Mitsubishi Lancer Evolution 8. Manual — part 100
MANUAL TRANSMISSION - INPUT SHAFT
22-25
>>C<< Fitting 3rd-4th gear synchroniser
assembly
Make sure synchroniser ring does not get
chewed up when fitting assembly.
Fit 3rd-4th gear synchroniser assembly using the
following special tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer 100 (MD998813)
• Installer adaptor (MD998823)
>>D<< Fitting 4th gear sleeve
Fit 4th gear sleeve using the following special
tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer 100 (MD998813)
• Installer adaptor (MD998822)
>>E<< Fitting thrust washer
Use only 1 thrust washer.
1. Select a thrust washer that will make
Dimension A in the drawing the standard
length.
Standard length: 167.6 ~ 167.7 mm
How to select the thrust washer
a. Using a height gauge, measure Dimension B
(in the drawing - distance between 4th gear
bearing sleeve and front bearing).
b. Select a thrust washer that produces the
standard length when its thickness is added to
Dimension B.
2. Fit thrust washer using the following special
tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer 100 (MD998813)
• Installer adaptor (MD998822)
Care required
Care required
MANUAL TRANSMISSION - INPUT SHAFT
22-26
>>F<< Fitting 5th gear sleeve
Fit 5th gear sleeve using the following special tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer 100 (MD998813)
• Installer adaptor (MD998822)
>>G<< Fitting 5th-6th gear synchroniser hub /
synchroniser key / synchroniser sleeve
Synchroniser hub must not be re-used.
1. Join 5th-6th gear synchroniser hub and
synchroniser sleeve in direction shown in drawing.
2. Fit synchroniser keys and springs in positions
shown in the drawing.
>>H<< Fitting 5th-6th gear synchroniser
assembly
Make sure synchroniser ring does not get
chewed up when fitting assembly.
Fit 5th-6th gear synchroniser assembly using the
following special tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer 100 (MD998813)
• Installer adaptor (MD998822)
Care required
Care required
5th gear
6th gear
4 oil grooves
3 oil grooves
Distinguishing
groove
Central
protrusion
Central
protrusion
MANUAL TRANSMISSION - INPUT SHAFT
22-27
>>I<< Fitting 6th gear sleeve
Fit 6th gear sleeve using the following special tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer adaptor (MD998818)
>>J<< Fitting snap ring
Select a snap ring that produces the standard
clearance between the snap ring and the snap ring
groove, and fit it.
Standard clearance: 0 ~ 0.1 mm
>>K<< Fitting input shaft rear bearing
Fit input shaft rear bearing so that its snap ring
groove runs in the direction shown in the
drawing.
Press fit input shaft rear bearing using the following
special tools:
• Bearing remover (MD998801)
• Installer cap (MD998812)
• Installer adaptor (MD998818)
Care required
6th gear
Snap ring
groove
MANUAL TRANSMISSION - INPUT SHAFT
22-28
Checks
M1222001700114
Input Shaft
There must be no scratching, peeling, gouging,
uneven wear, warping or other abnormalities on the
input shaft.
Gears
1. There must be no scratching or wear on the
helical gears or clutch gear teeth sides for any of
the gears.
2. There must be no surface roughness, scratching
or wear on the synchroniser cones of any of the
gears (excluding 3rd).
3. There must be no scratching or wear on the inside
diameters or front/rear surfaces of any of the
gears.
Needle bearing
1. When the input shaft, sleeve and gears are
assembled and rotated, they must rotate
smoothly, with no play orabnormal noise.
2. The retainers must not be deformed.
Single cone 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.
4. Push synchroniser ring up against gear cone, and
check Clearance A. If clearance is below limit,
replace.
Limit: 0.7 mm
Gears
Synchroniser
ring
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