2007 MITSUBISHI LANCER EVOLUTION manual transmission

MANUAL TRANSMISSION OVERHAUL -General Description22B-2
GENERAL DESCRIPTION
SECTIONAL VIEW

MANUAL TRANSMISSION OVERHAUL -General Description22B-3
SECTIONAL VIEW

MANUAL TRANSMISSION OVERHAUL -General Description22B-4
SECTIONAL VIEW

MANUAL TRANSMISSION OVERHAUL -General Description22B-5
SECTIONAL VIEW
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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 -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