Mitsubishi Lancer Evolution 7. Manual — part 267
MANUAL TRANSMISSION OVERHAUL -
Output Shaft
22B-33
"
GA2ND SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 2nd speed gear sleeve onto
the output shaft.
"
HA 3RD SPEED GEAR INSTALALTION
Using the special tool, install the 3rd speed gear onto the
output shaft.
Caution
(1) Press in so that the synchronizer ring does not bite
in.
(2) After assembling, confirm that the 2nd speed gear
rotates smoothly.
"
IA SNAP RING INSTALLATION
Select and install the snap ring onto the output shaft so that
the output shaft 3rd speed gear clearance is at the standard
value.
Standard value: 0.01 mm tight to 0.09 mm loose
"
JA 4TH SPEED GEAR INSTALLATION
Using the special tool, install the 4th speed gear onto the
output shaft.
"
KA 5TH SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 5th speed gear sleeve onto
the output shaft.
MD998364
Sleeve
MD998812
MD998814
MD998824
MD998364
3rd speed gear
MD998812
MD998814
MD998824
Snap ring
MD998364
4th speed gear
MD998812
MD998813
MD998821
MD998364
Sleeve
MD998812
MD998813
MD998821
MANUAL TRANSMISSION OVERHAUL -
Output Shaft
22B-34
"
LA SYNCHRONIZER 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.
"
NA REVERSE 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 hub
MD998812
MD998813
MD998821
MD998364
Reverse gear
MD998812
MD998820
Sleeve
MD998364
MD998812
MD998819
MANUAL TRANSMISSION OVERHAUL -
Output Shaft
22B-35
"
PA SNAP 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 Shaft
22B-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 ring
Outer ring
Cone
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