25.03.0033
2 Drenth Motorsport Gearboxes Figure 1: Rear and side view
Introduction The Mitsubishi Lancer Evolution XI-IX 5-speed gearkit is specially designed for the group N rally. This unit fits the OEM Bell housing and the OEM cover of the gearbox. The Drenth Mitsubishi EVO VI - IX gearkit has proven itself in FIA Group N Rally, Hill Climbing, Rally Cross, Circuit use and Track days. The gearkit can handle torque levels up to 650 Nm. This document contains information about the EVO XI-IX gearkit. It is useful for everyone who is using or rebuilding a EVO XI-IX gearkit. The user manual includes illustrated parts list, a gearkit assembly, parts list and a gear ratio list. For more detailed information please contact Drenth Gearboxes. Drenth Motorsport Gearboxes Fleuweweg 10 7468 AG Enter The Netherlands Phone: +31 (0)547 38 26 96 Fax: +31 (0)547 38 20 65 Last modified: August 2015 info@drenth-gearboxes.com Made by Arjan Hoogendijk www.drenth-gearboxes.com Mitsubishi EVO IX 3
4 Contents Introduction... 3 Contents... 3 1.0 Technical Specifications... 6 1.1 General Specifications... 7 1.2 Gears Overview... 8 2.0 Illustrated Parts List... 9 2.1 Layshaft... 10 2.2 Mainshaft... 12 2.3 Reverse shaft... 15 2.4 Differential... 17 2.5 Bell house and End cover bearings... 19 2.6 Shifting system... 21 3.0 Gearbox assembly... 25 3.1 General Instructions Notes... 26 3.2 Bearing assembly... 27 3.2.1 Main shaft bearing... 29
3.2.2 OEM Differential bearing... 31 3.2.4 Mainshaft bearing... 33 3.2.5 Layshaft bearing... 35 3.3 Main Assembly... 36 Step 3)... 40 Step 4)... 42 3.4 Run-in procedure... 50 4.0 Gear Ratio List... 51 5.0 Differential Bearing replacement... 52 6.0 Complete Parts List... 53 7.0 Contact Information... 56 7.0 Contact Information... 57 Address... 57 Contacts... 57 Sales department:... 57 Engineering:... 57 Mitsubishi EVO IX 5
1.0 Technical Specifications 6
1.1 General Specifications Max torque: 650 Nm Oil type: Castrol Syntrax Limited Slip Drenth Motorsport Gearboxes Oil quantity: 3.1 Liter for Gearbox / 0.6 Liter for Transfer Box Figure 2: Mitsubishi EVO IX Gearkit Mitsubishi EVO IX 7
8 1.2 Gears Overview Drenth Motorsport Gearboxes Figure 3: Gears overview
2.0 Illustrated Parts List Mitsubishi EVO IX 9
10 2.1 Layshaft Drenth Motorsport Gearboxes Figure 4: Layshaft
Layshaft Number QTY. Part Number Description Comments 1 1 38.03.0001 Layshaft (12-36 / 13-26) 2 1 38.03.0002 3 rd gear layshaft (17-25) 3 1 38.03.0003 4 th gear layshaft (18-20) 4 1 38.03.0004 5 th gear layshaft (28-24) 5 1 38.03.0005 Washer layshaft 6 1 38.03.0006 Circlip layshaft 7 1 38.03.0038 Layshaft bearing rear 8 3* 3* 3* 38.03.0065 38.03.0066 38.03.0067 Shim 63x80x0.1 Shim 63x80x0.3 Shim 63x80x1.0 * The Number of shims and the thicknesses are different in each gearbox because of minimal differences in dimensions of the bell housing and sleeve. Mitsubishi EVO IX 11
12 2.2 Mainshaft Drenth Motorsport Gearboxes Figure 5: Mainshaft
