Mitsubishi Lancer Evolution 8. Manual - part 94

22-1

CHAPTER 22

MANUAL TRANSMISSION

CONTENTS

Overview ...............................................22-2

Specifications .......................................22-3

Maintenance Standards .......................22-4

Sealants/Adhesives ..............................22-4

Lubricants .............................................22-4

Adjustment Shims, Thrust
Washers, Snap Rings ...........................22-5 

Tightening Torques ..............................22-6

Special Tools.........................................22-7

Transmission.......................................22-10 

Dismantling/Assembling.................................22-10 
Checks ...........................................................22-21

Input Shaft ...........................................22-22

Dismantling/Assembling.................................22-22
Checks ...........................................................22-28

Reverse Idler Gear ..............................22-30

Dismantling/Assembling.................................22-30
Checks ...........................................................22-32

Clutch Housing ...................................22-34

Dismantling/Assembling.................................22-34

Transmission Case .............................22-37

Dismantling/Assembling.................................22-37

Centre Differential...............................22-39

Dismantling/Assembling.................................22-39

Transfer................................................22-43

Dismantling/Assembling.................................22-43

MANUAL TRANSMISSION - OVERVIEW

22-2

OVERVIEW

Cross Section (Transmission)

MANUAL TRANSMISSION - SPECIFICATIONS

22-3

Cross Section (Transfer)

SPECIFICATIONS

M1222000200150

Transmission Type Table

1st gear

2.909

2nd gear

1.944

3rd gear

1.434

4th gear

1.100

5th gear

0.868

6th gear

0.693

Reverse

2.707

Transmission Type

Speedometer Gear
Ratio?

Final Reduction
Gear Ratio

Front
LSD?

Vehicle
Type

Engine
Type

W6MAA-1-GFNF

No

4-583

Yes

CT9A

4G63-I/C-T/C

Gear Ratio Table

MANUAL TRANSMISSION - MAINTENANCE STANDARDS

22-4

Maintenance Standards

Liquid Gaskets (Flow-In-Place Gasket)
On this transmission FIPG is used in several
assemblies. For the liquid gasket to fully achieve its
objectives, careful attention needs to be paid to the
amount used, the application procedure, and the
condition of the surfaces on which it is applied.
Not using enough will result in leakage, while if too
much is used it will overflow and block or constrict the
oil passages. Hence, to prevent leakage from joints, it
is absolutely essential to apply the correct amount
and leave no gaps.

Dismantling
Parts assembled using FIPG can be dismantled
easily; no special method is required. However, in
some cases you may need to tap it with a wooden
mallet or similar tool to break the sealant between the
mating surfaces.

Cleaning the Gasket Surface
Completely remove all material adhering to mating
surfaces using a gasket scraper. Make sure that the
surfaces on which the FIPG will be applied are
smooth. There must be no oil, grease or other
substances adhering to mating surfaces. Do not
forget to remove any old FIPG from fitting holes,
screw holes.

Application Procedure
Apply the FIPG within the specified diameter, leaving
no gaps. Make sure it is applied all the way around
fitting holes. Before it solidifies FIPG can be wiped
off. Fit the specified sections together while it is still
wet (within 10 minutes). Make absolutely sure that it
only adheres to the areas where it is needed. Do not
put any oil or water on the parts after fitting them
together, or drive the car, until sufficient time (about 1
hour) has elapsed.
The procedure for applying FIPG varies from
assembly to assembly, so be sure to use the
procedure described here.

Lubricants

M1222000400091

Sealants / Adhesives

Item

Standard (mm) Limit (mm)

Differential side bearing pre-load

0.15 to 0.20

-

Input shaft end play

0 to 0.06

-

Main shaft end play

0 to 0.06

-

Reverse idler gear end play

0.04 to 0.10

-

Distance between input shaft front bearing and thrust washer

167.6 to 167.7

-

Input shaft 6th gear bush end play

0 to 0.1

-

Wear on one side of shift fork claws

-

0.2

Clearance between synchroniser ring and gear

-

0.7

Clearance between synchroniser ring and synchroniser cone

-

0.2

Backlash on differential side gear and pinion

0.025 to 0.150

-

Item

Brand

Clutch housing 

ÅÃ

transaxle case mating surfaces

MZ100077 or equivalent

Reverse switch

MZ100077 or equivalent

Air breather

MZ100055 or equivalent

Differential drive gear bolt

0110106 or Locktight 648 or equivalent

Item

Brand

Lip on transfer oil seal

Sunlight No. 2 or Retinax A or equivalent

O-rings

M1222000300135

M1222000500128