
21. Outer race
22. Outer race

D23. Spacer

D24. Spacer

D25. Spacer
26. Oil guide
27. Oil guide