1998 MITSUBISHI LANCER EVOLUTION IV transmission

MANUAL TRANSMISSION – Transmission Assembly22A-7
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Transmission Oil Draining (Refer to P.22A-3.)
(2) Transfer Oil Draining (Refer to P.22A-3.)
(3) Under Cover Removal
(4) Front Exhaust Pipe Removal (Refer to GROUP 15.)
(5) Battery and Battery Tray Removal
(6) Air Cleaner Assembly RemovalPost-installation Operation
(1) Air Cleaner Assembly Installation
(2) Battery and Battery Tray Installation
(3) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(4) Under Cover Installation
(5) Transfer Oil Supplying (Refer to P.22A-3.)
(6) Transmission Oil Supplying (Refer to P.22A-3.)
(7) Shift Lever Operation Check
(8) Speedometer Operation Check
1
2
34 5
6
7
8 8
Unit: Nm {kgfm}
49 {5.0} 98 {10.0}*
88 {9.0}19 {1.9}
48 {4.9}19 {1.9}
Removal steps
1. Shift cable and select cable con-
nection
2. Backup lamp switch connector
3. Vehicle speed sensor connector
A4. Starter motor
5. Clutch release cylinder connection
6. Transmission assembly upper part
coupling bolts7. Transmission mount bracket
8. Transmission mount stopper

Engine assembly supporting
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.

MANUAL TRANSMISSION – Transmission Assembly22A-8
16 18
Unit: Nm {kgfm}
52 {5.3}*
19
17
9
10
12
1315
1214
69 {7.0} 69 {7.0} 15 – 33
{1.5 – 3.4} 39 {4.0}59 – 71
{6.0 – 7.2} 26 – 33
{2.7 – 3.4}48 {4.9}
52 {5.3}*
Lifting up of the vehicle
9. Stabilizer bar connection
10. Wheel speed sensor cable connec-
tion
11. Brake hose clamp
12. Tie rod end connection
13. Lower arm ball joint connection
A
Clutch release bearing connection
14. Centermember assembly
B15. Drive shaft connection
B16. Drive shaft connection

Strut assembly
(Refer to GROUP 33A.)C17. Output shaft

Air hose A
(Refer to GROUP 15 – Intercooler.)
18. Transmission assembly lower part
coupling bolts
19. Transmission assembly
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.

MANUAL TRANSMISSION – Transmission Assembly22A-9
REMOVAL SERVICE POINTS
ACLUTCH RELEASE BEARING SEPARATION
(1) Remove the cover from the service hole in the clutch
housing.
(2) While pushing the release fork by hand in the direction
A, insert a flap-tip screwdriver between the release bearing
and the wedge collar.
Caution
Be sure to push the release fork in the direction A
before inserting a screwdriver.
(3) Separate the release bearing from the wedge collar by
prying with the screwdriver (turning the screwdriver grip
90).
NOTE
The release fork is forced to move fully in the direction
B by the return spring as soon as it is separated from
the wedge collar.
Caution
If it is hard to turn the screwdriver (to pry off the
release bearing), remove the screwdriver once and
repeat the above procedure after pushing the release
fork fully in the direction A two to three times. Forcibly
prying can cause the release bearing to be damaged.
BDRIVE SHAFT / DRIVE SHAFT
DISCONNECTION
(1) To disconnect the left-hand drive shaft, insert a lever
as shown and pry out the shaft from the transmission.
To disconnect the right-hand drive shaft, apply a lever
and a hammer as shown and lever out the shaft from
the transfer assembly using the hammer as a fulcrum.
NOTE
Remove the drive shafts with the hub and knuckle
attached.
Caution
Do not attempt to pull out the drive shaft from the
BJ in this stage since it can cause the TJ to be
damaged. Be sure to remove the drive shaft first from
the transmission side using a lever.
(2) Suspend the removed drive shaft with a wire so that
there are no sharp bends in any of the joints.
COUTPUT SHAFT REMOVAL
(1) Use the special tools (MB991612, MB990211) to remove
the output shaft.
(2) Use a shop towel to cover the transmission case not
to let foreign material get into it.
Service hole
Release fork
Wedge collar
Release bearing
Trans-
mission
side
Lever
Projection
Hammer
Lever
Output shaft
Transmission caseMB990211
MB991612

MANUAL TRANSMISSION – Transfer Assembly22A-10
TRANSFER ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Transmission Oil Draining and Supplying
(Refer to P.22A-3.)

