1998 MITSUBISHI LANCER EVOLUTION IV 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-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 – 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

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-24

I5TH SPEED GEAR INSTALLATION

JTHRUST PLATE INSTALLATION
Select and install a thrust plate so that the input shaft 5th
speed gear clearance will have the standard value.
Standard value: 0 – 0.09 mm
Caution
Install the plate with its identification stamped surface
faced against the thrust plate stopper.

KTHRUST PLATE STOPPER INSTALLATION
Install the thrust plate stopper by pressing the special tools
with hand. Make sure that the stopper is not installed aslant.

LBALL BEARING INSTALLATION

MSNAP RING INSTALLATION
Select and install a snap ring so that the input shaft rear
bearing clearance will have the standard value.
Standard value: 0 – 0.12 mm
MD998801MD998812
MD998813
MD998825
Stamped
surface
Thrust plate
MD998812
MD998813
MD998825
MD998812
MD998819
MD998801
Snap ring