1998 MITSUBISHI LANCER EVOLUTION IV service

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-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 – 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 – Select Lever22B-37
SELECT LEVER
DISASSEMBLY AND REASSEMBLY
1098 7 6
5
4321
Unit: Nm {kgf
m}
11 {1.2}
Disassembly steps

A1. Dust cover
2. Nut
3. Spring washer
4. Washer
5. Select lever bushing6. Select lever shoe
7. Select lever
8. Select lever bushing

A9. Dust cover
10. Select lever shaft
REASSEMBLY SERVICE POINT

ADUST COVER INSTALLATION
Dust cover

MANUAL TRANSMISSION OVERHAUL – Control Housing22B-39
DISASSEMBLY SERVICE POINT
A
LOCK PIN REMOVAL
Drive the lock pin out of position from the direction shown.
REASSEMBLY SERVICE POINTS

ANEEDLE BEARING INSTALLATION
Press fit the needle bearing to the position shown in the
illustration, while making sure that the model number stamped
side is oriented in the direction shown.

BOIL SEAL INSTALLATION
Apply transmission oil to the oil seal lip area.
Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W

CAIR BREATHER INSTALLATION
(1) Apply a sealant to the outside circumference of the
inserting portion.
Specified sealant: THREEBOND 1501
(2) Make sure that the projecting portion is oriented in the
direction shown.
Lock pin
Control
finger
Control
housing
Needle
bearing Model
number
stamped
side
2 mm