M/T - Grinds on 2nd to 3rd/4th to 5th Gear Shifts

No.: TSB-04-22-003REV

DATE: November, 2004

MODEL: 2003-04 Evolution

This bulletin supercedes TSB-04-22-003, issued September, 2004, to correct the parts information. Revised information is indicated by >.

PURPOSE

A grinding noise during the 2nd-to-3rd gear shift or the 4th-to-5th gear shift may be due to a damaged synchronizer ring, sleeve, and spring. If the customer complains of this grinding noise, replace these parts with new, improved parts listed in this bulletin.

AFFECTED VEHICLES
2003-04 Lancer Evolution

PROCEDURE

1. Test drive the vehicle to determine when the grinding noise occurs. Note whether the noise occurs between the 2nd-to-3rd gear shift or the 4th-to-5th gear shift.

2. Replace the appropriate synchronizer sleeve, ring, and spring, depending on when the grinding noise occurs. Use the PARTS INFORMATION list in this bulletin to identify the required replacement parts. Refer to Group 22 in the Lancer Evolution service manual for parts replacement procedures.

Parts listed in this bulletin must be used together. Do not install new parts with earlier parts.

a. Inspect the speed gears. Replace the appropriate speed gear if damaged.

b. If the tapered roller bearing is damaged during removal, it must also be replaced.





3. Check the input shaft end play, output shaft preload, and center differential case preload values. Adjust as necessary.

Standard Values:

Input Shaft End Play: 0.05-0.17 mm (0.0020 - 0.0067 in.)
Output Shaft Preload: 0.13-0.18 mm (0.0051 - 0.0071 in.)
Center Differential Case Preload: 0.05 - 0.11 mm (0.0020 - 0.0043 in.)

4. Bleed the clutch as described in Group 21A of the Lancer Evolution service manual.

5. Check the clutch pedal free play and clutch pedal height. If out of specification, adjust as described in Group 21A of the Lancer Evolution service manual.

PARTS INFORMATION

Use the appropriate Genuine Mitsubishi Parts listed below.

IMPORTANT
Parts listed below must be used together. Do not install new parts with earlier parts.





For 2nd-to-3rd gear shift grinding noise, use the following new, improved parts shown.

WARRANTY INFORMATION

Normal warranty procedures apply.