2007 MITSUBISHI LANCER EVOLUTION service

MANUAL TRANSMISSION - Transfer Assembly22A-50
11 12
9
1013
14
15 16
13
59±9 N·m
59±9 N·m
44±5 N·m
69±10 N·m
52±7 N·m*
52±7 N·m*
69±10 N·m
9. Rear roll stopper connection bolt
10. Centermember assembly
11. Front propeller shaft
(Refer to GROUP 25.)
12. Transfer oil pressure hose assem-
bly
13. Gasket
14. Dust seal guard
AD"15. Transfer assembly
16. O-ring
Caution
*: Indicates parts which should be initially tightened,
and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine
on the vehicle body.
REMOVAL SERVICE POINTS
AA"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.MB991113 or
MB990635
Cord Ball joint
Nut

MANUAL TRANSMISSION - Transmission Assembly22A-53
10
10 11
9
1412 88
13
48±5 N·m
48±5 N·m
48±5 N·m
48±5 N·m
9.0±1.0 N·m
26±5 N·m
82±7 N·m*
47±7 N·m*
8. Transmission assembly upper part
coupling bolts
AA"9. Transmission mount assembly
"AA10. Transmission mount stopper
11. Transmission mount bracket
AB"DEngine assembly supporting
AC"DClutch release bearing connection
12. Bell housing cover13. Transmission assembly lower part
coupling bolts
14. Transmission assembly
Caution
*: Indicates parts which should be initially tightened,
and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine
on the vehicle body.
REMOVAL SERVICE POINTS
AA"ENGINE AND TRANSMISSION ASSEMBLY
SUPPORTING/TRANSMISSION MOUNT
ASSEMBLY REMOVAL
While supporting the engine and transmission assembly with
a garage jack, remove the transmission mount assembly.Engine and transmission
assembly
Garage jack

MANUAL TRANSMISSION - Transmission Assembly22A-54
AB"ENGINE ASSEMBLY SUPPORTING
Set the special tool to the vehicle to support the engine
assembly.
AC"CLUTCH RELEASE BEARING SEPARATION
1. Remove the cover from the service hole in the clutch
housing.
2. While pushing the release fork by hand in the direction
A, insert a flap-tip screwdriver between the release bearing
and the wedge collar.
Caution
Be sure to push the release fork in the direction A
before inserting a screwdriver.
3. Separate the release bearing from the wedge collar by
prying with the screwdriver (turning the screwdriver grip
90˚).
NOTE
The release fork is forced to move fully in the direction
B by the return spring as soon as it is separated from
the wedge collar.
Caution
If it is hard to turn the screwdriver (to pry off the
release bearing), remove the screwdriver once and
repeat the above procedure after pushing the release
fork fully in the direction a two to three times. Forcibly
prying can cause the release bearing to be damaged.
INSTALLATION SERVICE POINT
"AATRANSMISSION MOUNT STOPPER
INSTALLATION
Install so that the arrow on the transmission mounting stopper
faces the top of the vehicle.
MZ203827
MB991453
BA
Service hole
Release fork
Wedge collar
Release bearing
Transmission
mount bracket
Transmission
mount stopper Engine side

MANUAL TRANSMISSION -Sensor, Switch and Relay or vehicles with ACD and AYC>22A-56
SENSOR, SWITCH AND RELAY VEHICLES WITH ACD AND AYC>
REMOVAL AND INSTALLATION
Caution
Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP
52B Precautions in Servicing and Airbag Module Clock Spring.
1
3
2
4
5
Parking brake lever
Steering wheel sensor removal
steps
DSteering wheel and column cover
(Refer to GROUP 37A.)
1. Steering wheel sensor
G sensor removal steps
DFloor console (Refer to GROUP 52A.)
2. Longitudinal G sensor
3. Lateral G sensorElectric pump relay removal
4. Electric pump relay
ACD mode switch removal steps
DInstrument panel ornament (Refer to
GROUP 52A – Instrument Panel.)
5. ACD mode switch
NOTE
For details on the wheel speed sensor, refer to GROUP
35B.
REMOVAL SERVICE POINT
AA"STEERING WHEEL SENSOR REMOVAL
Remove the steering wheel sensor from the column switch.
Caution
Make sure no oil adheres to the steering wheel sensor
because a photocoupler is used.Steering wheel sensor

22B-1
MANUAL
TRANSMISSION
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 6..........................
SERVICE SPECIFICATIONS 6.................
SEALANTS 7................................
LUBRICANTS 8..............................
SNAP RINGS, SPACERS AND THRUST
PLATES FOR ADJUSTMENT 9................
TIGHTENING TORQUE 11....................
SPECIAL TOOLS 12..........................
TRANSMISSION 15...........................
INPUT SHAFT 22............................OUTPUT SHAFT 29..........................
REVERSE IDLER GEAR 37...................
SPEEDOMETER GEAR 38....................
SELECT LEVER 39...........................
CONTROL HOUSING 40......................
CLUTCH HOUSING 43........................
TRANSMISSION CASE 46....................
CENTER DIFFERENTIAL 48..................
TRANSFER 51...............................

MANUAL TRANSMISSION OVERHAUL -Specifications/Service Specifications22B-6
SPECIFICATIONS
TRANSMISSION MODEL TABLE
Transmission
modelGear ratioSpeedometer
gear ratioFinal
reduction
ratioFront LSDVehicle modelEngine model
W5M51 - 2 - X5BA28/364.529CT9A4G63 - I/C•T/C
W5M51 - 2 - X5B1B28/364.529Not providedCT9A4G63 - I/C •T/C
W5M51 - 2 - X5B2C28/364.529ProvidedCT9A4G63 - I/C •T/C
W5M51 - 2 - X5B3B28/364.529Not providedCT9A4G63 - I/C •T/C
W5M51 - 2 - X5B4C28/364.529ProvidedCT9A4G63 - I/C •T/C
GEAR RATIO TABLE
ABC
1st2.9282.785←
2nd1.950←←
3rd1.407←1.444
4th1.031←1.096
5th0.720←0.825
Reverse3.416←←
Transfer gear ratio0.3018←←
SERVICE SPECIFICATIONS
ItemsStandard value mmLimit value mm
Input shaft end play0.05 loose to 0.17 loose-
Input shaft front bearing end play0.01 tight to 0.12 loose-
Input shaft rear bearing end play0.01 tight to 0.12 loose-
Input shaft 5th speed gear end play0.01 tight to 0.09 loose-
Output shaft preload0.13 tight to 0.18 tight-
Output shaft bearing end play0.01 tight to 0.09 loose-
Output shaft 3rd speed gear end play0.01 tight to 0.09 loose-
Center differential case preload0.05 tight to 0.11 tight-
Center differential case pinion backlash0.025 - 0.150-
Clearance between synchronizer ring rear surface and gears-0.5
Provided

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