2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

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

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-26
"IA5TH SPEED GEAR INSTALLATION
Using the special tool, install the 5th speed gear onto the
input shaft.
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 4th speed gear
rotates smoothly.
"JATHRUST PLATE INSTALLATION
Select and install the thrust plate onto the input shaft so
that the input shaft 5th speed gear clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
Caution
Assemble the side with the identification stamp facing the
thrust plate stopper side.
"KATHRUST PLATE STOPPER INSTALLATION
Press the special tool by hand, and accurately fit the thrust
plate stopper onto the input shaft so that it is not inclined.
"LABALL BEARING INSTALLATION
Using the special tool, install the ball bearing onto the input
shaft.
"MASNAP RING INSTALLATION
Select and install the snap ring onto the input shaft so that
the input shaft rear bearing clearance is at the standard value.
Standard value: 0.01 mm tight to 0.12 mm looseMD998812
MD998813
MD998825 MD998801
Thrust
plateStamped
surface
MD998812
MD998813
MD998825
MD998801MD998812
MD998819
Snap
ring

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-27
INSPECTION
INPUT SHAFT
(1) There must be no damage, abnormal wear or seizure
on the outer diameter of the needle bearing installation
section.
(2) Check the spline for damage and wear.
NEEDLE BEARING
(1) When the needle bearing is assembled with the input
shaft and gears and rotated, the needle bearing must
rotate smoothly without play or abnormal noise.
(2) The holder must not be deformed.
SYNCHRONIZER RING
(1) The clutch gear teeth must not be damaged or broken.
(2) The inner diameter of the cone must not be damaged
or worn, and the screw threads must not be crushed.
(3) Press the synchronizer ring against the gears, and check
the clearance “A”. Replace if “A” is less than the limit
value.
Limit value: 0.5 mm
OUTER SYNCHRONIZER RING, INNER
SYNCHRONIZER RING AND SYNCHRONIZER CONE
(1) The gear teeth and cone surface must not be damaged
or broken.
Gear“A”
Synchronizer
ring

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-28
(2) Assemble the outer ring, inner ring and cone. Press
against the gears and check the clearance “A”. Replace
if “A” is less than the limit value.
Limit value: 0.5 mm
Caution
When replacing, replace the outer ring, inner ring and
cone as a set.
SYNCHRONIZER SLEEVE AND HUB
(1) When the synchronizer sleeve and hub are assembled
and slid, the parts should slide without catching.
(2) There must be no damage on the front and back ends
of the sleeve’s inner surface.
SYNCHRONIZER SPRING
The spring must not be weak, deformed or broken.
EACH SPEED GEAR
(1) None of the helical gears or clutch gear teeth must be
damaged or worn.
(2) The synchronizer cone surface must not be rough,
damaged or worn.
(3) The inner diameter and front/back surfaces of the gear
must not be damaged or worn.“A”
Outer ring
Cone
Inner ring

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-29
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
32
Apply gear oil on
all sliding sections
before installing.
36
23
30
33
3526
29
34
282524
31
1613107
118
965
34
1
42 21
22
1727
1213
15 14201918
Disassembly steps
"PA1. Snap ring
AA""OA2. Taper roller bearing
AB""NA3. Reverse gear sleeve
"NA4. Needle roller bearing
"NA5. Reverse gear
6. Synchronizer ring
"LA7. Synchronizer spring
"FA8. Synchronizer sleeve
AC""MA9. 5th-reverse speed synchronizer hub
10. Synchronizer ring
"LA11. Synchronizer spring
12. 5th speed gear
13. Needle roller bearing
"KA14. 5th speed gear sleeve
"JA15. 4th speed gear
"IA16. Snap ring
AD""HA17. 3rd speed gear
18. 2nd speed gear19. Needle roller bearing
AE""GA20. 2nd speed gear sleeve
21. Inner synchronizer ring
22. Synchronizer cone
23. Outer synchronizer ring
"DA24. Synchronizer spring
"FA25. Synchronizer sleeve
"EA26. 1st-2nd speed synchronizer hub
27. Outer synchronizer ring
"DA28. Synchronizer spring
29. Inner synchronizer ring
30. Synchronizer cone
31. 1st speed gear
32. Needle roller bearing
AF""CA33. 1st speed gear sleeve
AG""BA34. Taper roller bearing
"AA35. Oil seal
36. Output shaft

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-30
DISASSEMBLY SERVICE POINTS
AA"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the output shaft.
AB"REVERSE GEAR BEARING SLEEVE REMOVAL
Install the special tool on the reverse gear, and remove the
reverse gear bearing sleeve from the output shaft.
AC"5TH-REVERSE SPEED SYNCHRONIZER HUB
REMOVAL
Install the special tool on the 4th speed gear, and remove
5th-reverse synchronizer hub.
AD"3RD SPEED GEAR REMOVAL
Install the special tool on the 2nd speed gear, and remove
the 3rd speed gear.
AE"2ND SPEED GEAR SLEEVE REMOVAL
Install the special tool on the 1st speed gear, and remove
the 2nd speed gear sleeve.
MD998801Taper roller
bearing
MD998801
Sleeve
MD998801Synchronizer hub
MD9988013rd speed gear
MD998801
Sleeve