Mitsubishi Lancer Evolution X. Manual - part 629

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-29

OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY

M1222002200640

AK702341

3

4

5

6

7

8

9

11

16

10

14

13

12

15

18

17

19

20

21

22

24

25

26

1

27

2

AC

23

Apply gear oil to
all moving parts
before installation.

Removal steps 

>>M<<

1. Oil seal

<<A>>

>>L<<

2. Taper roller bearing

>>K<<

3. Snap ring

<<B>>

>>J<<

4. Taper roller bearing
5. Collar

<<C>>

>>I<<

6. 5th speed gear

<<C>>

>>H<<

7. 4th speed gear

>>G<<

8. Snap ring

<<D>>

>>F<<

9. 3rd speed gear
10.2nd speed gear
11. Needle roller bearing
12.Synchronizer outer ring
13.Synchronizer cone
14.Synchronizer inner ring

>>D<<

15.1st-2nd speed synchronizer 

sleeve

<<E>>

>>E<<

16.2nd speed gear sleeve

<<E>>

>>C<<

17.1st-2nd speed synchronizer 

hub

<<E>>

18.Synchronizer key

<<E>>

19.Synchronizer outer ring

<<E>>

20.Synchronizer cone

<<E>>

21.Synchronizer inner ring

<<E>>

>>B<<

22.Thrust bearing

<<E>>

23.1st speed gear

<<E>>

24.Needle roller bearing

<<E>>

>>B<<

25.Thrust bearing

<<E>>

>>A<<

26.1st speed gear sleeve
27.Output shaft

Removal steps (Continued)

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-30

Required Special Tools:

• MB990560: Rear axle shaft bearing remover
• MB990842: Drag link bushing remover and 

installer B

• MD998917: Bearing remover
• MD998812: Installer cap
• MD998814: Installer-200

• MD998824: Installer adapter (50)
• MD998822: Installer adapter (46)
• MD998813: Installer-100
• MD998821: Installer adapter (44)
• MD998819: Installer adapter (40)
• MD999601: Valve stem seal installer

DISASSEMBLY SERVICE POINTS

.

<<A>> TAPER ROLLER BEARING REMOVAL

1. Using a chisel or the like, knock off the roller cage of the 

taper roller bearing.

2. Using the special tools, MB990842 and MB990560, 

indicated below, remove the taper roller bearing.

.

<<B>> TAPER ROLLER BEARING REMOVAL

Using the special tools, MD998917 and MB990842, indicated 
below, remove the taper roller bearing.

.

<<C>> 5TH SPEED GEAR / 4TH SPEED GEAR 
REMOVAL

Using the special tools, MD998917 and MB990842, indicated 
below, remove the 5th speed gear and 4th speed gear.

.

AK703313AC

MB990842

MB990560

AK703177AC

MD998917

MB990842

AK703178

MD998917

AC

MB990842

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-31

<<D>> 3RD SPEED GEAR REMOVAL

Using special tool, MD998917, remove the 3rd speed gear.

.

<<E>> NEEDLE ROLLER BEARING / 
SYNCHRONIZER CONE / SYNCHRONIZER 
OUTER RING / SYNCHRONIZER INNER RING / 
THRUST BEARING / 2ND SPEED GEAR SLEEVE / 
1ST-2ND SPEED SYNCHRONIZER HUB / 1ST 
SPEED GEAR / 1ST SPEED GEAR SLEEVE 
REMOVAL

Using special tool, MD998917, support the 1st speed gear 
sleeve, and then remove the 2nd speed gear sleeve, 1st-2nd 
speed synchronizer hub, synchronizer cones, synchronizer 
outer rings, synchronizer inner rings, thrust bearings, 1st speed 
gear, needle roller bearing and 1st speed gear sleeve.

ASSEMBLY SERVICE POINTS

.

>>A<< 1ST SPEED GEAR SLEEVE INSTALLATION

Using the special tools, MD998812, MD998814 and 
MD998824, indicated below, install the 1st speed gear sleeve.

.

AK703301

AC

MD998917

AK703302

AC

MD998917

AK703303AC

MD998814

MD998812

MD998824

OUTPUT SHAFT

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-32

>>B<< THRUST BEARING INSTALLATION

Install the thrust bearings as shown.

.

>>C<< 1ST-2ND SPEED SYNCHRONIZER HUB 
INSTALLATION

1. Install the 1st-2nd speed synchronizer hub in the illustrated 

direction.

2. Using the special tools, MD998812, MD998814 and 

MD998824, indicated below, install the 1st-2nd speed 
synchronizer hub.

.

>>D<< 1ST-2ND SPEED SYNCHRONIZER SLEEVE 
INSTALLATION

1. Install the 1st-2nd speed synchronizer sleeve in the 

illustrated direction.

2. Install the synchronizer outer ring, synchronizer cone and 

synchronizer inner ring.

3. After installation, check that the 1st-2nd speed gears rotate 

smoothly.

.

AK703377AC

1st speed
gear sleeve

Needle roller bearing

Thrust bearing

AK703378

AC

Installation
direction

AK703304

AC

MD998812

MD998814

MD998824

AK703379

AC

Installation
direction

Identification
groove