Mitsubishi Evolution X. Manual - part 339

MANUAL TRANSAXLE DIAGNOSIS <MANUAL TRANSAXLE>

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MANUAL TRANSAXLE

22A-5

MANUAL TRANSAXLE DIAGNOSIS 

<MANUAL TRANSAXLE>

INTRODUCTION

M1221006900778

The manual transaxle can exhibit any of the following 
symptoms: noise or vibration is generated, oil leaks, 
shifting gears is hard or troublesome, or the tran-
saxle jumps out of gear.

The causes of these symptoms could come from: 
incorrect mounting, the oil level may be low, or a 
component of the transaxle may be faulty.

TROUBLESHOOTING STRATEGY

M1221007000712

Use these steps to plan your diagnostic strategy. If 
you follow them carefully, you will be sure that you 
have exhausted most of the possible ways to find a 
manual transaxle fault.
1. Gather information from the customer.

2. Verify that the condition described by the 

customer exists.

3. Find the malfunction by following the Symptom 

Chart.

4. Verify malfunction is eliminated.

SYMPTOM CHART

M1221007100838

Symptom

Inspection 
procedure

Reference page

Noise, Vibration

1

P.22A-5

Oil Leaks

2

P.22A-6

Hard Shifting

3

P.22A-7

Jumps Out of Gear

4

P.22A-8

SYMPTOM PROCEDURES

Inspection Procedure 1: Noise, Vibration

DIAGNOSTIC PROCEDURE

STEP 1. Check the idle speed.
Q: Does the idle speed meet the standard values?

YES : Go to Step 2.
NO :  Refer to GROUP 11A, On-vehicle Service 

− Idle 

Speed Check 

P.11A-12

.

STEP 2. Check whether the transaxle and engine mount is 
loose or damaged.
Q: Are the transaxle and engine mount loose or damaged?

YES : Tighten or replace the part. Then go to Step 7.
NO :  Go to Step 3.

MANUAL TRANSAXLE DIAGNOSIS <MANUAL TRANSAXLE>

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MANUAL TRANSAXLE

22A-6

STEP 3. Check that the oil level is up to the lower edge of 
the filler plug hole.

AC700330AE

Gasket

Transmission oil

Filler plug hole

Oil filler plug

Q: Is the oil level up to the lower edge of the filler plug 

hole?
YES : Go to Step 4.
NO :  Refill DiaQueen NEW MULTI GEAR OIL API 

classification GL-3, SAE 75W-80. Then go to Step 7.

STEP 4. Check for the specified oil.
Q: Is the specified oil DiaQueen NEW MULTI GEAR OIL API 

classification GL-3, SAE 75W-80?
YES : Go to Step 5.
NO :  If in doubt, replace the oil. Refer to 

P.22A-116

. Then 

go to Step 7.

STEP 5. Remove the transaxle. Check the end play of the 
input and output shafts.
Q: Does the end play of the input and output shafts meet 

the standard value?
YES : Go to Step 6.
NO :  Adjust the end play of the input and output shafts. 

Then go to Step 7.

STEP 6. Disassemble the transaxle. Check the gears for 
wear and damage.
Q: Are the gears worn or damaged?

YES : Replace the gears. Go to Step 7.
NO :  Go to Step 7.

STEP 7. Retest the systems.
Q: Is the noise or vibration still there?

YES : Return to Step 1.
NO :  The procedure is complete.

Inspection Procedure 2: Oil Leaks

DIAGNOSTIC PROCEDURE

STEP 1. Visual check.
Raise the vehicle, and check for oil leaks. If oil leak is 
difficult to locate, steam clean the transaxle and drive 
the vehicle for at 10 minutes. Then check the leak 
again.

Q: Is the oil leak(s) found?

YES : 

Go to Step 2.

NO : 

Check for the oil leaks around the engine. 
Then go to Step 4.

MANUAL TRANSAXLE DIAGNOSIS <MANUAL TRANSAXLE>

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MANUAL TRANSAXLE

22A-7

STEP 2. Visual check at the clutch housing.

Q: Do oil leaks appear around the joint between the 

engine and the clutch housing?
YES : 

Remove the transaxle. Check the input 

shaft oil seal, and replace if necessary. 
Then go to Step 4.

NO : 

Go to Step 3.

STEP 3. Check the oil seal or O-ring for damage.

Q: Is the oil seal or O-ring damaged?

YES : 

 Replace the oil seal or the O-ring. Then go 

to Step 4.

NO : 

Go to Step 4.

STEP 4. Retest the system.

Q: Is the oil still leaking?

YES : 

Return to Step 1.

NO : 

The procedure is complete.

Inspection Procedure 3: Hard Shifting

DIAGNOSTIC PROCEDURE

STEP 1. Check the transaxle control

Q: Are the shift cable and the select cable in good 

condition?
YES : 

Go to Step 2.