Mainshaft Number QTY. Part Number Description Comments 9 1 38.03.0088** Mainshaft (13-56) For different final drive see pag. 51 10 1 38.03.0009 Needle bearing 1st gear 11 1 38.03.0043 1 st gear mainshaft 12 2 38.03.0010 Split ring 13 1 38.03.0011 Hub 1 st /2 nd gear 14 1 38.03.0012 Dogring 1 st /2 nd gear Old version: 38.03.0008 Please check part number on the part. 15 1 38.03.0015 2 nd gear mainshaft (13-26) For different ratio s see pag. 51 16 1 38.03.0017 3 rd gear mainshaft (17-25) For different ratio s see pag. 51 17 1 38.03.0016 Hub 3 rd /4 th gear 18 1 38.03.0018 Dogring 3 rd /4 th gear 19 1 38.03.0019 4 th gear mainshaft (18-20) For different ratio s see pag. 51 20 1 38.03.0020 5 th gear mainshaft (28-24) For different ratio s see pag. 51 21 1 38.03.0022 Dogring 5 th /reverse gear 22 1 38.03.0021 Hub 5 th /reverse gear 23 1 38.03.0023 Inner track reverse gear 24 1 38.03.0025 Reverse gear mainshaft (13-26-41) 25 1 38.03.0036 Inner track mainshaft 26 1 38.03.0027 Circlip mainshaft 27 1 38.03.0034 Mainshaft bearing (rear) 28 3* 3* 1* 1* 38.03.0060 38.03.0061 38.03.0062 38.03.0063 Shim 60x72x0.1 Shim 60x72x0.3 Shim 60x72x1.0 Shim 60x72x2.0 29 4 38.03.0014 Needle bearing 2 nd /3 rd /4 th /5 th gear 30 1 38.03.0024 Needle bearing reverse gear * The Number of shims and the thicknesses are different in each gearbox because of minimal differences in dimensions of the bell housing and sleeve. ** Depending on type of the gearbox 38.03.0007 is used. Mitsubishi EVO IX 13
14 Number QTY. Part Number Description 76* 1 38.03.0007 Mainshaft (13-56) *It is possible that the mainshaft nr. 76 is used. 38.03.0007 is the old version, 38.03.0088 with steel sleeve is for in an stiffer housing. See also gearbox assembly from page 19.
2.3 Reverse shaft Drenth Motorsport Gearboxes Figure 6: Reverse shaft Mitsubishi EVO IX 15
16 Reverse shaft Number QTY. Part Number Description Comments 31 1 38.03.0809 Circlip OEM part 32 1 38.03.0808 Spring OEM part 33 1 38.03.0807 Trust washer OEM part 34 1 38.03.0033 Reverse idler 35 1 38.03.0805 Needle bearing OEM part 36 1 38.03.0804 Reverse shaft OEM part 37 1 38.03.0806 Ball reverse OEM part
2.4 Differential Drenth Motorsport Gearboxes Figure 7: Differential Mitsubishi EVO IX 17
18 Differential Number QTY. Part Number Description Comments 38 1 38.03.0093 Differential bearing (crown wheel side) OEM part 39 10 38.03.0047 Differential bolts M12x35 OEM part* 40 1 38.03.0042 Crown wheel (13-56) 41 1 38.03.0850 Differential complete OEM part 42 1 38.03.0094 Differential bearing OEM part * OEM bolt can be replaced with new bolts 35.01.0084.
2.5 Bell house and End cover bearings Drenth Motorsport Gearboxes Figure 8: Bearing placement Mitsubishi EVO IX 19
20 Bell house and End cover bearings Number QTY. Part Number Description Comments 7 1 38.03.0038 Layshaft bearing rear 8 3* 3* 3* 38.03.0065 38.03.0066 38.03.0067 Shim 63x80x0.1 Shim 63x80x0.3 Shim 63x80x1.0 27 1 38.03.0034 Mainshaft bearing rear 28 6* 6* 2* 2* 38.03.0060 38.03.0061 38.03.0062 38.03.0063 Shim 60x72x0.1 Shim 60x72x0.3 Shim 60x72x1.0 Shim 60x72x2.0 38 1 38.03.0093 Differential bearing (crown wheel side) OEM part 42 1 38.03.0094 Differential bearing OEM part 43 1 38.03.0801 End cover OEM part 44 1 38.03.0800 Bell house OEM part 45 1 38.03.0089 Mainshaft bearing sleeve Ø72 mm Becomes nr. 66 when the bell housing is used 46 1 38.08.0090 Mainshaft bearing (front) 47 1 38.03.0037 Layshaft bearing (front) 66 1 38.03.0096 Oversized sleeve Ø72.5mm (used bell housing) Only for an used bell housing 75 1 38.03.0035** Mainshaft bearing front Only when you use mainshaft 38.03.0007 (nr. 76) * The Number of shims and the thicknesses are different in each gearbox because of minimal differences in dimensions of the bell housing and sleeve. **When you are using Mainshaft 38.03.0007 you need to use the mainshaft bearing (front) 38.03.0035, you don t need the bearing sleeve (see picture in the centre below). See page 12 for the assembly of the mainshaft.
