1998 MITSUBISHI LANCER EVOLUTION IV clutch

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-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 – 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-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 – Output Shaft22B-34
OUTER SYNCHRONIZER RING / INNER
SYNCHRONIZER RING / SYNCHRONIZER CONE
(1) Check to ensure that the clutch gear tooth surfaces and
cone surfaces are not damaged and broken.
(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.
Damage, Break
Damage, Break
Damage,
Break
Gear
Outer ring
Cone
Inner ring
Sleeve
Hub

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-41
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
4
2
1
3
8 6 7
5*
9.8 {1.0}
Unit: Nm {kgf
m}
Disassembly steps
1. Clutch release bearing retainer

E2. Oil seal
A

D3. Outer race
B

C4. Outer race
B5. Bushing*

A6. Cover-A

A7. Cover-B
8. Clutch housing
NOTE:
*: Never remove the bushings from the clutch housing.
Only the case when installing new bushings into a new clutch housing, refer to
B.

MANUAL TRANSMISSION OVERHAUL – Clutch Housing22B-42
DISASSEMBLY SERVICE POINTS
A
OUTER RACE REMOVAL
B
OUTER RACE REMOVAL
REASSEMBLY SERVICE POINTS

ACOVER-A / COVER-B INSTALLATION
Install the covers directed as shown in the illustration

BBUSHING INSTALLATION
Press fit the bushing to the illustrated position, while making
sure that the split ends of the bushing do not coincide with
the air purge groove.
Outer race
MD999566
MD999566
Cover-B
Cover-A
Bushing
Air purge groove
Bushing
1 mm