Mitsubishi Evolution X. Manual — part 380

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-33

>>E<< 2ND SPEED GEAR SLEEVE
INSTALLATION

AK703305

AC

MD998812

MD998824

MD998814

Using the special tools, MD998812, MD998814 and
MD998824, indicated below, install the 2nd speed gear sleeve.

.

>>F<< 3RD SPEED GEAR INSTALLATION

AK703306

AC

MD998812

MD998822

MD998814

Using the special tools, MD998812, MD998814 and
MD998822, indicated below, install the 3rd speed gear.

.

>>G<< SNAP RING INSTALLATION

AK703179

Select and install appropriate snap ring onto the output shaft so
that the clearance of the output shaft-3rd speed gear meets the
standard value.

Standard value: 0.01

− 0.09 mm (0.0004 − 0.0035 inch)

.

>>H<< 4TH SPEED GEAR INSTALLATION

AK703307

AC

MD998812

MD998821

MD998813

Using the special tools, MD998812, MD998813 and
MD998821, indicated below, install the 4th speed gear.

.

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-34

>>I<< 5TH SPEED GEAR INSTALLATION

AK703308

AC

MD998812

MD998819

MD998813

Using the special tools, MD998812, MD998813 and
MD998819, indicated below, install the 5th speed gear.

.

>>J<< TAPER ROLLER BEARING INSTALLATION

AK703309

AC

MD998812

MD998819

MD998813

Using the special tools, MD998812, MD998813 and
MD998819, indicated below, press-fit the taper roller bearing.

.

>>K<< SNAP RING INSTALLATION

AK703380AC

Snap ring

Select and install appropriate snap ring onto the output shaft so
that the clearance of the taper roller bearing meets the stan-
dard value.

Standard value: 0.01

− 0.09 mm (0.0004 − 0.0035 inch)

.

>>L<< TAPER ROLLER BEARING INSTALLATION

AK703414AC

MD998812

MD998819

Using the special tools, MD998812 and MD998819, indicated
below, install the taper roller bearing.

.

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-35

>>M<< OIL SEAL INSTALLATION

AK702519

AD

3.5 mm
(0.1378 inch)

Oil seal

AK703176AC

MD999601

Using special tool, MD999601, drive the oil seal as deep as
shown into place.

INSPECTION

M1222002300294

.

OUTPUT SHAFT

AK702518

AC

• Check the needle bearing mounting portion of the shaft for

damage, wear and seizure.

• Check the splines for damage and wear.

.

NEEDLE BEARING

• Combine the needle bearing with the input shaft and gears

and check that it smoothly rotates without noise or play.

• Check the needle bearing retaining sleeve for deformation.

.

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-36

SPEED GEARS

AK204169AD

1. Check that the helical and clutch gears of each speed gear

are not damaged or worn in the tooth surface.

2. Check that the synchronizer cones of the 1st and 2nd speed

gears are not roughened, damaged or worn in the surface.

3. heck that the inner, front and rear surfaces of each speed

gear are not damaged or worn.

.

SYNCHRONIZER RING

AK703376AC

1. Check that the outer synchronizer ring clutch gear is free of

damage.

2. Check that the synchronizer rings and synchronizer cones

are free of damage or wear in the contact surface and
broken screw threads.

3. Check that the outer synchronizer ring and synchronizer key

contact surface is free of damage and wear.

AK703160

AC

Outer ring

Gear

Cone

Inner ring

A

4. Join the outer and inner synchronizer rings and synchronizer

cone together and check clearance "A" shown. If "A" is less
than the limit value, replace them.

Limit A (from back of outer ring to clutch gear): 0.5

mm (0.02 inch)

.

SYNCHRONIZER SLEEVE AND HUB

AK703375

• Combine the synchronizer sleeve and hub, and check that

they slide smoothly.

• Check that the sleeve is free of damage at its inside spline

ends.