2.6 Shifting system Drenth Motorsport Gearboxes Figure 9: Shifting system Mitsubishi EVO IX 21
22 Shifting sytem Number QTY. Part Number Description Comments 48 6 38.03.0045 Spiral pin 5mm 49 1 38.03.0031 Selector fork 5 th /reverse gear 50 1 38.03.0030 Selector fork 3 rd /4 th gear 51 1 38.03.0029 Selector fork 1 st /2 nd gear 52 1 38.03.0162 Selector arm 5 th /reverse gear OEM part 53 1 38.03.0161 Selector arm 3 rd /4 th gear OEM part 54 1 38.03.0160 Selector arm 1 st /2 nd gear OEM part 55 1 38.03.0162 Selector fork shaft 5 th /reverse gear OEM part 56 1 38.03.0161 Selector fork shaft 3 rd /4 th gear OEM part 57 1 38.03.0160 Selector fork shaft 1 st /2 nd gear OEM part
2.7 Shifting tower Drenth Motorsport Gearboxes Figure 10: Shifting tower Mitsubishi EVO IX 23
24 Shifting tower ITEM NO PART NR QTY NAME PART Notes 1 38-03-0044 1 Interlocker 2 38-03-0342 1 Reverse lock plate OEM part 3 38-03-0843 1 Cover selector tower OEM part 4 38-03-0844 1 Rubber cover OEM part 5 38-03-0863 1 Spring OEM part 6 38-03-0865 2 Bolt M8 OEM part 7 38-03-0868 1 Main selector OEM part 8 38-03-0869 1 Spiral pin 5mm OEM part 9 38-07-0037 1 Selector shaft set OEM part 10 38-08-0058 1 Spring OEM part 11 38-08-0957 1 Pin OEM part 12 38-08-0963 2 Washer M8 OEM part
3.0 Gearbox assembly Mitsubishi EVO IX 25
26 3.1 General Instructions Notes First read the manual in general and check if all the parts are there. For an easy and faster assembly lay all the parts in the right order. Every part has got his own personal number. The number reference is shown in the parts list. Before the assembly all parts must be clean and undamaged. Also a clean tray is recommended Only genuine Drenth parts should be used when assembling and servicing this gearkit. For durability it s recommended to use new nuts, seals and circlips during the re-assembly of the gearbox. During the assembly only use lubrications that are recommended by Drenth Motorsports Gearboxes (Castrol Syntrax Limited Slip 75W 140).
3.2 Bearing assembly General information On the next page several illustrations are shown where each bearing needs to be placed. The bearings have got the same number as in Chapter 2 Illustrated Parts List. When the mainshaft (nr. 76) and bearing 75 are used, the housing does not need to be changed. Each bearing has to be slightly lubricated. Please note that not each bearing is assembled under heating conditions. To intercept the expansion due the heat, the bearings need to be adjusted with shims. This has to be done with bearing 7, 27 and 38. To determine the correct thickness of the shims see page 29 to 35. Bearing assembly: o The oven must be preheated. o Heat each section to a temperature of 100 / 110 C. o When the casing has reached this temperature, give it approximately 30 minutes to insure an even temperature distribution. o Before fitting the bearings make sure the outer track of the bearing is clean. o Once the casing is at the correct temperature and the bearings are clean, fit the bearings promptly and without delay. Try to avoid more heating cycles. Use a tool, for example a ring, which fits directly over the outer track of the bearing. o To avoid damage fit each bearing as straight as possible. o Heating conditions may not exceed 130 Celsius. Mitsubishi EVO IX 27
28 Drenth Motorsport Gearboxes Figure 11: Bearing assembly. (Only use bearing 75 when mainshaft (nr. 76) is used)
3.2.1 Main shaft bearing In the OEM gearbox the bearing fitting has a loose fit. When the gearbox reaches operation temperature, the aluminium housing expands more than the steel outer track of the bearing. Causing the outer track to turn in the housing and creating a bigger bearing fitting. After a certain time of race/ rally use, the bearing fitting becomes oversized and oval instead of circular. The solution for used housings is cutting the bearing fitting to 72.5 mm and fit it with a oversized steel sleeve (nr. 66, part nr. 38.03.0096) with a smaller bearing than used before. New housings can be fitted with a standard steel sleeve (nr. 45, part nr. 38.03.0089) and bearing without cutting the bearing fitting. Both steel sleeves have a tight fitting in the housing that prevents the bearings to turn. How this is done is described on the next few pages. Boring the used housing Originally the bearing fitting is 72 mm in diameter. If the housing is used and oval, it s recommended to make the bearing fitting circular again by cutting +0.5 mm in diameter. Cut the housing with the dimensions shown in the figure below. After cutting, the fitting must be 72.5 mm in diameter. The cutting dimension is tolerated: -0.00 +0.01 Drenth Motorsport Gearboxes Figure 12: Boring dimensions Mitsubishi EVO IX 29
