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.