NO : 

Repair or replace the shift cable and the 
select cable. Refer to 

P.22A-121

. Then go 

to Step 7.

STEP 2. Check the transaxle oil.

Q: Is the oil dirty?

YES : 

Replace the oil. Refer to 

P.22A-116

. Then 

go to Step 7

NO : 

Go to Step 3.

STEP 3. Check the clutch system.

Q: Is the clutch system normal?

YES : 

Go to Step 4.

NO : 

Repair or replace the clutch system. Refer 
to GROUP 21B, Clutch 

P.21B-4

. Then go to 

Step 7.

STEP 4. Remove and disassemble the transaxle. 
Check the control housing.

Q: Is the control housing in good condition?

YES : 

Go to Step 5.

NO : 

Repair or replace the control housing (Refer 
to GROUP 22B, Transaxle 

P.22B-12

) Then 

go to Step 7.

STEP 5. Check for poor meshing or worn 
synchronizer ring and gear cone.

Q: Is poor meshing or worn synchronizer ring and 

gear cone found?
YES : 

Repair or replace the synchronizer ring and 

gear cone. Then go to Step 7.

NO : 

Go to Step 6.

STEP 6. Check the synchronizer spring for 
weakness.

Q: Is the synchronizer spring weak?

YES : 

Replace the synchronizer spring. Then go 

to Step 7.

NO : 

Go to Step 7.

STEP 7. Retest the system.

Q: Is the shifting of the gears still hard?

YES : 

Return to Step 1.

NO : 

The procedure is complete.

DIAGNOSIS <S-AWC(SUPER ALL WHEEL CONTROL)>

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MANUAL TRANSAXLE

22A-8

Inspection Procedure 4: Jumps Out of Gear

DIAGNOSTIC PROCEDURE

STEP 1. Check the transaxle control

Q: Are the gearshift cable and the select cable in good 

condition?
YES : 

Go to Step 2.

NO : 

Repair or replace the gearshift cable and 
the select cable. Refer to 

P.22A-121

. Then 

go to Step 5.

STEP 2. Remove and disassemble the transaxle. 
Check the control housing.

Q: Is the control housing in good condition?

YES : 

Go to Step 3.

NO : 

Repair or replace the control housing (Refer 
to GROUP 22B, Transaxle 

P.22B-12

) Then 

go to Step 5.

STEP 3. Check the shift forks for wear.

Q: Is the shift forks worn?

YES : 

Replace the shift fork. Refer to GROUP 

22B, transaxle 

P.22B-12

. Then go to Step 5.

NO : 

Go to Step 4.

STEP 4. Check the clearance.

Q: Is the clearance between the synchronizer hub and 

sleeve excessive?
YES : 

Replace the synchronizer hub or sleeve. 

Refer to GROUP 22B, Input Shaft 

P.22B-27

 

and Output Shaft 

P.22B-35

. Then go to Step 

5.

NO : 

Go to Step 5.

STEP 5. Retest the system.

Q: Does the transaxle still jump out of gear?

YES : 

Return to Step 1.

NO : 

The procedure is complete.

DIAGNOSIS <S-AWC(SUPER ALL WHEEL CONTROL)>

INTRODUCTION

M1221006900831

The S-AWC system can exhibit any of the following 
symptoms: noise or vibration is generated or fluid 
leaks.

The causes of these symptoms could come from: 
incorrect mounting, the fluid level may be low, or a 
component of the S-AWC may be faulty.

TROUBLESHOOTING STRATEGY

M1221007000790

Use these steps to plan your diagnostic strategy. If 
you follow them carefully, you will find most S-AWC 
malfunctions.
1. Gather as much information as possible about the 

complaint from the customer.

2. Verify that the condition described by the 

customer exists.

3. Check the vehicle for any S-AWC Diagnostic 

Trouble Codes (DTCs).

4. If you can not verify the condition and there are no 

DTCs, the malfunction is intermittent. For 
information on how to cope with intermittent 
malfunctions, refer to GROUP 00, How to Use 
Troubleshooting/Inspection Service Points 

− How 

to Cope with Intermittent Malfunction 

P.00-15

.

5. If you can verify the condition but there are no 

DTCs, or the system can not communicate with 
scan tool, refer to the Symptom Chart 

P.22A-14

.

6. If there is a DTC, record the number of the code, 

then erase the code from memory using scan tool.

7. Reconfirm the symptom.
8. If a DTC is set again, go to the Inspection Chart 

for Diagnostic Trouble Codes.

9. If a DTC is not set again, the malfunction is 

intermittent. For information on how to cope with 
intermittent malfunctions, refer to GROUP 00, 
How to Use Troubleshooting/Inspection Service 
Points 

− How to Cope with Intermittent 

Malfunction 

P.00-15

.

10.Verify malfunction is eliminated. After repairs are 

completed, the complaint conditions to confirm 
the malfunction has been eliminated.