30 Instruction notes: Make sure the bearings (nr. 46, 47 and outer track of bearing 42) and sleeve (nr. 45 or 66) are clean. The bearings (nr. 46, 47 and outer track of bearing 42) has to be slightly lubricated with oil. Press fit the bearing (nr. 46) and sleeve (nr. 45 or 66) together. Measure the distance from the mounting surface of the bell housing to the bottom of the bearing fitting. This distance must be 61.2 mm +/- 0.05 (figure 12). If not, the distance can be adjusted with shims (nr. 28). The oven must be preheated. Heat the aluminium bell housing to a temperature of 100 / 110 C. Heating conditions may not exceed 130 Celsius. When the bell housing has reached this temperature, give it approximately 30 minutes to insure an even temperature distribution. Once the casing is at the correct temperature, fit the bearing with the sleeve promptly and without delay. Also fit bearing 47 and outer track of bearing 42 in the housing. Try to avoid more heating cycles. Final check if the distance between the mounting surface and the outer track of bearing. This distance must be 38.2 +/- 0.05 mm. 61.2 ± 0.05 38.2 ± 0.05 Bearing and sleeve Number QTY. Part number Description Comments 46 1 38.08.0090** Mainshaft bearing front 45 1 38.03.0089 Normal sleeve 72 mm in diameter (new bell housing) 66 1 38.03.0096 Oversized sleeve 72,5 mm in diameter (used bell housing) 28 3* 3* 1* 1* 38.03.0060 38.03.0061 38.03.0062 38.03.0063 Shim 60x72x0.1 Shim 60x72x0.3 Shim 60x72x1.0 Shim 60x72x2.0 Drenth Motorsport Gearboxes * The number of shims and thickness are different in each gearbox, because of minimal differences in dimensions of the bell housing and sleeve. Figure 13.1: Mounting dimensions
Instruction notes (Mainshaft 38.03.0007): Make sure the bearings (nr. 75, 47 and outer track of bearing 42) are clean. The bearings (nr. 75, 47 and outer track of bearing 42) has to be slightly lubricated with oil. Measure the distance from the mounting surface of the bell housing to the bottom of the bearing fitting. This distance must be 61.2 mm +/- 0.05 (figure 12.1). If not, the distance can be adjusted with shims (nr. 28). The oven must be preheated. Heat the aluminium bell housing to a temperature of 100 / 110 C. Heating conditions may not exceed 130 Celsius. When the bell housing has reached this temperature, give it approximately 30 minutes to insure an even temperature distribution. Once the casing is at the correct temperature, fit the bearing promptly and without delay. Also fit bearing 47 and outer track of bearing 42 in the housing. Try to avoid more heating cycles. Final check if the distance between the mounting surface and the outer track of bearing. This distance must be 38.2 +/- 0.05 mm. Bearing and sleeve Number QTY. Part number Description Comments 75 1 38.03.0035 Mainshaft bearing front 28 3* 3* 1* 1* 38.03.0060 38.03.0061 38.03.0062 38.03.0063 Shim 60x72x0.1 Shim 60x72x0.3 Shim 60x72x1.0 Shim 60x72x2.0 * The number of shims and thickness are different in each gearbox, because of minimal differences in dimensions of the bell housing and sleeve. In the rest of the manual the mainshaft 38.03.0088 (the most recent one) will be described. Drenth Motorsport Gearboxes Figure 13.2: Mounting dimensions Mitsubishi EVO IX 31
32 3.2.2 OEM Differential bearing Instruction notes: Bearing 42 and the differential must be assembled first (see previous step). Make sure the bearing (nr. 38) and shims (nr. 28) are clean. The bearing (nr. 38 and 42) has to be slightly lubricated with oil. To measure the distance that must be shimmed, put two pieces of solder (Ø2mm and 10mm in length) on top of the outer track over bearing 38. Then put the end cover on top of the bell housing and tighten the bolts (according to the specifications given on page 46) to make sure there is no clearance between the bell housing and end cover. Now take the end cover away and measure the crushed section of the pieces of solder. Preload on differential bearings must be 0.4-0.5 mm. Thickness crushed solder + preload = thickness shims Place the calculated shims in the end cover, as pictured on page 28. Drenth Motorsport Gearboxes Figure 14: Differential bearing shim
