Mitsubishi Evolution X. Manual — part 378

INPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-25

>>B<< THRUST BEARING INSTALLATION

AK703374AC

(thick)

3rd speed gear

(thin)

Black

Colorless

(thin)

Colorless

(thick)

Black

Install the thrust bearings as shown.

.

>>C<< 3RD-4TH SPEED SYNCHRONIZER HUB /
3RD-4TH SPEED SYNCHRONIZER SLEEVE
INSTALLATION

AK703159

Identification groove

Installation
direction

AC

1. Install the 3rd-4th speed synchronizer hub and synchronizer

sleeve in the illustrated direction.

AK703169

AC

MD998812

MD998813

MD998822

2. Using the special tools, MD998812, MD998813 and

MD998822, indicated below, install the 3rd-4th speed
synchronizer sleeve, 3rd-4th speed synchronizer hub,
synchronizer outer ring, synchronizer inner ring and
synchronizer cone.

3. After installation, check that the 3rd speed gear rotates

smoothly.

.

>>D<< 4TH SPEED GEAR SLEEVE
INSTALLATION

AK703170

AC

MD998812

MD998813

MD998822

Using the special tools, MD998812, MD998813 and
MD998822, indicated below, install the 4th speed gear sleeve.

.

INPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-26

>>E<< 5TH SPEED GEAR SLEEVE INSTALLATION

AK703171

AC

MD998812

MD998813

MD998822

Using the special tools, MD998812, MD998813 and
MD998822, indicated below, install the 5th speed gear sleeve.

.

>>F<< 5TH SPEED SYNCHRONIZER HUB / 5TH
SYNCHRONIZER SLEEVE INSTALLATION

AK703158

Identification
groove

Identification
groove

Installation
direction

AC

1. Install the 5th speed synchronizer hub and synchronizer

sleeve in the illustrated direction.

AK703172

AC

MD998812

MD998813

MD998822

2. Using the special tools, MD998812, MD998813 and

MD998822, indicated below, install the 5th speed
synchronizer hub and synchronizer sleeve.

3. After installation, check that the 5th speed gear rotates

smoothly.

.

>>G<< TAPER ROLLER BEARING INSTALLATION

AK703173

AC

MD998812

MD998822

MD998813

Using the special tools, MD998812, MD998813 and
MD998822, indicated below, press-fit the taper roller bearing.

.

INPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-27

>>H<< SNAP RING INSTALLATION

AK703174

Select and install appropriate snap ring onto the input 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)

.

>>I<< OIL SEAL INSTALLATION

AK702519

AD

3.5 mm
(0.1378 inch)

Oil seal

AK703175AC

MD999601

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

INSPECTION

M1222001700330

.

INPUT SHAFT

AK702517AC

• Check the needle bearing mounting portion of the shaft for

damage, wear and seizure.

• Check the splines for damage and wear.

.

INPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-28

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.

.

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 cone of each speed gear is not

roughened, damaged or worn in the surface.

3. Check 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.

AK703161

AC

Gear

Cone

Outer ring

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.