Mitsubishi Lancer Evolution IX. Manual — part 292

AK204166AF

28

29

30

31

32

33

34

35

35

48

36

36

37

38

39

40

41

42

43

44

51

45

46

47

49

50

52

53

54

55

56

57

14 ± 1 N·m

Apply gear oil to
all moving parts
before installation.

Disassembly steps

28. Reverse lever assembly
29. Shifter cap
30. Reverse fork rod
31. Reverse shift fork
32. Retaining pin
33. Reverse bracket
34. Reverse bracket fork rod
35. Interlock ball
36. Retaining pin
37. 1st-2nd bracket
38. 1st-2nd fork rod
39. 1st-2nd shift fork
40. Retaining pin
41. C-ring
42. 3rd-4th fork rod
43. Interlock pin
44. 3rd-4th bracket
45. Retaining pin
46. C-ring
47. 5th-6th fork rod
48. Interlock pin
49. 5th-6th shift fork

50. 3rd-4th shift fork
51. 5th-6th bracket
52. Interlock ball
53. Shift check sleeve
54. Main shaft assembly
55. Input shaft assembly
56. Reverse idler gear assembly
57. Center differential

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-13

Reassembly steps

57. Center differential

>>A<<

56. Reverse idler gear assembly

>>A<<

55. Input shaft assembly

>>A<<

54. Main shaft assembly
38. 1st-2nd fork rod
37. 1st-2nd bracket
36. Retaining pin

>>B<<

39. 1st-2nd shift fork

>>C<<

53. Shift check sleeve

>>D<<

42. 3rd-4th fork rod
43. Interlock pin

>>D<<

44. 3rd-4th bracket

>>D<<

50. 3rd-4th shift fork

Disassembly steps (Continued)

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-14

DISASSEMBLY SERVICE POINTS
<<A>> DIFFERENTIAL SIDE BEARING
OUTER RACE REMOVAL

AK203785

1. Heat the transmission case to about 100

°C

(maximum temperature: 120

°C).

AK204353

AK204353AC

MB990810

MB991968

MB991967

2. Using the following special tools, remove the

differential side bearing outer race.

• Side bearing puller (MB990810)

• Claw (MB991967)

• Bridge (MB991968)

REASSEMBLY SERVICE POINTS
>>A<< INPUT SHAFT ASSEMBLY / MAIN
SHAFT ASSEMBLY / REVERSE IDLER
GEAR ASSEMBLY INSTALLATION

AK203325AD

Reverse idler gear assembly

1. Place the reverse idler gear assembly at the

installation location without actually inserting it
into the clutch housing.

AK203326AC

Input shaft
assembly

Main shaft
assembly

CAUTION

Be careful not to scratch the input shaft oil seal.
(Protect it from scratches by wrapping vinyl tape
around the splined portion of the input shaft
assembly.)
2. Insert the input shaft assembly and then the main

shaft assembly into the clutch housing, leaving
some space between each assembly and the
housing.

>>D<<

41. C-ring

>>D<<

40. Retaining pin

>>E<<

52. Interlock ball

>>F<<

47. 5th-6th fork rod
48. Interlock pin

>>F<<

51. 5th-6th bracket

>>F<<

49. 5th-6th shift fork

>>F<<

46. C-ring

Reassembly steps (Continued)

>>F<<

45. Retaining pin

>>G<<

35. Interlock ball

>>H<<

34. Reverse bracket fork rod

>>H<<

33. Reverse bracket
32. Retaining pin
31. Reverse shift fork
30. Reverse fork rod

>>I<<

28. Reverse lever assembly
29. Shifter cap

Reassembly steps (Continued)

AB

AK203327

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-15

CAUTION

Make sure to fit the lock pin at the end of the
reverse idler gear assembly into the groove in
the clutch housing.
3. Move the reverse idler gear assembly so that its

parts fit into the spaces between the housing and
the partially inserted shaft assemblies, and then
insert the three assemblies together into the
clutch housing.

>>B<< 1ST-2ND FORK ROD / 1ST-2ND
SHIFT FORK INSTALLATION

AK203328

CAUTION

• The retaining pin is not reusable.
• When installing the retaining pin, insert an

Allen wrench into the hole on the other side of
the fork rod to keep the fork from slipping
down.

Install the 1st-2nd fork rod in the clutch housing and
then install the 1st-2nd shift fork on the fork rod by
hammering in the retaining pin.

>>C<< SHIFT CHECK SLEEVE
INSTALLATION

AK204448AC

1st-2nd
fork rod

Shift
check
sleeve

CAUTION

The transmission assembly contains parts that
resemble shift check sleeves. Make sure not to
mistakenly install a similar part instead of the
shift check sleeve (length: 36.25 mm).
Install the shift check sleeve.

>>D<< 3RD-4TH BRACKET / 3RD-4TH
SHIFT FORK / 3RD-4TH FORK ROD
INSTALLATION

AK204449AC

3rd-4th fork rod

Interlock pin

CAUTION

Apply Vaseline to the interlock pin and be careful
not to drop it during installation.
1. Install the interlock pin on the 3rd-4th fork rod.
2. Install the 3rd-4th bracket, 3rd-4th shift fork, and

3rd-4th fork rod.

CAUTION

The C-ring is not reusable.
3. Install the C-ring on the 3rd-4th shift fork

AK203330

TRANSMISSION

MANUAL TRANSMISSION OVERHAUL

22B-16

CAUTION

• The retaining pin is not reusable.
• When installing the retaining pin, insert an

Allen wrench into the hole on the other side of
the fork rod to keep the fork from slipping
down.

4. Hammer the retaining pin into the 3rd-4th bracket.

>>E<< INTERLOCK BALL INSTALLATION

AK204450AC

Interlock balls

CAUTION

Make sure that the interlock balls do not fall out
of their locations.
Install the two interlock balls.

>>F<< 5TH-6TH BRACKET / 5TH-6TH
SHIFT FORK / 5TH-6TH FORK ROD
INSTALLATION

AK204451AC

5th-6th fork rod

5th-6th shift check parts

Interlocl pin

CAUTION

Apply Vaseline to the interlock pin and be careful
not to drop it during installation.
1. Install the interlock pin in the 5th-6th fork rod.

CAUTION

Install the 5th-6th fork rod with its three grooves
facing the 5th-6th shift check parts.
2. Install the 5th-6th bracket, 5th-6th shift fork, and

5th-6th fork rod.

CAUTION

The C-ring is not reusable.
3. Install the C-ring on the 5th-6th bracket.

AK203332

CAUTION

• The retaining pin is not reusable.
• When installing the retaining pin, insert an

Allen wrench into the hole on the other side of
the fork rod to keep the fork from slipping
down.

4. Hammer the retaining pin into the 5th-6th shift

fork.

>>G<< INTERLOCK BALL INSTALLATION

AK204452AC

Interlock balls

CAUTION

Make sure that the interlock steel balls do not fall
out of their locations.
Install the two interlock steel balls.