1999 MITSUBISHI LANCER EVOLUTION VI Workshop Manual

CLUTCH – On-vehicle Service21A-3
4. Measure the clutch pedal play.
Standard value (B): 1 – 3 mm
5. If the clutch pedal play is not within the standard value,
loosen the setting nut and move the push rod to adjust.
Caution
Do not push in the master cylinder push rod at this
time.
6. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6–13 mm
Standard value (D): 85 mm or more
7. If the clutch pedal free play and the distance between
the clutch pedal and the toeboard when the clutch is
disengaged do not agree with the standard values, it
is probably the result of either air in the hydraulic system
or a faulty master cylinder or clutch. Bleed the air, or
disassembly and inspect the master cylinder or clutch.
8. Turn back the carpet, etc.
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
Clutch pedal clevis pin play
B
Clutch pedal free play
Distance between the clutch pedal and the
toeboard when the clutch is disengagedC
D

CLUTCH – Clutch Pedal21A-4
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P. 21A-2.)
13 Nm
1
14 13
12 2
818
911
3
10
13 Nm
29 Nm
19
64
7
12 Nm
5
517
15 16 12
Removal steps
1. Clutch master cylinder installation
nut
2. Master cylinder member bracket
installation bolt
3. Clevis pin
4. Pedal support member and clutch
pedal assembly
5. Split pin
6. Clevis pin
7. Bushing
8. Rod A9. Rod B
10. Turn over spring
11. Bolt
12. Bushing
13. Pipe
14. Clutch pedal
15. Pedal pad
16. Stopper
17. Adjusting bolt
18. Locking nut
19. Pedal support member

CLUTCH – Clutch Control21A-5
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation

Clutch Fluid Draining

Air Cleaner RemovalPost-installation Operation

Air Cleaner Installation

Clutch Fluid Supplying

Clutch Line Bleeding (Refer to P.21A-3.)

Clutch Pedal Adjustment (Refer to P. 21A-2.)
15 Nm
Specified grease:
MITSUBISHI genuine grease
Part No. 0101011
56 8
7
6
1
4
13 Nm
15 Nm
15 Nm
19 Nm
5
15 Nm
3
2
7
Release
fork
Clutch master cylinder removal
steps
1. Clevis pin
2. Clutch pipe connection
3. Clutch master cylinder
Clutch release cylinder removal
steps
4. Clutch pipe connection
5. Clutch release cylinderClutch line removal steps
6. Clutch pipe
7. Hose clip
8. Clutch hose

CLUTCH – Clutch Control21A-6
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
13 Nm
6 7
3
1
2
Piston repair kitClutch fluid:
Brake fluid DOT3 or DOT4
Grease: Rubber grease
2 5
4
413
44 8
Disassembly steps
1. Piston stopper ring
A2. Push rod assembly
3. Boot
4. Piston assembly
5. Reservoir cap
6. Spring pin
7. Reservoir tank
8. Clutch master cylinder bodyCaution
Do not disassemble piston assembly.
INSTALLATION SERVICE POINT
APUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of the clutch pedal easier.
122.5 mm

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 4. . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH HOUSING 5. . . . . . . . . . . . . . . . . . . . . .
REVERSE IDLER GEAR 6. . . . . . . . . . . . . . . . .

MANUAL TRANSMISSION OVERHAUL – General22B-2
GENERAL
OUTLINE OF CHANGE
Of the newly introduced transmission model, the service procedures for the following unit sections are
described.

Transmission

Clutch housing

Reverse idler gear

MANUAL TRANSMISSION OVERHAUL – Specifications22B-3
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
W5M51-1-X6A2B29/364.529Not available
W5M51-1-X6A3B29/364.529Available
W5M51-1-X7A2B30/364.529Not available
W5M51-1-X7A3B30/364.529Available

Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-2-X6AA29/364.529Not available
W5M51-2-X6A1A29/364.529Available
W5M51-2-Z6AB29/364.875Not available
W5M51-2-X6A2B29/364.529Not available
W5M51-2-Z6A1B29/364.875Available
W5M51-2-X6A3B29/364.529Available

Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-2-X6A4A29/364.529Not available
W5M51-2-X6A6B29/364.529Not available
W5M51-2-Z6AB29/364.875Not available
W5M51-2-X6A8A29/364.529Available
W5M51-2-Z6A7B29/364.529Available
W5M51-2-X6A1B29/364.875Available

MANUAL TRANSMISSION OVERHAUL – Transmission22B-4
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
1 2 34 5
6
78
910
11
18 Nm
69 Nm69 Nm 18 Nm
69 Nm
3.9 Nm32 Nm32 Nm
3
Disassembly steps
1. Transfer
J2. O-ring
3. Roll stopper bracket
4. Insulator washer
(EVOLUTION-IV only)
5. Shift cable bracketI6. Select lever
H7. Speedometer gear
8. Back-up lamp switch
9. Gasket
10. Plug
11. Gasket
NOTE:
For each service point, refer to Basic Manual. (Pub. No. S9806CNCP9)