1998 MITSUBISHI LANCER EVOLUTION IV bearing

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 – 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-32

LSYNCHRONIZER SPRING INSTALLATION

M5TH-REVERSE SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 5th-reverse 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.

NREVERSE GEAR / NEEDLE ROLLER BEARING /
REVERSE GEAR BEARING SLEEVE
INSTALLATION

OTAPER ROLLER BEARING INSTALLATION
Synchronizer spring
Installation
direction
5th-reverse speed
synchronizer hub
MD998364
MD998812
MD998813
MD998821
Reverse gear
Reverse gear
bearing sleeve
MD998364
MD998812
MD998820
Taper roller
bearing
MD998364
MD998812
MD998819

MANUAL TRANSMISSION OVERHAUL – Output Shaft22B-33

PSNAP RING INSTALLATION
Select and install a snap ring so that the output shaft rear
bearing clearance will have the standard value.
Standard value: 0 – 0.09 mm
INSPECTION
OUTPUT SHAFT
Check the splines for damage and wear.
NEEDLE ROLLER BEARING
(1) Check to ensure that when the bearing sleeve and gear
are combined and made to rotate, they rotate smoothly
without looseness and noise.
(2) Check the cage for deformation.
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 diameter 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
Snap ring
Gear
Synchronizer
ring

MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear22B-35
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil to all
moving parts before
installation.
5
4321
TFM0807
Disassembly steps
1. Snap ring
2. Thrust washer
3. Reverse idler gear
4. Needle roller bearing
5. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) Check to ensure that when the 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.

MANUAL TRANSMISSION OVERHAUL – Control Housing22B-38
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
5
4
32 169 7
8
10 11 12
1314
15
16
17 19
18
Unit: Nm {kgf
m}
18 {1.9}
Disassembly steps
A

F1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate

E7. Spring pin

D8. Spring pin
9. Stopper body
10. Neutral return spring11. Spacer
12. Control shaft

C13. Air breather
14. Control shaft boot

B15. Oil seal

A16. Needle bearing
17. Spring washer
18. Stopper bracket
19. Control housing