Manual Transaxle - Except Evolution: Diagnosis Mitsubishi Lancer IX

TROUBLESHOOTING STRATEGY

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. 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.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart.
4. Verify malfunction is eliminated.

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Scheme 193

1. STEP 1. Check the idle speed. Q: Does the idle speed meet the standard values? YES: Go to Step 2. NO: Refer to «CURB IDLE SPEED CHECK»(ref-183616-S13564203572005081800000) .
2. 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.
3. STEP 3. Check that the oil level is up to the lower edge of the filler plug hole. Q: Is the oil level up to the lower edge of the filler plug hole? YES: Go to Step 4. NO: Refill gear oil SAE 75W - 90W or 75W - 85W conforming to API classification GL-4. Then go to Step 7 .
4. STEP 4. Check for the specified oil. Q: Is the specified oil gear oil SAE 75W - 90W or 75W - 85W conforming to API classification GL-4? YES: Go to Step 5. NO: If in doubt, replace the oil. Refer to «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 7 .
5. 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 .
6. 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.
7. STEP 7. Retest the systems. Q: Is the noise or vibration still there? YES: Return to Step 1 . NO: The procedure is complete.

DIAGNOSIS

1. 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 leak(s) around the engine. Then go to Step 4 .
2. 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.
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.
4. STEP 4. Retest the system. Q: Is the oil still leaking? YES: Return to Step 1 . NO: The procedure is complete.

1. 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 «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 7 .
2. STEP 2. Check the transaxle oil. Q: Is the oil dirty? YES: Replace the oil. Refer to «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 7 . NO: Go to Step 3.
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 «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 7 .
4. 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 «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 7 .
5. STEP 5. Check for poor meshing of 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.
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.
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.

1. 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 «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 6 .
2. STEP 2. Remove and disassemble the transaxle. Check the poppet spring for breakage. Q: Is the poppet spring broken? YES: Replace the poppet spring. Refer to «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 6 . NO: Go to Step 3.
3. STEP 3. Check the control housing. Q: Is the control housing in good condition? YES: Go to Step 4. NO: Repair or replace the control housing. Refer to «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 6 .
4. STEP 4. Check the gear shift forks for wear. Q: Is the gear shift forks worn? YES: Replace the gear shift fork. Refer to «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 6 . NO: Go to Step 5.
5. STEP 5. Check the clearance. Q: Is the clearance between the synchronizer hub and sleeve excessive? YES: Replace the synchronizer hub or sleeve. Refer to «INPUT SHAFT»(ref-183625-S20127638762005081800000) and «OUTPUT SHAFT»(ref-183625-S09042275432005081800000) «ON-VEHICLE SERVICE»(ref-183624-S33429171462005081800000) . Then go to Step 6. NO: Go to Step 6.
6. STEP 6. Retest the system. Q: Does the transaxle still jump out of gear? YES: Return to Step 1 . NO: The procedure is complete.

Scheme 194

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Scheme 196

1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of the filler plug hole.
3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)

Scheme 197

1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 y 1 ft-lb)
4. Fill with gear oil SAE 75W - 90W or 75W - 85W conforming to API classification GL-4 until the level comes to the lower portion of filler plug hole. Quantity: 2.2 dm 3 (2.3 quarts)
5. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 y 1 ft-lb)