2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

MANUAL TRANSMISSION OVERHAUL -Sealants22B-7
SEALANTS
TRANSMISSION
ItemsSpecified sealants
Clutch housing and transmission case contact surfaceMITSUBISHI genuine sealant Part
No MD997740orequivalent
Control housing and transmission case contact surface
No.MD997740or equivalent
Under cover and transmission case contact surface
Air breather3M SUPER WEATHERSTRIP No.8001 or
equivalent
Center differential drive gear bolt3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)
FIPG is used for several members of this transmission. With this gasket, caution is required to the application
amount, application procedure and state of the application surface so that the performance is sufficiently
attained.
If sufficient gasket is not applied, leaks could occur, and if too much is applied, the gasket could protrude
and plug or restrict the oil flow passage. Thus, to prevent leaks from the joined sections, it is absolutely
necessary to evenly apply the correct amount.
DISASSEMBLY
The parts assembled with FIPG can be easily disassembled without special means. However, in some
cases, the sealant on the contact surfaces must be broken by lightly tapping with a wood hammer or
similar tool.
Washing the gasket surface
Completely remove all matters adhered on the contact surfaces with a gasket scraper. Confirm that the
FIPG application surface is smooth. There must be no grease or foreign matter on the contact surfaces.
Always remove the old FIPG that has entered the mounting holes and screw holes.
APPLICATION PROCEDURES
Apply an even coat of FIPG within the predetermined radius (1.5±0.3 mm). Completely cover the areas
around the mounting holds. The FIPG can be wiped off if it has not hardened. Install at the set position
while the FIPG is still wet (within 10 minutes). When installing, make sure that the FIPG does not get
on areas other than the required areas. After installing, do not subject the application areas to oil or
water or start operation until the FIPG has sufficiently hardened (approx. one hour).
The FIPG application procedures differ according to the member, so follow the procedures given in this
manual and apply the FIPG.

MANUAL TRANSMISSION OVERHAUL -Lubricants22B-8
LUBRICANTS
TRANSMISSION
ItemsSpecified lubricants
Drive shaft oil seal lip sectionMITSUBISHI genuine “DIA-QUEEN” multi
gearoil<75W/85W>orequivalent
Input shaft oil seal lip section
gear oil<75W/85W> or equivalent
Control shaft oil seal lip section
Select lever shoeMITSUBISHI genuine grease Part
No.0101011 or equivalent
TRANSFER
ItemsSpecified lubricants
Drive shaft oil seal lip sectionMITSUBISHI genuine “DIA-QUEEN
SUPER”hypoidgearoil(GL 5)or
Front differential oil seal lip section
SUPER”hypoidgear oil(GL-5)or
equivalent
Each O-ring

MANUAL TRANSMISSION OVERHAUL -Snap Rings, Spacers and Thrust
Plates for Adjustment22B-9
SNAP RINGS, SPACERS AND THRUST PLATES FOR ADJUSTMENT
SPACERS (FOR ADJUSTMENT OF INPUT SHAFT END PLAY)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.34
1.43
1.5234
43
52MD723600
MD723603
MD7236061.61
1.70
1.7961
70
79MD723609
MD756760
MD756763
SNAP RINGS (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.43
1.51Green, two pieces
White, two piecesMD746708
MD7467091.59Yellow, two piecesMD746710
SNAP RINGS (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.44
1.51None
BlueMD746602
MD7466031.58BrownMD746604
THRUST PLATES (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
3.82
3.86
3.90
3.940
2
3
5MD748465
MD748466
MD748467
MD7484683.98
4.02
4.06
4.106
7
8
9MD748469
MD748470
MD748471
MD748472
SPACERS (FOR ADJUSTMENT OF OUTPUT SHAFT PRELOAD)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.86
0.89
0.92
0.95
0.98
1.01
1.04
1.07
1.10
1.13
1.1686
89
92
95
98
01
04
07
J
D
KMD720938
MD720939
MD720940
MD720941
MD720942
MD720943
MD720944
MD720945
MD710454
MD700270
MD7104551.19
1.22
1.25
1.28
1.31
1.34
1.37
1.40
1.43
1.46L
G
M
N
E
O
P
None
Q
RMD710456
MD700271
MD710457
MD710458
MD706574
MD710459
MD710460
MD706573
MD710461
MD710462

