2007 MITSUBISHI LANCER EVOLUTION manual transmission

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-34
"LASYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring at the position shown in the
illustration.
"MA5TH-REVERSE SPEED SYNCHRONIZER HUB
INSTALLATION
Using the special tool, install the 5th-reverse synchronizer
hub onto the output shaft in the direction shown in the
illustration.
Caution
After assembling, confirm that the 5th speed gear rotates
smoothly.
Caution
Press in so that the synchronizer ring does not bite in.
"NAREVERSE GEAR/NEEDLE ROLLER
BEARING/REVERSE GEAR BEARING SLEEVE
INSTALLATION
Using the special tool, install the reverse gear/needle roller
bearing/reverse gear bearing sleeve onto the output shaft.
"OATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing onto
the output shaft.
Synchronizer
spring
Reverse
side 5th
speed
side
Installation
direction
MD998364 Synchronizer hubMD998812
MD998813
MD998821
MD998364 Reverse gearMD998812
MD998820
Sleeve
MD998364MD998812
MD998819

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-35
"PASNAP RING INSTALLATION
Select and install the snap ring onto the output shaft so that
the output shaft rear bearing clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
INSPECTION
OUTPUT SHAFT
Check the spline for damage and wear.
NEEDLE BEARING
(1) When the needle bearing is assembled with the bearing
sleeve and gear 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
Snap ring
Gear“A”
Synchronizer
ring

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-36
OUTER SYNCHRONIZER RING, INNER
SYNCHRONIZER RING AND SYNCHRONIZER CONE
(1) The gear teeth and cone surface must not be damaged
or broken.
(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.
Gear
“A”
Inner ringOuter ring
Cone

MANUAL TRANSMISSION OVERHAUL -Reverse Idler Gear22B-37
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil on
all sliding sections
before installing.
7653
41
2
Disassembly steps
1. Snap ring
2. Cone spring
3. Thrust washer
4. Steel ball5. Reverse idler gear
6. Needle roller bearing
7. Reverse idler gear shaft
INSPECTION
NEEDLE ROLLER BEARING
(1) When the needle bearing is assembled with the shaft
and gear and rotated, the needle bearing must rotate
smoothly without play or abnormal noise.
(2) The holder must not be deformed.

MANUAL TRANSMISSION OVERHAUL -Speedometer Gear22B-38
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
Apply gear oil on
all sliding sections
before installing.
34
2
1
Disassembly steps
1. e-clip
2. Speedometer driven gear
3. O-ring
4. Sleeve

MANUAL TRANSMISSION OVERHAUL -Select Lever22B-39
SELECT LEVER
DISASSEMBLY AND REASSEMBLY
3
4 6
1 5
2 7
8
9
10
11±1N•m
Disassembly steps
"AA1. Dust cover
2. Nut
3. Spring washer
4. Plane washer
5. Select lever bush6. Select lever shoe
7. Select lever
8. Select lever bush
"AA9. Dust cover
10. Select lever shaft
REASSEMBLY SERVICE POINT
"AADUST COVER INSTALLATION
Install the dust cover onto the select lever.
Dust
cover

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-40
CONTROL HOUSING
DISASSEMBLY AND REASSEMBLY
16107
11
8
9
6
5
3 41
2
17 1213
15 14
18
18±3N•m
Disassembly steps
AA""FA1. Lock pin
2. Interlock plate
3. Control finger
4. Pin
5. Return spring
6. Stopper plate
"EA7. Spring pin
"DA8. Spring pin
9. Stopper body10. Neutral return spring
11. Control shaft
"CA12. Air breather
13. Control shaft boot
"BA14. Oil seal
"AA15. Needle bearing
16. Spring washer
17. Stopper bracket
18. Control housing

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-41
DISASSEMBLY SERVICE POINT
AA"LOCK PIN REMOVAL
Tap out the lock pin from the direction shown in the illustration.
REASSEMBLY SERVICE POINTS
"AANEEDLE BEARING INSTALLATION
Press the needle bearing into the dimensions shown in the
illustration so that the type stamp side faces the indicated
direction.
"BAOIL SEAL INSTALLATION
Apply transmission oil on the oil seal lip section.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"CAAIR BREATHER INSTALLATION
(1) Apply sealant on the periphery of the insertion section.
Sealant
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or
equivalent
(2) Install so that the protrusion faces the direction shown
in the illustration.
Lock pin
Control
finger
Control
housing
Needle
bearing
2mm Type
stamp
side