Mitsubishi Lancer Evolution 8. Manual - part 98

MANUAL TRANSMISSION - TRANSMISSION

22-17

>>J<< Fitting shift check sleeves, check balls,
check springs and check ball plugs

• Check balls must not be re-used.
• Make sure you use shift check sleeves and

check springs of correct length (A: short, B:
long)

• Make sure that check balls do not fall into air

breather groove on clutch housing.

Fit shift check sleeves (2), check balls (2), check
springs (2), and check ball plugs (2).

>>K<< Fitting differential side bearing
adjustment shim(s)

You must use no more than 2 shims.
Fit adjustment shim(s) so that pre-load for
differential side bearing will be standard thickness.
Standard thickness : 0.15 – 0.21 mm
1. Shim selection method

(1) Measure distance from end of transaxle case
to shim fitting surface (Dimension L1) and
distance from end of clutch housing to end of
differential side bearing (L2).
(2) Calculate clearance between transaxle case
and differential side bearing outer race using
following formula: L = L1 – L2
(3) Select shim(s) with thickness of L (calculation
result) plus 0.15 – 0.21 (standard value).

2. Measurement method

(1) Fit measurement adaptor (Special tool No.
MB991969) to differential side bearing hole in
transaxle case, and calculate
Dimension L1, shown in drawing, using following
formula: L1 = 25.00 (height of MB991969) –
Measurement ‘a’
(2) Fit outer race to differential side bearing on
final gear side.
Pushing gently to keep outer race horizontal,
rotate final gear at least 5 times.
Comment: Reason for rotating final gear is to run
in bearing roller.

Care required

Care required

Transaxle
case

Differential side bearing
outer race

Adjustment Shim

Straight edge

Straight edge

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Measure dimensions at 3 optional points on
outer race. Check whether outer race is
horizontal before measuring.
(3)Using a height gauge, measure distance from

differential side bearing outer race to transaxle
fitting surface on clutch housing (Dimension L2).

>>L<< Fitting differential side bearing outer race.
1. Heat transaxle case to about 100˚C (maximum

120˚C).

2. Using the bearing outer race installer (Special tool

No. MB991966), fit differential side bearing outer
race.

>>M<< Fitting adjustment shims

You must only use one of each type of shim.
Fit shim(s) you have selected.
Comment: Refer to ‘Pre-assembly adjustment’
(below) when selecting shims.
Pre-assembly adjustment
(1)Put solder (length about 10mm, diameter 1.6mm)

on input shaft rear bearings at locations shown on
drawing.

Care required

Care required

Big testers

Height Gauge

Solder

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(2)  Put solder (length about 10mm, diameter

1.6mm) on transaxle case at locations shown in
drawing (main shaft rear bearing fitting area).

(3)  Put solder (length about 10mm, diameter

1.6mm) on transaxle case locations shown in
drawing (reverse idler bosses).

(4)  Temporarily locate snap ring on main shaft rear

bearing area of transaxle case.

(5)  With snap ring temporarily located on main shaft

bearing area, open out snap ring to make it
bigger than the bore plug fitting hole, and put
transaxle onto clutch housing.

For this operation, use the transaxle case bolts
you remove.
(6)  Tighten fitting bolts to specified torque.

For this operation, use the O-ring you remove.
(7) Fit control assembly and tighten fitting bolts to

specified torque.

(8) Shift to 2nd gear, lift up main shaft, and fit snap

ring securely to main shaft rear bearing.
Comment: See control assembly fitting section
for how to shift gears.

(9) Return control assembly to neutral position and

remove fitting bolts. Then remove control
assembly.

(10) Remove transaxle case.
(11) Remove snap ring from main shaft rear bearing,

then remove transaxle case.

(12) Remove solder, measure thickness of squashed

solder using a micrometer, and select shims
which will give the appropriate end play.

Comment: If solder has not been squashed, repeat
operations (1) to (11) using solder with a larger diameter.
Input shaft end play: standard thickness: 0 – 0.06 mm
Main shaft end play: standard thickness: 0 – 0.06 mm
Reverse idler gear end play: standard thickness:0.04 – 0.10mm

Care required

Care required

Solder

Solder

Bolt colours
A: yellow
B: black

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22-20

>>N<< Fitting transaxle case

Snap rings must not be re-used.
1. Temporarily assemble snap ring on man shaft

rear bearing on transaxle.

2. Squeeze sealant (liquid gasket) into transaxle

locations shown in drawing.
Liquid gasket brand:
MZ100077 or equivalent

3. With snap ring temporarily assembled on main

shaft bearing, open out snap ring to make it
bigger than the bore plug fitting hole and put
transaxle case onto clutch housing,

Bolts (B) must not be re-used.
4. Tighten fitting bolts to specified torque.

>>O<< Fitting control assembly

O-rings must not be re-used.
1. Fit control assembly, and tighten fitting bolts to
specified torque.
2. Shift to 2nd gear, lift main shaft up and fit snap
ring securely to main shaft rear bearing.
Comment: Shift to 2nd gear by moving shift lever
in the order shown in the drawing.

>>P<< Fitting reverse switch
1. Put sealant (liquid gasket) on screw area on

reverse switch.
Liquid gasket: 
MZ100077 or equivalent

2. Fit reverse switch to transaxle case.

Care required

Care required

Care required

Bolt colours
A: yellow
B: black