3.2.3 Drenth Differential bearing Instruction notes: Bearing 77b, and the inner track of bearing 77a on the differential, must be assembled first. Make sure the bearing (nr. 77a) and shims (nr. 28) are clean. The bearing (nr. 99a) has to be slightly lubricated with oil. To measure the distance that must be shimmed, put two pieces of solder (Ø2mm and 10mm in length) on top of the outer track over bearing 99a. Then put the end cover on top of the bell housing and tighten the bolts (according to the specifications given on page 46) to make sure there is no clearance between the bell housing and end cover. Now take the end cover away and measure the crushed section of the pieces of solder. Thickness crushed solder - Free play = thickness shims Use no pre-load, always round down to the nearest thickness of a shim to make sure the free play is 0.00 0.05 mm. Place the calculated shims in the end cover, as pictured on page 28. Check after shimming if the shaft runs free and if the differential has a free play of 0.00 0.05 mm. Detail differential bearing Drenth Motorsport Gearboxes Figure 14.2: Drenth differential bearing shim Mitsubishi EVO IX 33
34 3.2.4 Mainshaft bearing Instruction notes: Bearing 46 and the main shaft must be assembled first. o For assemble instructions see pages 35 to 40. Make sure the bearing (nr. 27) and shims (nr. 28) are clean. The bearing (nr. 27) has to be slightly lubricated with oil. To measure the distance that must be shimmed, put shims in the end cover. Make sure there are enough shims, so you need only a small piece of solder on top of the outer track over bearing 27. Then put the end cover on top of the bell housing and tighten the bolts (according to the specifications given on page 46) to make sure there is no clearance between the bell housing and end cover. Now take the end cover away and measure the crushed section of the pieces of solder. Thickness crushed solder - Free play = thickness shims Use no pre-load, always round down to the nearest thickness of a shim to make sure the free play is 0.00 0.05 mm. Place the calculated shims in the end cover, as pictured on page 28. Check after shimming if the shaft runs free. Drenth Motorsport Gearboxes Figure 15: Mainshaft bearing shim
3.2.5 Layshaft bearing Instruction notes: Bearing 47 and the lay shaft (nr. 1) must be assembled first. o For assemble instructions see pages 36 to 41. Make sure the bearing (nr. 7) and shims (nr. 8) are clean. The bearing (nr. 7) has to be slightly lubricated with oil. To measure the distance that must be shimmed, put shims in the end cover. Make sure there are enough shims, so you need only a small piece of solder on top of the outer track over bearing 27. Then put the end cover on top of the bell housing and tighten the bolts (according to the specifications given on page 46) to make sure there is no clearance between the bell housing and end cover. Now take the end cover away and measure the crushed section of the pieces of solder. Thickness crushed solder - Free play = thickness shims Use no pre-load, always round down to the nearest thickness of a shim to make sure the free play is 0.00 0.05 mm. Place the calculated shims in the end cover, as pictured on page 28. Check after shimming if the shaft runs free. Drenth Motorsport Gearboxes Figure 16: Layshaft bearing shim Mitsubishi EVO IX 35
36 3.3 Main Assembly Step 1) Start with the bell housing (nr. 44). Fit the outer track of the differential bearing into the bell house (page 30). Press fit the differential bearings onto the differential. Slightly lubricate the differential bearings. Fit the crown wheel on the differential and tighten the bolts (nr. 39) with 132 Nm of torque and use loctite 270. Drenth Motorsport Gearboxes Figure 17: Step 1
Drenth Motorsport Gearboxes Figure 18: Step 2 Mitsubishi EVO IX 37
38 Step 2) For step 2 the layshaft and Mainshaft are used as a base for further assembly. Each bearing (10, 29 and the Mainshaft bearing) has to be slightly lubricated. The assembly sequence: o First place the mainshaft (9/76) into the bearing in the bell housing. o Now place the bearing (10), the first gear (11) and the split ring (12, 2x) over the mainshaft. o The hub (13) and dog ring (14) slide over each other and fit over the mainshaft. Make sure the inner spline of the dog ring fits correctly over the outer spline of the hub (see picture below). o Place the bearing (29) and second gear (15) over the mainshaft. o At last place layshaft (1) in the bearing (47). Drenth Motorsport Gearboxes Figure 19: Dogring placement
