< Measurement using a solder > Mitsubishi Lancer Evolution IX

< Measurement using a solder >

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

1. Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39 in) long] on the input shaft rear bearing as indicated in the illustration.
2. Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39 in) long] on the main shaft rear bearing fitting surface in the transaxle case as indicated in the illustration.
3. Put solders [1.0 mm (0.039 in) diameter, about 10 mm (0.39 in) long] on the surface of the reverse idler gear mounting boss in the transaxle case as indicated in the illustration and then Install the shim having the minimum thickness.
4. Install the snap ring temporarily in the main shaft rear bearing location in the transaxle case.
5. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole, and place the transaxle case over the clutch housing. CAUTION: In the following step, use the same transaxle case bolts that were removed during disassembly.
6. Install and tighten the transaxle case bolts to the specified torque. Tightening torque: 63 +/- 1 N. m (46 +/- 1 ft-lb) CAUTION: In the following steps, make sure to use the same O-rings that were removed during disassembly.
7. Install the control assembly and tighten its bolts to the specified torque. Tightening torque: 7.3 +/- 1.0 N. m (65 +/- 9 in-lb)
8. With the gear shifted into 2nd gear, raise the main shaft and install the snap ring tightly on the main shaft rear bearing. NOTE: Refer to «CONTROL ASSEMBLY INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/manual-trans/#overhaul-w6maa-lancer-evolution__o-control-assembly-installation) for the method for shifting the gear into 2nd.
9. Return the control assembly to the neutral position and remove its mounting bolts. Remove the control assembly.
10. Remove the transaxle case.
11. Remove the snap ring from the main shaft rear bearing, remove the transaxle case, and then take out crushed solders. Input shaft and mainshaft If the solders have not crushed, use thicker solders (1.6 mm diameter, about 10 mm long) and repeat steps 4 to 10 . Reverse idler gear If the solders have not crushed, use thicker shim and repeat steps 4 to 10 .
12. Measurer the thickness of the crushed solder with a micrometer. Input shaft and mainshaft Select a shim that will provide the standard value. Input shaft and mainshaft end play Shim thickness: (T -0 mm) to [T -0.06 mm (0.0024 inch)] T: The crushed solder thickness Standard value: 0 - 0.06 mm (0 - 0.0024 inch) Reverse idler gear Based on the sum of the crushed thickness and the thickness of the shim used during measurement, select the thickness of the shim to obtain the standard clearance. Reverse idler gear end play Shim thickness: [T 1 + T 2 -0.04 mm (0.0016 inch) to [T 1 + T 2 -0.10 mm (0.0039 inch)] T 1 : The crushed solder thickness T 2 : Used shim thickness Standard value: 0.04 -0.10 mm (0.0016 -0.0039 inch)

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

1. Put plastigage [about 10 mm (0.39 in) diameter, about 10 mm (0.39 in) long] on the input shaft rear bearing as indicated in the illustration.
2. Put plastigage [about 10 mm (0.39 in) diameter, about 10 mm (0.39 in) long] on the main shaft rear bearing fitting surface in the transaxle case as indicated in the illustration.
3. Put plastigage [about 10 mm (0.39 in) diameter, about 10 mm (0.39 in) long] on the surface of the reverse idler gear mounting boss in the transaxle case as indicated in the illustration and then Install the shim having the minimum thickness.
4. Install the snap ring temporarily in the main shaft rear bearing location in the transaxle case.
5. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole, and place the transaxle case over the clutch housing. CAUTION: In the following step, use the same transaxle case bolts that were removed during disassembly.
6. Install and tighten the transaxle case bolts to the specified torque. Tightening torque: 63 +/- 1 N. m (46 +/- 1 ft-lb) CAUTION: In the following steps, make sure to use the same O-rings that were removed during disassembly.
7. Install the control assembly and tighten its bolts to the specified torque. Tightening torque: 7.3 +/- 1.0 N. m (65 +/- 9 in-lb)
8. With the gear shifted into 2nd gear, raise the main shaft and install the snap ring tightly on the main shaft rear bearing. NOTE: Refer to «CONTROL ASSEMBLY INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/manual-trans/#overhaul-w6maa-lancer-evolution__o-control-assembly-installation) for the method for shifting the gear into 2nd.
9. Return the control assembly to the neutral position and remove its mounting bolts. Remove the control assembly.
10. Remove the transaxle case.
11. Remove the snap ring from the main shaft rear bearing, remove the transaxle case, and then take out crushed plastigage.
12. If the plastigage have not crushed, replace the shim with a thicker one and repeat steps 4 to 11 .
13. Measure the shim width of the crushed plastigage at its widest part using a scale printed on the plastigage package. Standard value Input shaft end play: 0 mm -0.06 mm (0 - 0.0024 inch) Mainshaft end play: 0 mm -0.06 mm (0 - 0.0024 inch) Reverse idler gear end play: 0.04 - 0.10 mm (0.0016 - 0.0039 inch)