2007 MITSUBISHI LANCER EVOLUTION manual transmission

MANUAL TRANSMISSION OVERHAUL -Transmission22B-18
DISASSEMBLY SERVICE POINTS
AA"SPRING PIN REMOVAL
Shift the 5th-reverse speed shift fork in the direction shown
in the illustration, and remove the spring pin.
AB"3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/5TH-REVERSE SPEED SHIFT
RAIL/5TH-REVERSE SPEED SHIFT FORK
REMOVAL
(1) Move each shift rail in the direction shown in the illustration,
and remove from the shift rail hole on the clutch housing.
(2) Remove each shift rail and shift fork as a set.
AC"CENTER DIFFERENTIAL/OUTPUT SHAFT/INPUT
SHAFT REMOVAL
Remove the input shaft, output shaft and center differential
from the clutch housing at the same time.
ADJUSTMENT BEFORE REASSEMBLY
SELECTION OF INPUT SHAFT END PLAY/OUTPUT
SHAFT END PLAY/OUTPUT SHAFT PRELOAD AND
CENTER DIFFERENTIAL PRELOAD ADJUSTMENT
SPACER
(1) Install the input shaft, output shaft and center differential
onto the clutch housing at the same time.
(2) Set solder (approx. 10 mm long, 1.6 mm diameter) on
the input shaft rear bearing at the position shown in the
illustration.
5th-reverse
speed shift
fork
3rd-4th speed
shift rail
5th-reverse
speed shift rail
Output shaft
Center differentialInput
shaft
Output shaft
Center differentialInput
shaft
Solder

MANUAL TRANSMISSION OVERHAUL -Transmission22B-19
(3) Set solder (10 mm long, 1.6 mm diameter) on the
transmission case at the position shown in the illustration.
(4) Install the outer race onto the transmission case.
(5) Install the transmission case, and tighten the bolt with
the specified torque.
(6) If the solder has not been crushed, carry out steps (2) to (5) with
solder having a larger diameter.
(7) Using a micrometer, measure the thickness of the crushed solder,
and select a spacer so that the end play and preload are at the
standard values.
Standard value:
Input shaft end play
0.05mm loose to 0.17mm loose
Output shaft preload
0.13mm tight to 0.18mm tight
Center differential preload
0.05mm tight to 0.11mm tight
REASSEMBLY SERVICE POINTS
"AAINPUT SHAFT/OUTPUT SHAFT/CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and center differential onto
the clutch housing at the same time.
"BA5TH-REVERSE SPEED SHIFT
FORK/5TH-REVERSE SPEED SHIFT
RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH
SPEED SHIFT RAIL INSTALLATION
(1) Assemble the 3rd-4th speed shift rail, fork and the
5th-reverse speed shift rail and fork.
Solder
Solder
Output shaft
Center differentialInput
shaft
3rd-4th speed
shift rail
5th-reverse
speed shift rail 5th-reverse
speed shift
fork
3rd-4th speed
shift rail

MANUAL TRANSMISSION OVERHAUL -Transmission22B-20
(2) Slide each shift rail in the direction shown in the illustration,
and then install onto the shift rail hole on the clutch
housing.
"CASPRING PIN INSTALLATION
Install the spring pin onto the shift rail so that the slit faces
the direction shown in the illustration.
"DASPACER INSTALLATION
Install the spacer selected in the section “Adjustment before
reassembly”.
"EATRANSMISSION CASE INSTALLATION
Apply sealant at the positions of the transmission case shown
in the illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
"FAUNDER COVER INSTALLATION
Apply sealant at the positions of the transmission case shown in the
illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
3rd-4th speed
shift rail
5th-reverse
speed shift rail
Spring pin
Shift rail

MANUAL TRANSMISSION OVERHAUL -Transmission22B-21
"GACONTROL HOUSING INSTALLATION
Apply sealant at the positions of the transmission case shown
in the illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
"HASPEEDOMETER GEAR INSTALLATION
Apply transmission oil on the O-ring for the speedometer
gear.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"IASELECT LEVER INSTALLATION
Apply grease on the sliding section of the select lever shoe’s
control shaft.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011 or
equivalent
"JAO-RING INSTALLATION
Apply transmission oil on the O-ring.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
INSPECTION
BACKUP LIGHT SWITCH
Check the continuity between the terminals.
ItemsContinuity
Switch pressedContinuity not established
Switch releasedContinuity established
Control shaft
Select
lever
shoe

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-22
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
2
81
Apply gear oil on
all sliding sections
before installing.
13
1911 12
18
10 1514
21
22 201716
4
3
5 6
7
9
18
Disassembly steps
"MA1. Snap ring
AA""LA2. Ball bearing
AB""KA3. Thrust plate stopper
"JA4. Thrust plate
AC""IA5. 5th speed gear
6. 4th speed gear
7. Needle roller bearing
AD""HA8. 4th speed gear sleeve
9. Synchronizer ring
"GA10. Synchronizer spring
"FA11. Synchronizer sleeve"EA12. 3rd-4th speed synchronizer hub
13. Outer synchronizer ring
"DA14. Synchronizer spring
15. Synchronizer cone
16. Inner synchronizer ring
17. 3rd speed gear
18. Needle roller bearing
"CA19. Snap ring
AE""BA20. Ball bearing
"AA21. Oil seal
22. Input shaft

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-23
DISASSEMBLY SERVICE POINTS
AA"BALL BEARING REMOVAL
Using the special tool, remove the ball bearing from the input
shaft.
AB"THRUST PLATE STOPPER REMOVAL
Using a screwdriver, lift the stopper at the position shown
in the illustration, and remove the thrust plate stopper.
AC"5TH SPEED GEAR REMOVAL
Using the special tool, remove the 5th speed gear from the
input shaft.
AD"4TH SPEED GEAR SLEEVE REMOVAL
Install the special tool on the 3rd speed gear, and remove
the 4th speed gear sleeve from the input shaft.
AE"BALL BEARING REMOVAL
Using the special tool, remove the ball bearing from the input
shaft.
MD998801
MD998801
MD998801
MD998801

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-24
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
Accurately tap in the oil seal to the dimensions shown in
the illustration.
"BABALL BEARING INSTALLATION
Using the special tool, install the ball bearing onto the input
shaft.
"CASNAP RING INSTALLATION
Select and install the snap ring so that the input shaft front
bearing clearance is at the standard value.
Standard value: 0.01 mm tight to 0.12 mm loose
"DASYNCHRONIZER SPRING INSTALLATION
Accurately install the synchronizer spring onto the position
of the synchronizer ring shown in the illustration.
"EA3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 3rd-4th speed synchronizer hub onto the input
shaft at the direction shown in the illustration.Oil seal3.5 mm
MD998812
MD998813
MD998818 MD998801
Snap ring
Synchronizer spring
Identification mark3rd
speed
side
4th speed
side Installation
direction

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-25
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 3rd speed gear
rotates smoothly.
"FASYNCHRONIZER SLEEVE INSTALLATION
(1) Install the synchronizer sleeve onto the input shaft at
the direction shown in the illustration.
(2) Align the synchronizer hub deep grooves with the sleeve
protrusions and install.
"GASYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring onto the input shaft.
"HA4TH SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 4th speed gear sleeve onto
the input shaft.
MD998812
MD998813
MD998825 MD998801
3rd
speed
side4th
speed
side
Installation
directionIdentification
groove
Synchronizer sleeve protrusion section
Synchronizer
hub deep
groove section
Synchronizer spring
MD998812
MD998813
MD998825 MD998801