Mitsubishi Lancer Evolution 7. Manual — part 265
MANUAL TRANSMISSION OVERHAUL -
Input Shaft
22B-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.
"
FA SYNCHRONIZER 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.
"
HA 4TH SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 4th speed gear sleeve onto
the input shaft.
MD998812
MD998813
MD998825
MD998801
3rd
speed
side
4th
speed
side
Installation
direction
Identification
groove
Synchronizer sleeve protrusion section
Synchronizer
hub deep
groove section
Synchronizer spring
MD998812
MD998813
MD998825
MD998801
MANUAL TRANSMISSION OVERHAUL -
Input Shaft
22B-26
"
IA 5TH 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.
"
JA THRUST 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.
"
KA THRUST 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.
"
LA BALL 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 loose
MD998812
MD998813
MD998825
MD998801
Thrust
plate
Stamped
surface
MD998812
MD998813
MD998825
MD998801
MD998812
MD998819
Snap
ring
MANUAL TRANSMISSION OVERHAUL -
Input Shaft
22B-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 Shaft
22B-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
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