Mitsubishi Lancer Evolution 8. Manual - part 90

8

MANUAL TRANSMISSION – TRANSMISSION

Dismantling Order
27. Spring pin

34. 5th gear-Reverse shift rail

28. 1st-2nd gear shift rail

35. 5th gear-Reverse shift fork

29. 1st-2nd gear shift fork

36. Centre differential

30. Spring pin

37. Output shaft

31. Spring pin

38. Input shaft

32. 3rd-4th gear shift rail

39. Clutch housing

33. 3rd-4th gear shift fork

Put gear oil on all
sliding sections
when fitting



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9

MANUAL TRANSMISSION – OUTPUT SHAFT

Dismantling Order
1.  Snap ring

18. Snap ring

2.  Tapered roller bearing

19. 3rd gear

3.  Reverse gear sleeve

20. 2nd gear

4.  Needle roller bearing

21. Needle roller bearing

5.  Reverse gear

22. 2nd gear sleeve

6.  Inner synchroniser ring

23. Inner synchroniser ring

7.  Synchroniser cone

24. Synchroniser cone

8.  Outer synchroniser ring

25. Outer synchroniser ring

9.  Synchroniser spring

26. Synchroniser spring

10. Synchroniser sleeve

27. Synchroniser sleeve

11. 5th gear-Reverse synchroniser hub

28. 1st-2nd gear synchroniser hub

12. Synchroniser ring

29. Outer synchroniser ring

13. Synchroniser spring

30. Synchroniser spring

14. 5th gear

31. Inner synchroniser ring

15. Needle roller bearing

32. Synchroniser cone

16. 5th gear sleeve

33. 1st gear

17. 4th gear

34. Needle roller bearing

Output Shaft

Dismantling / Assembling

Put gear oil on all
sliding sections
when fitting



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10

MANUAL TRANSMISSION – OUPUT SHAFT

Dismantling Order
35. 1st gear sleeve

37. Oil seal

36. Tapered roller bearing

38. Output shaft

Checks
Synchroniser ring (for 5th gear)
1. There must be no scratching / damage on clutch

gear teeth surfaces.

2. There must be no scratching / wear / squashed

threads on inside diameter of cone.

3. Push synchroniser ring up against gear and

check Clearance A. If clearance is below limit,
replace ring.
Limit: 0.5 mm

Outer synchroniser ring, inner synchroniser ring
and synchroniser cone (for Reverse)

Note
These 3 parts should be replaced as a set, not
separately.
1. There must be no scratching / damage on the

gear teeth surfaces or the cone surface.

2. Assemble the outer ring, inner ring and the cone,

push them up against the gear and check
Clearance A. If it is below the limit, replace them.
Limit: 0.5 mm



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Synchroniser
ring

Gear

Gear

Outer ring

Cone

Inner ring

11

MANUAL TRANSMISSION – OUTPUT SHAFT

Outer synchroniser ring, inner synchroniser
ring, synchroniser cone (for 1st, 2nd gears)
Note
These 3 parts should be replaced as a set, not
separately.
1. There must be no scratching / damage on the

gear teeth surfaces or the cone surface.

2. Assemble the outer ring, inner ring and the cone,

push them up against the gear and check
Clearance A. If it is below the limit, replace them.
Limit: 0.5 mm

Synchroniser spring
Spring must not be weakened, deformed or broken.

Gear

Outer ring

Cone

Inner ring