M/T - Rattling Noise Idling in Neutral
No.: TSB-05-22-001DATE: July, 2005
MODELS: See Below
SUBJECT:
M/T RATTLING NOISE AT IDLE
PURPOSE
Some vehicles may experience a rattling noise coming from the manual transaxle ("neutral gear rattle") when the engine is idling. The noise may result from a damaged input shaft bearing, reverse idler gear, or clutch disc (due to clutch hub to input shaft spline wear). The noise is typically most noticeable when the A/C compressor engages. Follow the steps in this bulletin to determine the cause of the rattle and replace the affected transaxle component(s).
NOTE:
Transmission removal is NOT necessary to remove the reverse idler gear.
Performing the repairs in this bulletin will improve the severity of the "neutral gear rattle", but may not fully eliminate the noise. A small level of noise is acceptable and will not affect transaxle durability.
AFFECTED VEHICLES:
2002-05 Lancer and Lancer Evolution equipped with 5-speed manual transmission
PROCEDURE
Follow the FLOWCHART shown. Observe the following points during repair:
1. Replace the input shaft bearing if the rattle occurs both when the transaxle is cold and when it is at normal operating temperature.
a. If the input shaft bearing is being replaced, inspect all bearings for wear. Carefully rotate each bearing and check for smooth rotation. Replace any bearings that do not turn smoothly.
b. EVOLUTION ONLY: Be sure to check the shaft clearances carefully, and adjust as necessary. Refer to Group 22 in the appropriate service manual for clearance specifications.
2. If the rattle occurs only at normal operating temperature:
a. LANCER ONLY: Use the reverse idler gear kit (listed in the PARTS INFORMATION section of this bulletin) to replace the related parts. If the noise continues after installing the reverse idle gear repair kit, replace the clutch disc.
NOTE:
Transmission removal is NOT necessary to remove the reverse idler gear.
b. EVOLUTION ONLY: Replace the reverse idler gear components listed in the PARTS INFORMATION section of this bulletin. If the noise continues after replacing the reverse idle gear components, replace the clutch disc.
PARTS INFORMATION
Use the Genuine Mitsubishi Part's shown.
WARRANTY INFORMATION
Normal warranty procedures apply.