Drenth Motorsport Gearboxes Figure 20: Step 3 Mitsubishi EVO IX 39
40 Step 3) During this step the 3 rd 4 th and 5 th gear are assembled. The three needle bearings (29) must be slightly lubricated. Place all the parts in the order which is given on the exploded view on the page above. Make sure the inner spline of the dog ring (18 and 22) fits correctly over the outer spline of the hub (17 and 21). Finish this step by putting the circlip (6) over the layshaft. Drenth Motorsport Gearboxes Figure 21: Dogring placement
Drenth Motorsport Gearboxes Figure 22: Step 4 Mitsubishi EVO IX 41
42 Step 4) During this step the reverse gear is assembled. Needle bearing (30) has to be slightly lubricated. Press-fit inner track (23) on the mainshaft. o Assemble bearing (30) and reverse gear (24). Press-fit inner track (25) on the mainshaft. Finish this step by putting the circlip (26) over the main shaft.
Drenth Motorsport Gearboxes Figure 23: Step 5 Mitsubishi EVO IX 43
44 Step 5) During this step the selector system is assembled into the bell housing. Place the selector forks (49, 50 and 51) over the dogrings on the Mainshaft. Place the selector fork shafts (55, 56 and 57) through the selector forks and the selector arms (52, 53 and 54) into the bell housing. Put the spiral pins (48) trough the selector forks, the selector shafts and the selector arms. o Check if all pins fit in tight, due to vibrations the pins can come out and cause damage to the gearbox. o Also check if the selectors (nr. 52, 53 & 54) are in one line. Drenth Motorsport Gearboxes Figure 24: Selector system
Drenth Motorsport Gearboxes Figure 25: Step 6 Mitsubishi EVO IX 45
46 Step 6) During this step the end cover is assembled on the bell housing to enclose the gearbox Before assembling the end cover (nr. 43), the dowels (nr. 67 and 68) need to be placed. To secure the end cover, use the original bolts (nr. 69). Tighten the 15 original bolts (M10x40) with 44 Nm. Drenth Motorsport Gearboxes Figure 26: Assembled bell housing
Step 7) During this step the shifting tower is assembled onto the gearbox. For the assembly sequence of the selector shaft see page 23 & 24. Use sealant to seal the shifting tower plate. Put the gearshift system into the gearbox and align the fingers in the selectors. Tighten the original bolts with 30Nm. Drenth Motorsport Gearboxes Figure 27: Shifting tower Mitsubishi EVO IX 47
48 Drenth Motorsport Gearboxes Figure 28.2: OEM gearbox cover Drenth Motorsport Gearboxes Figure 28.1: Step 8
Step 8) During this step we assemble the reverse gear. Needle bearing (nr. 35) has to be slightly lubricated. Place all parts in the order which is given on the exploded view on this page. o Make sure that the ball (nr. 37) fits properly in the spacer (nr. 33) and in the shaft (nr. 36). Now place the assembled reverse gear in the housing and secure the bolt (nr. 72) with 50Nm. Mount the OEM gearbox cover (see figure 27.1, nr. 73) in its place using the OEM bolts (M6x10, nr. 74) tighten it with 14 Nm and use silicone sealant to prevent leakage. Finally turn the oil plug (nr. 70) in the housing with 20 Nm. Drenth Motorsport Gearboxes Figure 29: Reverse gear Mitsubishi EVO IX 49
50 3.4 Run-in procedure Run through the gears while the gearbox is not mounted underneath the car. Make sure that the layshaft rotates smoothly. When this is working and the oil level is correct, the gearbox can be mounted on a test bench or underneath the car. For the first test the wheels should be tilted from the ground. Before the test run make sure the gearbox is in the neutral position. During the test run go through all the gears in a low rpm range. Stay on low rpm until the gearbox is warmed-up. After warm-up check all gearshifts. During the run also concentrate on noise production, vibrations and the temperature. When one of them is out of the ordinary, stop the test and locate the problem. After the first test the gearbox is ready for a test drive. The procedure is the same as the first test. Slowly build-up the engine rpm and torque when the temperature level starts to increase. During the warm-up of the gearbox don t warm-up the brakes.
