2007 MITSUBISHI LANCER EVOLUTION clutch

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 -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-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 -Clutch Housing22B-43
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
7
5*3
6
4
2
18
9.8±2N•m
Disassembly steps
1. Clutch release bearing retainer
"EA2. Oil seal
AA""DA3. Outer race
AB""CA4. Outer race"BA5. Bush*
"AA6. Cover A
"AA7. Cover B
8. Clutch housing
NOTE
*: Refer to the installation procedures only when replacing the clutch housing.
DISASSEMBLY SERVICE POINTS
AA"OUTER RACE REMOVAL
Using the special tool, remove the outer race from the clutch
housing.MD999566