1998 MITSUBISHI LANCER EVOLUTION IV Workshop Manual

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-23
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.

FSYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
(2) When the synchronizer sleeve is installed, make sure
that the deep groove portion of the synchronizer hub
is aligned with the projecting portion of the sleeve.

GSYNCHRONIZER SPRING INSTALLATION

H4TH SPEED GEAR SLEEVE INSTALLATION
MD998801MD998812
MD998813
MD998825
Identification groove
Installation
direction
Synchronizer sleeve projections
Synchronizer hub
deep grooves
Synchronizer spring
MD998801MD998812
MD998813
MD998825

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

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-25
INSPECTION
INPUT SHAFT
(1) Check the outside diameter of the needle bearing
mounting portion for damage, abnormal wear and seizure.
(2) Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the input shaft and gear are
combined and made to rotate, they rotate smoothly without
looseness and noise.
(2) Check to ensure that the cage is not deformed.
SYNCHRONIZER RING
(1) Check to ensure that the clutch gear tooth surfaces are
not damaged and broken.
(2) Check to ensure that the cone inside surface is not
damaged or worn and that the threads are not crushed.
(3) Press the synchronizer ring against the gear and check
clearance “A”. If “A” is less than the limit, replace.
Limit: 0.5 mm
OUTER SYNCHRONIZER RING / INNER
SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surface and
cone surface are not damaged and broken.
Gear
Synchronizer
ring
Damage, Break
Damage, Break
Damage,
Break

MANUAL TRANSMISSION OVERHAUL – Input Shaft22B-26
(2) Install the outer ring, inner ring and cone, press them
against the gear, and check clearance “A”. If “A” is less
than the limit, replace.
Limit: 0.5 mm
Caution
When any of the outer ring, inner ring or cone has
to be replaced, replace them as a set.
SYNCHRONIZER SLEEVE AND HUB
(1) Check to ensure that when the synchronizer sleeve and
hub are combined and made to slide, they slide smoothly
without binding.
(2) Check to ensure that the front and rear ends of the sleeve
inside surface are not damaged.
Caution
When replacement of either the synchronizer sleeve
or hub is necessary, make sure that the synchronizer
sleeve and hub are replaced as a set.
SYNCHRONIZER SPRING
Check to ensure that the spring is not sagging, deformed
or broken.
SPEED GEARS
(1) Check to ensure that the helical and clutch gear tooth
surfaces are not damaged or worn.
(2) Check to ensure that the synchronizer cone surfaces
are not roughened, damaged or worn.
(3) Check to ensure that the gear inside diameter and front
and rear surfaces are not damaged and worn.
Outer ring
Cone
Inner ring
Sleeve
Hub

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-27
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
18
19
20 21
22
23
35
1124
10 1213
987654
3
2 1
26
2725
13 14
15
16 172928
3231
36
3433
4 30
Disassembly steps

P1. Snap ring
A

O2. Taper roller bearing
B

N3. Reverse gear bearing sleeve

N4. Needle roller bearing

N5. Reverse gear
6. Synchronizer ring

L7. Synchronizer spring

F8. Synchronizer sleeve
C

M9. 5th-reverse speed synchronizer hub
10. Synchronizer ring

L11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing

K14. 5th speed gear sleeve

J15. 4th speed gear

I16. Snap ring
D

H17. 3rd speed gear
18. 2nd speed gear19. Needle roller bearing
E

G20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring

D24. Synchronizer spring

F25. Synchronizer sleeve

E26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring

D28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing
F

C33. 1st speed gear sleeve
G

B34. Taper roller bearing

A35. Oil seal
36. Output shaft

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 – Output Shaft22B-30

DSYNCHRONIZER SPRING INSTALLATION

E1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 1st-2nd speed synchronizer hub in such a way
that it will be oriented in the direction shown.
Caution
When the hub is installed, make sure that the synchronizer
ring is not caught.

FSYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve in such a way that it will
be oriented in the direction shown.
(2) When the synchronizer sleeve is installed, make sure
that the deep groove portion of the synchronizer hub
is aligned with the projecting portion of the sleeve.
Synchronizer spring
Installation
direction
1st-2nd speed
synchronizer
hub
MD998364MD998824
MD998812
MD998814
Identification groove
Installation
direction
Synchronizer sleeve projections
Synchronizer hub deep grooves