Mitsubishi Lancer Evolution IX. Manual — part 294

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-21

CAUTION

In the following steps, make sure to use the same
O-rings that were removed during disassembly.
7. Install the control assembly and tighten its bolts to

the specified torque.

8. With the gear shifted into 2nd gear, raise the main

shaft and install the snap ring tightly on the main
shaft rear bearing.
NOTE: Refer to CONTROL ASSEMBLY INSTAL-
LATION for the method for shifting the gear into
2nd.

9. Return the control assembly to the neutral

position and remove its mounting bolts. Remove
the control assembly.

10.Remove the transmission case.
11.Remove the snap ring from the main shaft rear

bearing, then remove the transmission case.

12.Remove the crushed pieces of solder.
13.If the solder has not been crushed at all:

(1) In the case of the input shaft rear bearing and

the main shaft rear bearing, use the thicker
solder (1.6 mm diameter, about 10 mm long)
and repeat steps 4 to 12.

(2) In the case of the reverse idler gear, use the

thicker shim and repeat steps 4 to 12.

AK301249

14.Use a micrometer to measure the thickness of the

each crushed solder beads and record the each
measured value.

15.Select each shim with the thickness calculated by

the following formula that will adjust each end play
to a value within the standard value range.
(1) In the case of the input shaft rear bearing and

the main shaft rear bearing:

Shim thickness: (T1

− 0 mm) to (T1 − 0.06

mm)
T1: The crushed solder thickness mm
Standard input shaft end play: 0 mm

− 0.06

mm
Standard main shaft end play: 0 mm

− 0.06

mm

(2) In the case of the reverse idler gear:

Shim thickness: (T1 + T2

− 0.04 mm) to (T1 +

T2

− 0.10 mm)

T1: The crushed solder thickness mm
T2: The shim thickness used for measure-
ment mm
Standard reverse idler gear end play: 0.04
mm

− 0.10 mm

<Measurement using Plastigage>

AK204380AF

Plastigage

1. Put the plastigage (about 10 mm long) on the

input shaft rear bearing as indicated in the
illustration. Install the adjusting shim having
minimum thickness.

AK204385

Plastigage

AF

2. Put the plastigage (about 10 mm long) on the

main shaft rear bearing fitting surface in the
transmission case as indicated in the illustration.
Install the adjusting shim having minimum
thickness.

AK204386AF

Plastigage

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-22

3. Put the plastigage (about 10 mm long) on the

surface of the reverse idler gear mounting boss in
the transmission case as indicated in the
Illustration. Install the adjusting shim having
minimum thickness.

4. Install the snap ring temporarily in the main shaft

rear bearing location in the transmission case.

5. Install the adjusting thrust washer having the

minimum thickness.

6. Expand the snap ring in the main shaft rear

bearing location through the bore plug mounting
hole, and place the transmission case over the
clutch housing.

AK204378AC

A

A

A

A

A

A

A

A

A

A

B

B

B

B

B

B

B

B

B

A

A

Bolt colors

A: Yellow
B: Black

CAUTION

In the following step, use the same transmission
case bolts that were removed during disassem-
bly.
7. Install and tighten the transmission case bolts to

the specified torque.

AK204384

AK204384AC

1

2

CAUTION

In the following steps, make sure to use the same
O-rings that were removed during disassembly.
8. Install the control assembly and tighten its bolts to

the specified torque.

9. With the gear shifted into 2nd gear, raise the main

shaft and install the snap ring tightly on the main
shaft rear bearing.

NOTE: Refer to CONTROL ASSEMBLY INSTAL-
LATION for the method for shifting the gear into
2nd.

10.Return the control assembly to the neutral

position and remove its mounting bolts. Remove
the control assembly.

11.Remove the transmission case.
12.Remove the snap ring from the main shaft rear

bearing, then remove the transmission case.

13.Remove the crushed pieces of plastigage.
14.If the plastigage has not been crushed at all, use

thicker adjusting shim and repeat steps 4 to 13.

AK402081

Plastigage

Shim

AI

15.Measure the width of the each crushed plastigage

at its widest part using a scale printed on the
plastigage package and record the each
measured value.