4.0 Gear Ratio List Homologated gear ratio (FIA Group N) 1 st gear 2 nd gear 3 rd gear 4 th gear 5 th gear Final drive 3.000 2.000 1.471 1.111 0.857 4.308 Gear ratio s available for Hillclimb, Rallycross and Time attack. Different Layshafts Available (with fixed gears) Free to choose 3 rd Free to choose 4 th Free to choose 5 th gears gears gears 1 st gear 2 nd gear 3 rd gear 3 rd gear 4 th gear 5 th gear 3.000 2.000 1.611 1.471 1.111 1.211 3.000 2.077 1.611 1.556 1.167 1.095 3.000 2.000 1.211 1.000 2.692 2.000 1.316 0.960 1.368 0.857 Other final drive ratios 4.857 4.846 3.923 3.643 3.444 Different gear ratios are available on request Ratio requests from customers will be added to the list In consultation with the customer the ideal ratios can be calculated Mitsubishi EVO IX 51
52 5.0 Differential Bearing replacement Due the straight cut teeth profile there are no axial forces. Therefore the tapered roller bearing are no longer specifically needed and can be replaced with new cylindrical roller bearings. These bearings are specifically engineered and fabricated for the Drenth EVO XI-IX Group N. When replacing the standard differential bearings, the Drenth cylindrical roller bearings must be mounted according to chapter 3.2 (Bearing Assembly). These bearings must be adjusted with shims but don t need to be pre-loaded. For a detailed description of the mounting instructions please see page 33. The new differential bearings are available as a set of the two bearings with adjusting shims. For more information about the bearings please contact our sales department. Differential Bearing replacement Number QTY. Part Description number 77 1 38.03.0152 Roller bearing set (included shims) 77a 1 38.03.0150 Differential bearing (crown wheel side) 77b 1 38.03.0151 Differential bearing (bell housing) Drenth Motorsport Gearboxes Figure 30: Differential Bearing upgrade
6.0 Complete Parts List Mitsubishi EVO IX 53
54 Number QTY. Part Number Description Number QTY. Part Number Description 1 1 38.03.0001 Layshaft (12-36 / 13-26) 23 1 38.03.0023 Inner track reverse gear Reverse gear mainshaft (13-2 1 38.03.0002 3 rd gear layshaft (17-25) 24 1 38.03.0025 26-41) 3 1 38.03.0003 4 th gear layshaft (18-20) 25 1 38.03.0036 Inner track mainshaft 4 1 38.03.0004 5 th gear layshaft (28-24) 26 1 38.03.0027 Circlip mainshaft 5 1 38.03.0005 Washer layshaft 27 1 38.03.0034 Mainshaft bearing (rear) 6 1 38.03.0006 Circlip layshaft 28 6* 6* 2* 2* 38.03.0060 38.03.0061 38.03.0062 38.03.0063 Shim 60x72x0.1 Shim 60x72x0.3 Shim 60x72x1.0 Shim 60x72x2.0 7 1 38.03.0038 Layshaft bearing rear 29 4 38.03.0014 Needle bearing 2 nd /3 rd /4 th /5 th gear 8 3* 3* 3* 38.03.0065 38.03.0066 38.03.0067 Shim 63x80x0.1 Shim 63x80x0.3 Shim 63x80x1.0 30 1 38.03.0024 Needle bearing reverse gear 9 1 38.03.0088 Mainshaft (13-56) 31 1 38.03.0809* Circlip 10 1 38.03.0009 