Mitsubishi Lancer Evolution IX. Manual — part 297

REVERSE IDLER GEAR

MANUAL TRANSMISSION OVERHAUL

22B-33

2. Check the synchronizer cone surface of the

reverse idler gear for roughness, damage and
excessive wear.

3. Check the inside surface and front and back sides

of the reverse idler gear for damage and
excessive wear.

SYNCHRONIZER RING

AK204103

AK204103AC

1. Check the clutch gear on the synchronizer ring for

damaged and missing teeth.

2. Check the inner surface of the synchronizer ring

cone for damage and excessive wear. Also check
that the inside ridges are intact.

3. Check the synchronizer key contact surface of the

synchronizer ring for damage and excessive
wear.

AK204104

A

AD

Reverse
idler gear

Synchronizer ring

4. Press the synchronizer ring against the cone of

the reverse idler gear and check clearance A.
Replace the synchronizer ring if the clearance is
less than the limit.

Limit: 0.7 mm

REAR REVERSE IDLER GEAR AND
REVERSE IDLER GEAR SLEEVE

AK204113AC

Match marks

CAUTION

When assembling the reverse idler gear sleeve
and reverse idler gear sleeve, align the match
marks that were made during disassembly.

AK204105AC

Reverse
idler gear

Rverse idler
gear sleeve

1. Check that the reverse idler gear sleeve slides

smoothly on the reverse idler gear hub when they
are combined.

AK204106

AK204106AC

2. Check the front and back ends of the inner splines

of the reverse idler gear sleeve for damage.

3. Check the helical gear teeth and clutch gear teeth

of the reverse idler gear for damage and
excessive wear.

4. Check the front, back, and inner surfaces of the

reverse idler gear for damage and excessive
wear.

CLUTCH HOUSING

MANUAL TRANSMISSION OVERHAUL

22B-34

CLUTCH HOUSING

DISASSEMBLY AND REASSEMBLY

M1222003700165

AK204363

7.3 ± 1.0 N·m

2

3

4

6

8

7

7

5

1

9

10

35 ± 4 N·m

11

11

13

12

AC

Apply gear oil to
all moving parts
before installation.

Disassembly steps

1.

Magnet

>>C<<

2.

Main shaft bearing retainer

3.

Main shaft front bearing

>>B<<

4.

Oil channel

<<A>>

>>D<<

5.

Differential side bearing outer race

>>A<<

6.

Input shaft oil seal

7.

Dowel pin

8.

Knock pin

9.

Drain plug gasket

10. Drain plug
11. Cover A
12. Maintenance hole cover
13. Clutch housing

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

AK203782

1. Heat the clutch housing to about 100

°C

(maximum temprerature: 120

°C).

AK204356

AK204356AC

MB990810

MB991968

MB991967

CLUTCH HOUSING

MANUAL TRANSMISSION OVERHAUL

22B-35

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 OIL SEAL INSTAL-
LATION

AK203784

AK203784AC

MD998323

CAUTION

The oil seal is not reusable.
Using the special tool Bearing installer (MD998323) ,
install the input shaft oil seal into the clutch housing.

>>B<< OIL CHANNEL INSTALLATION

AK203323AD

Spot facing

Ribs

Install the oil channel so that the ribs located on the
channel's main shaft side are fitted into the spot
faced portion on the clutch housing.

>>C<< BEARING RETAINER
INSTALLATION

AK203324AE

Stamp mark

Bearing retainer

Install the bearing retainer so that the stamp mark is
visible, and tighten the mounting bolt to the specified
torque.

>>D<< DIFFERENTIAL SIDE BEARING
OUTER RACE INSTALLATION

AK203782

1. Heat the clutch housing to about 100

°C

(maximum temperature: 120

°C).

AK204357

AK204357AC

MB991966

2. Using the special tool Bearing outer race installer

(MB991966) to install the differential side bearing
outer race in the clutch housing.

TRANSMISSION CASE

MANUAL TRANSMISSION OVERHAUL

22B-36

TRANSMISSION CASE

DISASSEMBLY AND REASSEMBLY

M1222013400121

AK204369

AK204369AC

1

10

2

3

4

6

7

35 ± 4 N·m

8

5

8

9

Disassembly steps

>>C<<

1.

Oil gutter

>>C<<

2.

Baffle plate

3.

Welch plug

>>B<<

4.

Differential oil seal

>>A<<

5.

Air breather

6.

Filler plug

7.

Drain plug gasket

8.

Rod bushing

9.

Stud

10. Transaxle case

Disassembly steps (Continued)