16.Select each shim with the thickness calculated by

the following formula that will adjust each end play
to a value within the standard value range.
(1) In the case of the input shaft rear bearing and

the main shaft rear bearing:

Shim thickness: (T2 + T3

− 0 mm) to (T2 + T3

− 0.06 mm)
T2: The shim thickness used for measure-
ment mm
T3: The crushed plastigage thickness mm
Standard input shaft end play: 0 mm

− 0.06

mm
Standard main shaft end play: 0 mm

− 0.06

mm

(2) In the case of the reverse idler gear:

Shim thickness: (T2 + T3

− 0.04 mm) to (T2 +

T3

− 0.10 mm)

T2: The shim thickness used for measure-
ment mm
T3: The crushed plastigage thickness mm
Standard reverse idler gear end play: 0.04
mm

− 0.10 mm

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-23

INSPECTION

M1222001100156

BACK LIGHT SWITCH

AK501906

1. Check the back light switch for proper continuity

between the terminals.

Item

Continuity

Press switch

Yes

Release switch

No

2. Replace the backlight switch if the continuity is not

as indicated above.

OIL TEMPERATURE SENSOR

AK501915

1. Measure the resistance of the oil temperature

sensor in order to check of operation of it.

Temperature (

°C)

Resistance (k

Ω)

0

5.790

20

2.45

± 0.14

40

1.148

60

0.5865

80

0.3222

100

0.1884

2. Replace the oil temperature sensor if the

continuity is not as indicated above.

FORK ROD / REVERSE LEVER
ASSEMBLY / SHIFT FORK

AK204455AC

Fork rod

Reverse lever assembly

Shift fork

1. Inspect contacting and rubbing surfaces for

excessive wear, damage, bend, or other defects.
Replace if necessary. (Parts with slight contact
marks need not be replaced.)

AK204454AC

Wear on
one side

Original finger
tip width

Wear on
one side

2. Check if the width of each shift fork finger tip

(which rubs against the coupling sleeve) is greater
than the limit.

Item

Limit for wear
on one side
mm

Original finger
tip width mm

1st-2nd shift
fork

0.2

7.80

− 7.93

3rd-4th shift fork 0.2

7.80

− 7.93

5th-6th shift fork 0.2

6.10

− 6.23

Reverse shift
fork

0.2

12.80

− 12.93

INPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-24

INPUT SHAFT

DISASSEMBLY AND REASSEMBLY

M1222001600162

AK204089

AK204089AC

14

15

16

17

19

18

20

21

2

1

3

6

5

7

12

13

10

4

8

21

22

25

24

9

11

23

8

22

26

27

28

29

30

31

32

Apply gear oil to
all moving parts
before installation.

Disassembly steps

<<A>>

>>K<<

1. Input shaft rear bearing

>>J<<

2. Snap ring

<<B>>

>>I<<

3. 6th gear sleeve

<<B>>

4. Needle roller bearing

<<B>>

5. 6th gear
6. Synchronizer ring

<<C>>

>>H<<

7. 5th-6th synchronizer assembly

>>G<<

8. Synchronizer spring

>>G<<

9. Synchronizer sleeve

>>G<<

10. Synchronizer key

>>G<<

11. 5th-6th synchronizer hub

<<C>>

12. Synchronizer ring

<<C>>

13. 5th gear
14. Needle roller bearing

<<D>>

>>F<<

15. 5th gear sleeve

<<D>>

>>E<<

16. Thrust washer

<<D>>

17. 4th gear

<<D>>

18. Needle roller bearing

<<D>>

>>D<<

19. 4th gear sleeve

<<D>>

20. Synchronizer ring

<<D>>

>>C<<

21. 3rd-4th synchronizer assembly

>>B<<

22. Synchronizer spring

>>B<<

23. Synchronizer sleeve

>>B<<

24. Synchronizer key

>>B<<

25. 3rd-4th synchronizer hub

<<D>>

26. Synchronizer outer ring

<<D>>

27. Synchronizer cone

<<D>>

28. Synchronizer inner ring

<<D>>

29. 3rd gear
30. Needle roller bearing

<<E>>

>>A<<

31. Ball bearing
32. Input shaft

Disassembly steps (Continued)