Needle bearing 1st gear 32 1 38.03.0808* Spring 11 1 38.03.0043 1 st gear mainshaft 33 1 38.03.0807* Trust washer 12 2 38.03.0010 Split ring 34 1 38.03.0033 Reverse idler 13 1 38.03.0011 Hub 1 st /2 nd gear 35 1 38.03.0805* Needle bearing 14 1 38.03.0012 Dogring 1 st /2 nd gear 36 1 38.03.0804* Reverse shaft 15 1 38.03.0015 2 nd gear mainshaft (13-26) 37 1 38.03.0806* Ball reverse Differential bearing (crown 16 1 38.03.0017 3 rd gear mainshaft (17-25) 38 1 38.03.0093* wheel side) 17 1 38.03.0016 Hub 3 rd /4 th gear 39 10 38.03.0047* Differential bolts M12x35 18 1 38.03.0018 Dogring 3 rd /4 th gear 40 1 38.03.0042 Crown wheel (13-56) 19 1 38.03.0019 4 th gear mainshaft (18-20) 41 1 38.03.0850* Differential complete 20 1 38.03.0020 5 th gear mainshaft (28-24) 42 1 38.03.0094* Differential bearing 21 1 38.03.0022 Dogring 5 th /reverse gear 43 1 38.03.0801* End cover 22 1 38.03.0021 Hub 5 th /reverse gear 44 1 38.03.0800* Bell house
Number QTY. Part Number Description Number QTY. Part Number Description 45 1 38.03.0089 Mainshaft bearing sleeve Ø72 mm 63 1 38.03.0844 Rubber cover 46 1 38.08.0090 Mainshaft bearing (front) 64 1 38.07.0037* Selector lever 47 1 38.03.0037 Layshaft bearing (front) 65 1 38.07.0037* Selector finger Oversized sleeve Ø72.5mm 48 9 38.03.0045 Spiral pin 5mm 66 1 38.03.0096 (used bell housing) 49 1 38.03.0031 Selector fork 5 th /reverse gear 67 2 38.03.0802* Dowel 10x20 50 1 38.03.0030 Selector fork 3 rd /4 th gear 68 1 38.10.0026 Dowel 10x16 51 1 38.03.0029 Selector fork 1 st /2 nd gear 69 15 38.03.0822* Bolts M10x40 52 1 38.03.0162* Selector arm 5 th /reverse gear 70 1 38.08.0942* Oil plug 53 1 38.03.0161* Selector arm 3 rd /4 th gear 71 1 38.03.0811* washer 54 1 38.03.0160* Selector arm 1 st /2 nd gear 72 1 38.03.0810* Reverse bolt 55 1 38.03.0162* Selector fork shaft 5 th /reverse gear 73 1 38.03.0812* Gearbox cover 56 1 38.03.0161* Selector fork shaft 3 rd /4 th gear 74 6 38.03.0822* Bolt M6x10 57 1 38.03.0160* Selector fork shaft 1 st /2 nd gear 75 1 38.03.0035 Mainshaft bearing front 58 1 38.03.0044 Interlocker 76 1 38.03.0007 Mainshaft (13-56) Differential bearing (crown 77a 1 38.03.0150 59 1 38.07.0037* Main selector wheel side) Roller bearing set (included 60 1 38.03.0842* Spring 77 1 38.03.0152 shims) Differential bearing (bell 77b 1 38.03.0151 61 1 38.07.0037* Main selector shaft housing) 62 1 38.03.0843* Cover selector tower * OEM parts Mitsubishi EVO IX 55
7.0 Contact Information 56
7.0 Contact Information Address Drenth Motorsport Gearboxes Fleuweweg 10 7468 AG Enter The Netherlands Phone: +31 (0)547 38 26 96 Fax: +31 (0)547 38 20 65 www.drenth-gearboxes.com info@drenth-gearboxes.com Contacts Sales department: Johan Drenth Johan@drenth-gearboxes.com Engineering: Jeroen Grolleman Jeroen@drenth-gearboxes.com 57 Mitsubishi EVO IX
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