Mitsubishi Lancer Evolution 8. Manual — part 94
22-1
CHAPTER 22
MANUAL TRANSMISSION
CONTENTS
Overview . . . . . . . . . . . ...22-2
Specifications . . . . . . . . . ...22-3
Maintenance Standards . . . . . ...22-4
Sealants/Adhesives . . . . . . . ..22-4
Lubricants . . . . . . . . . . . .22-4
Adjustment Shims, Thrust
Washers, Snap Rings . . . . . . ...22-5
Tightening Torques . . . . . . . ..22-6
Special Tools. . . . . . . . . . .22-7
Transmission. . . . . . . . . ...22-10
Dismantling/Assembling. . . . . . . . .22-10
Checks . . . . . . . . . . . . . . ...22-21
Input Shaft . . . . . . . . . . ...22-22
Dismantling/Assembling. . . . . . . . .22-22
Checks . . . . . . . . . . . . . . ...22-28
Reverse Idler Gear . . . . . . . ..22-30
Dismantling/Assembling. . . . . . . . .22-30
Checks . . . . . . . . . . . . . . ...22-32
Clutch Housing . . . . . . . . ...22-34
Dismantling/Assembling. . . . . . . . .22-34
Transmission Case . . . . . . . .22-37
Dismantling/Assembling. . . . . . . . .22-37
Centre Differential. . . . . . . ...22-39
Dismantling/Assembling. . . . . . . . .22-39
Transfer. . . . . . . . . . . . 22-43
Dismantling/Assembling. . . . . . . . .22-43
MANUAL TRANSMISSION - OVERVIEW
22-2
OVERVIEW
Cross Section (Transmission)
MANUAL TRANSMISSION - SPECIFICATIONS
22-3
Cross Section (Transfer)
SPECIFICATIONS
M1222000200150
Transmission Type Table
1st gear
2.909
2nd gear
1.944
3rd gear
1.434
4th gear
1.100
5th gear
0.868
6th gear
0.693
Reverse
2.707
Transmission Type
Speedometer Gear
Ratio?
Final Reduction
Gear Ratio
Front
LSD?
Vehicle
Type
Engine
Type
W6MAA-1-GFNF
No
4-583
Yes
CT9A
4G63-I/C-T/C
Gear Ratio Table
MANUAL TRANSMISSION - MAINTENANCE STANDARDS
22-4
Maintenance Standards
Liquid Gaskets (Flow-In-Place Gasket)
On this transmission FIPG is used in several
assemblies. For the liquid gasket to fully achieve its
objectives, careful attention needs to be paid to the
amount used, the application procedure, and the
condition of the surfaces on which it is applied.
Not using enough will result in leakage, while if too
much is used it will overflow and block or constrict the
oil passages. Hence, to prevent leakage from joints, it
is absolutely essential to apply the correct amount
and leave no gaps.
Dismantling
Parts assembled using FIPG can be dismantled
easily; no special method is required. However, in
some cases you may need to tap it with a wooden
mallet or similar tool to break the sealant between the
mating surfaces.
Cleaning the Gasket Surface
Completely remove all material adhering to mating
surfaces using a gasket scraper. Make sure that the
surfaces on which the FIPG will be applied are
smooth. There must be no oil, grease or other
substances adhering to mating surfaces. Do not
forget to remove any old FIPG from fitting holes,
screw holes.
Application Procedure
Apply the FIPG within the specified diameter, leaving
no gaps. Make sure it is applied all the way around
fitting holes. Before it solidifies FIPG can be wiped
off. Fit the specified sections together while it is still
wet (within 10 minutes). Make absolutely sure that it
only adheres to the areas where it is needed. Do not
put any oil or water on the parts after fitting them
together, or drive the car, until sufficient time (about 1
hour) has elapsed.
The procedure for applying FIPG varies from
assembly to assembly, so be sure to use the
procedure described here.
Lubricants
M1222000400091
Sealants / Adhesives
Item
Standard (mm) Limit (mm)
Differential side bearing pre-load
0.15 to 0.20
-
Input shaft end play
0 to 0.06
-
Main shaft end play
0 to 0.06
-
Reverse idler gear end play
0.04 to 0.10
-
Distance between input shaft front bearing and thrust washer
167.6 to 167.7
-
Input shaft 6th gear bush end play
0 to 0.1
-
Wear on one side of shift fork claws
-
0.2
Clearance between synchroniser ring and gear
-
0.7
Clearance between synchroniser ring and synchroniser cone
-
0.2
Backlash on differential side gear and pinion
0.025 to 0.150
-
Item
Brand
Clutch housing
ÅÃ
transaxle case mating surfaces
MZ100077 or equivalent
Reverse switch
MZ100077 or equivalent
Air breather
MZ100055 or equivalent
Differential drive gear bolt
0110106 or Locktight 648 or equivalent
Item
Brand
Lip on transfer oil seal
Sunlight No. 2 or Retinax A or equivalent
O-rings
M1222000300135
M1222000500128
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