Mitsubishi Lancer Evolution IX. Manual — part 296
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INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-29
INSPECTION
M1222001700147
INPUT SHAFT
AK204168
AK204168AC
Check the input shaft for damage, flaking, dents,
uneven wear, bend, and other defects.
SPEED GEARS
AK204169
AK204169AC
1. Check the helical gear teeth and clutch gear teeth
of each speed gear for damage and excessive
wear.
2. Check the synchronizer cone surface of each
speed gear for roughness, damage, and
excessive wear (3rd gear excepted).
3. Check the inside surface and front and back sides
of each speed gear for damage and excessive
wear.
NEEDLE ROLLER BEARINGS
1. Combine each needle roller bearing with the input
shaft, corresponding sleeve, and gear. Rotate the
assembly, checking for smooth rotation,
looseness, and noise.
2. Check the retainer for deformation.
SINGLE CONE SYNCHRONIZER RING
AK204170
AK204170AC
1. Check the clutch gear on the synchronizer ring for
damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
ridges are intact.
3. Check the synchronizer key contact surfaces of
the synchronizer ring for damage, and excessive
wear.
AK204104
A
AE
Speed gear
Synchronizer ring
4. Press the synchronizer ring against the cone of
the adjacent speed gear, and check clearance A.
Replace the synchronizer ring if the clearance is
below the limit.
Limit: 0.7 mm
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INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL
22B-30
DOUBLE CONE SYNCHRONIZER RING
AK204172AC
Inner synchronizer ring
Synchronizer ring
cone
Outer synchronizer ring
1. Check the clutch gear on the outer synchronizer
ring for damaged and missing teeth.
2. Check the contact surfaces between each
synchronizer ring and synchronizer cone for
damage and wear. Also check that the cone
ridges are intact.
3. Check the synchronizer key contact surfaces of
the outer synchronizer ring for damage and
excessive wear.
AK204173 AC
A
B
Inner synchronizer ring
Synchronizer ring cone
Outer synchronizer ring
4. Combine the synchronizer rings and synchronizer
cone, and check clearances A and B shown in the
illustration. Replace them if either of the
clearances is greater than the limit.
Limit: 0.2 mm
SYNCHRONIZER KEYS
AK204174
AK204174AC
Check the synchronizer hub contact surfaces of each
synchronizer key for damage and excessive wear.
SYNCHRONIZER SPRINGS
Check the synchronizer springs for loss of tension,
deformation, and breakage.
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REVERSE IDLER GEAR
MANUAL TRANSMISSION OVERHAUL
22B-31
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
M1222012500125
AK204079
AK204079
4
5
6
2
3
7
8
9
11
13
14
10
AC
1
12
Apply gear oil to
all moving parts
before installation.
Disassembly steps
1. Rear reverse idler gear assembly
2. Rear reverse idler gear
<<A>> >>B<<
3. Reverse idler gear sleeve
>>A<<
4. Insert spring
5. Synchronizer ring
6. Needle bearing
7. Washer
8. Thrust bearing
9. Front reverse idler gear
10. Needle bearing
11. Washer
12. Thrust bearing
13. Pin
14. Reverse idler fear shaft
Disassembly steps (Continued)
![](/vehicles/winoney/wruvea/ger/dig.png)
REVERSE IDLER GEAR
MANUAL TRANSMISSION OVERHAUL
22B-32
DISASSEMBLY SERVICE POINTS
<<A>> REVERSE IDLER GEAR SLEEVE
REMOVAL
AK204113AC
Match marks
CAUTION
Meshing problems may occur if the original
spline engagement phase is changed during
reassembly.
Make match marks on the reverse idler gear sleeve
and reverse idler gear hub.
REASSEMBLY SERVICE POINTS
>>A<< INSERT SPRING INSTALLATION
AK204114AC
Clutch
housing
side
Install each insert spring on the reverse idler gear
sleeve, making sure to insert it in the right direction.
>>B<< REVERSE IDLER GEAR SLEEVE
INSTALLATION
AK204113AC
Match marks
CAUTION
Meshing problems may occur if the spline
engagement phase is changed during reassem-
bly.
Align the match marks when engaging the splines.
INSPECTION
M1222012400043
REVERSE IDLER SHAFT
AK204101
AK204101AC
Check the reverse idler shaft for damage, flaking,
dents, uneven wear, bend, and other defects.
THRUST BEARING
1. Check the thrust bearing for smooth rotation,
without looseness or noise, when rotated together
with the washers.
2. Check the retainer for deformation.
NEEDLE BEARING
1. Check the needle bearing for smooth rotation,
without looseness or noise, when rotated together
with the reverse idler gear and shaft.
2. Check the retainer for deformation.
FRONT REVERSE IDLER GEAR
AK204102
AK204102AC
1. Check the helical gear teeth and clutch gear teeth
of the reverse idler gear for damage and
excessive wear.
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