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Mitsubishi Lancer Evolution 8. Manual - part 97

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22-13

Assembly Order (cont.)

47. Interlock

>>H<<

32. Reverse

bracket

>>F<<

50.

5th-6th gear bracket

31.

Retaining pin

>>F<<

48.

5th-6th gear shift fork

30.

Reverse shift fork

>>F<<

C ring

29.

Reverse fork rod

>>F<<

44. Retaining pin

>>I<<

27.

Reverse lever assembly

>>G<<

34. Interlock balls

28.

Shifter cap

>>H<<

33. Reverse bracket fork rod

Key Points for Dismantling
<<A>> Removing differential side bearing outer
race
1. Heat transaxle case to about 100˚C (maximum

120˚C).

2. Remove differential side bearing outer race using

the following special tools:
• Side bearing puller (MB990810)
• Claws (MB991967)
• Bridge (MB991968)

Key Points for Assembling
>>A<< Fitting input shaft assembly/main shaft
assembly/reverse idler gear assembly
1. Temporarily locate reverse idler gear assembly.

Reverse idler gear assembly

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22-14

When fitting assembly, make sure that you do
not scratch input idler shaft seal (Wind plastic
tape around spline of input shaft assembly).
2. Insert input shaft assembly first, then main shaft

assembly, so that they rest lightly (literally ‘float’)
on clutch housing.

Match up lock pin at tip of reverse idler gear
assembly with grooved location on clutch housing,
and fit this assembly.
3. Fit reverse idler gear assembly between input

shaft and main shaft assemblies, which are
resting lightly on clutch housing, then fit all 3 into
it at the same time.

>>B<< Fitting 1st-2nd gear fork rod and 1st-2nd
gear shift fork

• Retaining pins must not be re-used.
• When fitting retaining pin, use hexagonal
wrench to locate it.
Fit 1st-2nd gear fork rod and shift fork, then fit
retaining pin.

>>C<< Fitting shift check sleeve

Make sure you do not fit a similar part by
mistake (shift check sleeve length = 36.25mm).
Fit shift check sleeve.

Care required

Input shaft
assembly

Main shaft
assembly

1st-2nd Shift check
gear

sleeve

fork
rod

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>>D<< Fitting 3rd-4th gear bracket, shift fork and fork
rod

To prevent interlock pin from coming out, smear
vaseline on it. When fitting, take care not to drop it.
1. Fit interlock pin to 3rd-4th gear fork rod.
2. Fit 3rd-4th gear bracket, shift fork and fork rod.

C rings must not be re-used.
3. Fit C ring to 3rd-4th gear shift fork.

• Retaining pins must not be re-used.
• When fitting retaining pin, use hexagonal

wrench to locate it.

4. Fit retaining pin to 3rd-4th gear bracket.

>>E<< Fitting interlock balls

Make sure interlock balls do not fall from fitting
position.
Fit (2) interlock balls.

>>F<< Fitting 5th-6th gear bracket, shift fork and fork
rod

To prevent interlock pin coming out, smear
vaseline on it.
When fitting, take care not to drop it.
1. Fit interlock pin to 5th-6th gear fork rod

Fit 5th-6th gear shift check components, with the 3
grooves in the 5th-6th gear fork rod facing these
components.
2. Fit 5th-6th gear bracket / shift fork / fork rod.

C rings must not be re-used.
3. Fit C ring to 5th-6th gear bracket.

Care required

3rd-4th gear fork rod

Interlock
Pin

Interlock
balls

Interlock pin

5th-6th gear fork rod

5th-6th gear shift parts

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• Retaining pins must not be re-used.
• When fitting retaining pin, use hexagonal

wrench to locate it.

4. Fit retaining pin to 5th-6th gear shift fork.

>>G<< Fitting interlock balls

Make sure interlock balls do not fall from fitting
position.
Fit (2) interlock balls.

>>H<< Fitting reverse bracket fork rod and
reverse bracket

Fit reverse shift check components with the 2
grooves in the reverse bracket fork rod are
facing these components.
Fit reverse bracket fork rod and reverse bracket.

>>I<< Fitting reverse lever assembly
1. Fit shifter cap to cam on reverse lever assembly,
then fit reverse shift fork.
2. Lifting reverse shift fork up, bring it up against
cam on reverse bracket.

Care required

Interlock Balls

Reverse bracket
fork rod

Reverse lever assembly

Reverse Bracket

Reverse Shift Check parts

Content .. 95 96 97 98 ..