1998 MITSUBISHI LANCER EVOLUTION IV Workshop Manual

MANUAL TRANSMISSION OVERHAUL – Transmission22B-15
Apply gear oil to all
moving parts before
installation.
2829
3031
32
3334
3536 37
38
39 40
Disassembly steps

C28. Spring pin
29. 1st-2nd speed shift rail
30. 1st-2nd speed shift fork

C31. Spring pin
A

C32. Spring pin
B

B33. 3rd-4th speed shift rail
B

B34. 3rd-4th speed shift forkB

B35. 5th-reverse speed shift rail
B

B36. 5th-reverse speed shift fork
C

A37. Center differential
C

A38. Output shaft
C

A39. Input shaft
40. Clutch housing

MANUAL TRANSMISSION OVERHAUL – Transmission22B-16
DISASSEMBLY SERVICE POINTS
A
SPRING PIN REMOVAL
Shift the 5th-reverse shift fork in the direction shown in the
illustration.
B
3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED
SHIFT FORK / 5TH-REVERSE SPEED SHIFT
RAIL / 5TH-REVERSE SPEED SHIFT FORK
REMOVAL
Pull out the shift rails from the shift rail holes in the clutch
housing.
C
CENTER DIFFERENTIAL / OUTPUT SHAFT /
INPUT SHAFT REMOVAL
Remove the input shaft, output shaft and center differential
together.
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR ADJUSTING INPUT SHAFT
END PLAY / OUTPUT SHAFT PRELOAD /
DIFFERENTIAL PRELOAD
(1) Install the input shaft, output shaft and center differential
as a set to the clutch housing.
(2) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the input shaft rear bearing at the
positions shown in the illustration.
5th-reverse
shift fork
5th-reverse
shift rail3rd-4th
speed
shift rail
Output shaft
Center
differentialInput
shaft
Output shaft
Center
differentialInput
shaft
Solders

MANUAL TRANSMISSION OVERHAUL – Transmission22B-17
(3) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the transmission case at the positions
shown in the illustration.
(4) Install the bearing outer race.
(5) Install the transmission case and tighten the bolts to the
specified torque.
(6) Remove the transmission case. If the solder is not crushed,
repeat the steps (2) through (5) using the solder with
larger diameter.
(7) Measure the thickness of the crushed solder with a
micrometer and select spacers that will provide the
standard end play/preload value.
Standard value:
Input shaft end play 0 – 0.17 mm . . . . . . . . . .
Output shaft end play 0.13 – 0.18 mm . . . . . . . .
Center differential preload 0.05 – 0.11 mm . . . .
REASSEMBLY SERVICE POINTS

AINPUT SHAFT / OUTPUT SHAFT / CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and differential as a unit.

B5TH-REVERSE SPEED SHIFT FORK /
5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
RAIL INSTALLATION
(1) Install the 3rd-4th speed shift rails and fork, and
5th-reverse speed shift rail and fork.
Solders
Solders
Output shaft
Center
differentialInput
shaft
3rd-4th speed
shift fork
5th-reverse
speed shift fork5th-reverse
speed shift rail
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL – Transmission22B-18
(2) Slide the shift rails into the shift rail holes in the clutch
housing.

CSPRING PIN INSTALLATION
Install the spring pin with its slit directed as shown in the
illustration.

DSPACER INSTALLATION
Install the spacer selected in the section “ADJUSTMENT
BEFORE REASSEMBLY”.

ETRANSMISSION CASE INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.

FUNDER COVER INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.
3rd-4th speed
shift rail
5th-reverse
speed shift
rail
Spring pin
Shift rail

2 mm

2 mm

MANUAL TRANSMISSION OVERHAUL – Transmission22B-19

GCONTROL HOUSING INSTALLATION
Apply sealant to the illustrated position of the transmission
case.
Specified sealant: THREEBOND 1216
Caution
Squeeze out the sealant uniformly, while making sure
that it is not broken or excessively applied.

HSPEEDOMETER GEAR INSTALLATION
Apply transmission oil to the O-ring of the speedometer gear.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

ISELECT LEVER INSTALLATION
Apply grease to the control shaft sliding portion of the select
lever shoe.
Specified grease: MOLYWHITE TA No.1 or No.2

JO-RING INSTALLATION
Lubricate O-ring with transmission oil.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W
INSPECTION
BACK-UP LAMP SWITCH
Check for continuity between terminals.
Switch conditionContinuity
PressedNot exist
ReleasedExists

2 mm
Control shaft
Select
lever
shoe

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-20
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
1 2
3 4
5 6
79
810
Apply gear oil to all
moving parts before
installation.
21
19
11 12
14
13
15
16
17
18
20
1822
Disassembly steps

M1. Snap ring
A

L2. Ball bearing
B

K3. Thrust plate stopper

J4. Thust plate
C

I5. 5th speed gear
6. 4th speed gear
7. Needle roller bearing
D

H8. 4th speed gear sleeve
9. Synchronizer ring

G10. Synchronizer spring

F11. Synchronizer sleeve
E12. 3rd-4th speed synchronizer hub
13. Outer synchronizer ring

D14. Synchronizer spring
15. Synchronizer cone
16. Inner synchronizer ring
17. 3rd speed gear
18. Needle roller bearing

C19. Snap ring
E

B20. Ball bearing

A21. Oil seal
22. Input shaft

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-21
DISASSEMBLY SERVICE POINTS
A
BALL BEARING REMOVAL
B
THRUST PLATE STOPPER REMOVAL
Using a screwdriver, pry up the position shown in the illustration
and remove the thrust plate stopper.
C
5TH SPEED GEAR REMOVAL
D
4TH SPEED GEAR SLEEVE REMOVAL
Install the special tool to the 3rd speed gear and remove
the 4th speed gear sleeve.
E
BALL BEARING REMOVAL
MD998801
MD998801
MD998801
MD998801

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-22
REASSEMBLY SERVICE POINTS

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

BBALL BEARING INSTALLATION

CSNAP RING INSTALLATION
Select and install a snap ring so that the input shaft front
bearing end play will have the standard value.
Standard value: 0 – 0.12 mm

DSYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring securely to the illustrated
position of the outer synchronizer ring.

E3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the synchronizer hub in such a way that it will be oriented
in the direction shown.Oil seal
3.5 mm
MD998801MD998812
MD998813
MD998818
Snap ring
Synchronizer spring
Installation
direction
Identification mark