Removal and installation of transmission Lancer X

The main malfunctions, for the elimination of which it is necessary to remove the manual transmission from the car:

- increased (compared to usual) noise;

- difficult gear shifting;

- spontaneous disengagement or fuzzy engagement of gears;

- oil leakage through seals and gaskets.

In addition, the gearbox is removed to replace the clutch, flywheel and rear engine crankshaft oil seal.

The automatic transmission and CVT are removed for almost the same reasons that a manual is removed, except for the need to replace the clutch and flywheel, which in these cases are absent.

The methods for removing and installing manual and automatic transmissions, as well as the variator, are almost the same. The difference lies in the size and number of cables for the transmission control drive, as well as in the presence of an automatic transmission and a variator of hydraulic hoses connecting the gearbox to the cooling radiator.

Helpful Hints:

The work of removing and installing the gearbox is very laborious, so be sure to first make sure that its malfunctions are not caused by other reasons (insufficient oil level, defects in the clutch release drive, loosening of the gearbox, etc.).

The gearbox is quite heavy and its shape is not comfortable to hold, so we recommend removing the gearbox with an assistant.

Removal and installation of transmission Lancer X

1. Place the vehicle on a lift or pit.

2. Remove the decorative engine cover (see "Removing and installing the decorative engine cover", page 85).

3. Disconnect a wire from the minus plug of the storage battery.

4. Remove the air filter (see "Removing and installing the air filter", p. 115).

5. Remove the battery (see "Removing and installing the battery" p. 187).

6. Remove the battery mounting shelf (see "Removing and installing the battery mounting shelf", p. 254).

7. Drain the coolant (see "Changing the coolant", page 64).

8. Remove the engine intake manifold (see "Replacing the intake manifold gasket", from 94).

9. Remove the upper decorative bumper panel (see "Removing, disassembling and installing the front bumper", p. 230).

10. Turn out a bolt of fastening of a "mass" wire to an arm of a tube of system of cooling.

11. Squeeze the wire holder tabs.

12. Take away the "mass" wire from the gearbox housing.

13. Turn out two bolts of fastening of the block of management of the engine and take the block aside.

14. Turn out four bolts and remove protection of a crankcase of the engine.

15. Remove the front and left engine mudguards (see "Removing and installing mudguards and engine crankcase protection", page 85).

16.  Drain the oil from the gearbox (the photo shows the drain plug of the variator), see "Checking the level and replacing the working fluid in the variator (CVT)", p. 68).

17.  Drain the coolant, disconnect and remove the cooling system pipes connected to the thermostat housing (see "Removing and installing the thermostat housing assembly", p. 105).

18. Squeeze the pliers on the clamp that secures the variator heat exchanger hose to the cooling system tube.

19.  Slide the clamp along the hose.

20.  Disconnect the hose from the tube.

21. Squeeze the tabs on the harness holder.

22. Remove the harness from the gearbox housing bracket.

23. Turn out a back bolt of fastening of a tube of system of cooling.

24. Squeeze the bent ears of the clamp to the hose tube that supplies fluid from the thermostat housing. 

25. Slide the clamp over the hose and disconnect the hose from the tube.

26. Remove a hose from a branch pipe of a breather of a transmission and take aside.

27.  Turn out a bolt of forward fastening of a tube of system of cooling.

28. Pick up the handset.

29. Remove the starter from the engine (see "Removing and installing the starter", p. 195).

30. Disconnect the wiring harness connector from the speed sensor.

31. Using a screwdriver, remove the spring clip of the CVT control wiring harness block and disconnect the block from the connector.

32. Lock the CVT switch in the neutral position.

33. Turn away a nut of fastening of a tip of a cable of a drive of management by a transmission.

34. Disconnect the tip from the control lever.

35. Squeeze the retainer of the wiring harness block of the CVT operating mode switch.

36. Disconnect the harness block from the switch connector.

37. Without removing the latch, unscrew the nut securing the CVT control lever.

38. Remove the toothed washer under the nut.

39. Remove the lever.

40. Turn out two bolts of fastening of the switch of operating modes of a variator.

41.  Remove the switch.

42. Disconnect the front wheel drives from the gearbox (see "Removing and installing front wheel drives", p. 139).

43. Securely support the engine or hang it out using a hoist.

44. Disconnect the rear support of the power unit from the gearbox bracket by unscrewing the nut of the bolt of its fastening to the bracket and removing the bolt (see "Replacing the rear support of the power unit and the bracket of its fastening to the power unit", p. 87).

45. While holding with a wrench, unscrew the nut of the bolt securing the front engine mount to the guard rail bracket.

46. Remove the bolt securing the front support of the power unit.

47. Turn out three bolts of fastening of a protective bar of the power unit.

48. Remove the bar from the car.

49. Remove the CVT breather hose from the holder and remove the holder.

50. Turn away a nut and turn out a bolt of fastening of an arm of the air filter and the block of management of the engine.

51. Remove the bracket.

52. Remove the left support of the power unit (see "Replacing the left support of the power unit", page 88).

53. Turn out bolts of fastening of a transmission to the engine, after substituting a reliable support under a transmission.

54. While holding the box, remove the support.

55. Slightly lower the rear of the gearbox so that its studs come out of the holes in the bracket of the left support of the power unit. Move the gearbox as far back as possible (the input shaft should disengage) and remove it from under the car.

Warning:

When removing the gearbox, do not rest the end of the input shaft on the petals of the Belleville spring, so as not to deform them.

56. Establish a transmission and all removed details and knots in an order, the return to removal.

Helpful Hints:

Before installing the gearbox, we recommend lubricating the splines of the input shaft and the outer surface of the clutch release bearing guide bushing with a thin layer of refractory grease.

Check with a special mandrel how the clutch disc is centered (see "Removing and installing the clutch", p. 124).

Before connecting the front wheel drives to the gearbox, replace the circlips on the splined shank of the inner joints with new ones. Otherwise, it is possible to disconnect the drives from the gearbox while driving.

57. Fill with oil in the manual transmission (see "Checking and changing the oil in a manual transmission", page 68) or working fluid in the variator, see "Checking the level and changing the working fluid in the variator (CVT)", page . 68).

Source:  Mitsubishi Lancer X Owner's Manual