Transfer Oil Draining and Supplying
(Refer to P.22A-3.)
Front Exhaust Pipe Removal and Installation
(Refer to GROUP 15.)
Gear oil:
MITSUBISHI genuine “Dia-Queen
Super” hypoid gear oil (GL-5)
Unit: Nm {kgfm}
2
69 {7.0}
1
Removal steps

Drive shaft (Refer to P.22A-9.)

Output shaft (Refer to P.22A-9.)
1. Front propeller shaft
(Refer to GROUP 25)
A2. Transfer assembly
REMOVAL SERVICE POINT
ATRANSFER ASSEMBLY REMOVAL
Caution
(1) Use care not to damage the lip of the oil seal in the
transfer case.
(2) Use the special tool to cover the opening in the transfer
case to prevent oil from flowing out or foreign materi-
als from entering the case.
Oil seal lip MB991193

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL INFORMATION 2. . . . . . . . . . . . . . . .
SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 4. . . . . . . . . . . . . .
SEALANTS AND ADHESIVES 5. . . . . . . . . . . .
LUBRICANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
SNAP RINGS, SPACERS AND THRUST
PLATES FOR ADJUSTMENT 6. . . . . . . . . . . . .
TORQUE SPECIFICATIONS 9. . . . . . . . . . . . . .
SPECIAL TOOLS 10. . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION 13. . . . . . . . . . . . . . . . . . . . . . .
INPUT SHAFT 20. . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SHAFT 27. . . . . . . . . . . . . . . . . . . . . . .
REVERSE IDLER GEAR 35. . . . . . . . . . . . . . .
SPEEDOMETER GEAR 36. . . . . . . . . . . . . . . .
SELECT LEVER 37. . . . . . . . . . . . . . . . . . . . . . .
CONTROL HOUSING 38. . . . . . . . . . . . . . . . . .
CLUTCH HOUSING 41. . . . . . . . . . . . . . . . . . . .
TRANSMISSION CASE 44. . . . . . . . . . . . . . . . .
CENTER DIFFERENTIAL 46. . . . . . . . . . . . . . .
TRANSFER 49. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL TRANSMISSION OVERHAUL – General Information22B-2
GENERAL INFORMATION
SECTIONAL VIEW – Without Front Limited Slip Differential (Front LSD)

MANUAL TRANSMISSION OVERHAUL – General Information22B-3
SECTIONAL VIEW – With Front Limited Slip Differential (Front LSD)

MANUAL TRANSMISSION OVERHAUL –
Specifications /
Service Specifications22B-4
SPECIFICATIONS
TRANSMISSION MODEL TABLE
Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-1-X6AA29/364.529Not available
W5M51-1-X6A1A29/364.529Available
W5M51-1-X7AA30/364.529Not available
W5M51-1-X7A1A30/364.529Available
W5M51-1-Z6AB29/364.875Not available
W5M51-1-Z6A1B29/364.875Available
W5M51-1-Z7AB30/364.875Not available
W5M51-1-Z7A1B30/364.875Available
GEAR RATIO TABLE
AB
1st2.785←
2nd1.950←
3rd1.4071.444
4th1.0311.096
5th0.7610.825
Reverse3.416←
Transfer gear ratio0.3018←
SERVICE SPECIFICATIONS
ItemsAllowable rangeLimit
Input shaft end play mm0.05 – 0.17–
Input shaft front bearing clearance mm0 – 0.12–
Input shaft rear bearing clearance mm0 – 0.12–
Input shaft 5th speed gear clearance mm0 – 0.09–
Output shaft preload mm0.13 – 0.18–
Output shaft bearing clearance mm0 – 0.09–
Output shaft 3rd speed gear clearance mm0 – 0.09–
Center differential case preload mm0.05 – 0.11–
Center differential case pinion backlash mm0.025 – 0.150–
Synchronizer ring back surface to gear clearance mm–0.5