Mitsubishi Lancer Evolution 8. Manual — part 101
MANUAL TRANSMISSION - INPUT SHAFT
22-29
Double cone synchroniser ring
1. There must be no scratching / damage on the
outer synchroniser ring clutch gear.
2. There must be no scratching / wear / squashed
threads on any of the synchroniser ring
⇔
synchroniser cone contact surfaces.
3. There must be no scratching, damage or
excessive wear on the outer synchroniser ring
⇔
synchroniser key contact surfaces.
4. Assemble the synchroniser rings and synchroniser
cones and check Clearances ‘A’ and ‘B’ on the
drawing. If either is over limit, replace.
Limit: 0.2 mm
Synchroniser key
There must be no scratching or abnormal wear on
the synchroniser key € synchroniser hub contact
surfaces.
Synchroniser spring
Synchroniser springs must not be weakened,
deformed or damaged.
Inner synchronizer ring
Synchroniser cone
Inner synchronizer ring
Synchroniser cone
Outer synchronizer ring
Outer synchronizer ring
MANUAL TRANSMISSION - REVERSE IDLER GEAR
22-30
REVERSE IDLER GEAR
Dismantling / Assembling
Dismantling Order
Dismantling Order (continued)
1. Reverse idler gear (rear)
8. Thrust bearing
assembly
9. Reverse idler gear (front)
2. Reverse idler gear (rear)
10. Needle bearing
<<A>>
>>B<<
3. Reverse idler gear sleeve
11. Washers
>>A<<
4. Insert spring
12. Thrust bearing
5. Synchroniser
ring
13.
Pin
6. Needle bearing
14. Reverse idler gear shaft
7. Washers
Apply gear oil to
all sliding sections
when fitting.
MANUAL TRANSMISSION - REVERSE IDLER GEAR
22-31
Key Points for Removing
<<A>> Removing reverse idler gear sleeve
Mating may be faulty if the splines are re-
assembled at a different place when these parts
are re-used.
Mark the reverse idler gear sleeve and hub to
indicate where they must be re-assembled
Key Points for Assembly
>>A<< Fitting insert spring
Fit insert spring into reverse idler gear sleeve,
making sure fitting direction is correct.
>>B<< Fitting reverse idler gear sleeve
Mating may be faulty if the splines are re-
assembled at a different place when these parts
are re-used.
Match up marks made during dismantling when
reassembling the splines.
Care required
Care required
Marks
Clutch
housing
Marks
MANUAL TRANSMISSION - REVERSE IDLER GEAR
22-32
Reverse Idler Gear Checks
M1222012400021
Reverse idler shaft
There must be no scratching, peeling, gouging,
uneven wear, warping or other abnormalities on
reverse idler shaft.
Thrust bearing
1. When the thrust bearing is assembled with the
washer and rotated, rotation must be smooth and
there must be no play or abnormal noise.
2. Retainers must not be deformed.
Needle bearing
1. When reverse idler shaft and gear are assembled
and rotated, rotation must be smooth and there
must be no play or abnormal noise.
2. Retainers must not be deformed.
Reverse idler gear (front)
1. There must be no scratching or wear on the
reverse idler gear, helical gears or clutch gear
teeth sides.
2. There must be no roughness, scratching or wear
on reverse idler gear synchroniser cone surface.
3. There must be no scratching or wear on the inside
diameter or the front or rear surfaces of the
reverse idler gear.
Synchroniser ring
1. There must be no scratching or damage on the
synchroniser ring clutch gear.
2. There must be no scratching, wear or squashed
threads on the inside diameter of the synchroniser
ring cone.
3. There must be no scratching, damage or
excessive wear on the synchroniser ring
⇔
synchroniser key contact surface.
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