MANUAL TRANSMISSION OVERHAUL -Snap Rings, Spacers and Thrust
Plates for Adjustment22B-10
SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT BEARING CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
1.36
1.40
1.44
1.48
1.51Yellow
Green
None
Black
BlueMD748449
MD748450
MD746602
MD748451
MD7466031.55
1.58
1.63
1.68White
Brown
Orange
BlueMD748452
MD746604
MD748453
MD748454
SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR
CLEARANCE)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
2.81
2.85
2.89
2.93None
Blue
Brown
YellowMD746594
MD746595
MD746596
MD7465972.97
3.01
3.05
3.09Green
Black
White
OrangeMD746598
MD746599
MD746600
MD746601
SPACERS (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.74
0.77
0.80
0.83
0.86
0.89
0.92
0.95
0.98
1.0174
77
80
83
86
89
92
95
98
01MD727660
MD754476
MD727661
MD720937
MD720938
MD720939
MD720940
MD720941
MD720942
MD7209431.04
1.07
1.10
1.13
1.16
1.19
1.22
1.25
1.28
1.3104
07
J
D
K
L
G
M
N
EMD720944
MD750945
MD710454
MD700270
MD710455
MD710456
MD700271
MD710457
MD710458
MD706547
SPACERS (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PINION
BACKLASH)
Thickness mmIdentificationPart No.Thickness mmIdentificationPart No.
0.6
0.7
0.8-
-
-MD748362
MD748363
MD7483640.9
1.0
1.1-
-
-MD748365
MD748366
MD748367

MANUAL TRANSMISSION OVERHAUL -Tightening Torque22B-11
TIGHTENING TORQUE
TRANSMISSION
ItemsTightening torque N•m
Under cover mounting bolt6.9±1
Interlock plate bolt30±3
Clutch housing and transmission case tightening bolt44±5
Clutch release bearing retainer mounting bolt9.8±2
Control housing mounting bolt18±3
Shift cable bracket mounting bolt18±3
Speedometer gear mounting bolt3.9±1
Stopper bracket mounting bolt18±3
Select lever mounting bolt18±3
Select lever mounting nut11±1
Center differential drive gear mounting bolt132±5
Backup light switch32±2
Poppet spring32±2
Reverse idler gear shaft mounting bolt48±5
Roll stopper bracket mounting bolt69±9
TRANSFER
ItemsTightening torque N•m
Transfer cover mounting bolt23±3
Transmission and transfer tightening bolt69±9

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-12
SPECIAL TOOLS
ToolNumberNameUse
MB990887Arm bush remover
and installer ringInstallation of transfer oil seal
MB990891Bush remover and
installer baseInstallation of transfer oil seal
MB990928Installer adapterInstallation of input shaft oil seal
MB990932Installer adapterRemoval of differential case taper roller
bearing
MB990936Installer adapterInstallation of transfer oil seal
MB990935Installer adapterInstallation of output shaft front taper roller
bearing
MB990937Installer adapterInstallation of differential case taper roller
bearing and transfer extention housing oil
seal
MB990938HandleUse for installer adaptor
MB991445Bush remover and
installer baseInstallation of differential case taper roller
bearing outer race

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-13
Tool UseName Number
MD998364Camshaft oil seal
installerInstallation of each gear, bearing and sleeve
MD998800Oil seal installerInstallation of differential oil seal and transfer
cover oil seal
MD998801Bearing removerInstallation and removal of each gear, bearing
and sleeve
MD998812Installer capUse for installer and installer adaptor
MD998813Installer 100Use for installer cap and installer adaptor
MD998814Installer 200Use for installer cap and installer adaptor
MD998818Installer adapter
(38)Installation of input shaft front bearing
MD998819Installer adapter
(40)Installation of input shaft rear bearing and
output shaft taper roller bearing
MD998820Installer adapter
(42)Installation of reverse gear bearing sleeve

MANUAL TRANSMISSION OVERHAUL -Special Tools22B-14
Tool UseName Number
MD998821Installer adapter
(44)Installation of 4th speed gear, 5th speed gear
sleeve and 5th-reverse speed synchronizer
hub
MD998824Installer adapter
(50)Installation of 1st-2nd speed synchronizer
hub, 2nd speed gear sleeve and 3rd speed
gear
MD998825Installer adapter
(52)Installation of 1st speed gear sleeve, 3rd-4th
speed synchronizer hub, 4th speed gear
sleeve, 5th speed gear and thrust plate
stopper
MD998917Bearing removerInstallation and removal of each gear, bearing
and sleeve
MD999566ClawRemoval of taper roller bearing outer race